DONE BY:-E.

KRANTHI
3RD YEAR MECHANICAL ‘B’
welcome
 AUTOMOBILE

AUTOMOBILE
 What is an automobile??
• A self propelled vehicle powered by an IC engine or
steam engine or Electric motor,used for
transportation of goods and passengers.
 Brief history
• Around 1672, Ferdinand Verbiest, a priest from China built the first
steam-powered vehicle as a toy for the Chinese Emperor. Around
1769, Nicolas-Joseph Cugnot, Built the first self propelled (steam-
powered) road vehicle (military tractor) for the French army.
In 1885, Karl Friedrich Benz from Germany built
the first gasoline automobile powered by an
internal combustion engine.
IN 1888, A GERMAN INVENTOR ANDREAS FLOCKEN PRESENTED FLOCKEN
ELEKTROWAGEN - THE FIRST REAL ELECTRIC CAR OF THE WORLD.
 Changes over the years..

 Brakes (By Frederick William Lanchester in 1901)

 Aerodynamics
 Automatic Transmission
 Electronic Indicators (1939)
 Air Conditioning (1940)
 Power Steering
 Seat Belts (1956)
 Air Bag (1971)
 Greater use of plastic
 AWD
 ABS
 EFI
 Computer Diagnostics
 GPS
 Indian Automobile Industry

 The first car ran on Indian roads in 1897.

 An embryonic automotive industry emerged in India in the 1940s. Hindustan was
launched in 1942, long time competitor Premier in 1944.
 Mahindra & Mahindra was established by two brothers in 1945, and began assembly of
Jeep CJ-3A utility vehicles. Tata Motors also began in 1945.
 The growth was relatively slow in the 1950s and 1960s due to nationalization and the
license raj which hampered the Indian private sector.
 In 1980s, Suzuki and Toyota of Japan and Hyundai of South Korea, were
allowed to invest in the Indian market ultimately leading to the establishment
of an automotive industry in India.
 To promote the auto industry the government started the Delhi Auto Expo
which had its debut showcasing in 1986.
 As India began to liberalize their automobile market in 1991, a number of
foreign firms also initiated joint ventures with existing Indian companies.
 Today the automotive industry in India is one of the largest automotive
markets in the world.
 The majority of India's car manufacturing industry is based around three
clusters in the south, west and north with revenue share of 35%, 33% and
32% respectively.
 Main Parts of an Automobile

• Chassis
• Suspension and Steering System
• Transmission System
• Braking System
• Fuel Supply System
• Engine
• Electrical and Electronics
Vehicle Anatomy
CHASSIS DESIGN
 INTRODUCTION
 Chassis is a French term and was initially used to denote the
frame or main structure of a vehicle.
 It is now extensively used to denote the complete vehicle
except the body for the heavy vehicle having a separate body.
 The chassis contain all the major units necessary to propel the
vehicle, direct its motion, stop it, and allow it to run smoothly
over uneven surfaces.
 It is the main mounting for all the components including the
body.
 It is also known as carrying unit.
 Provides safety
 The chassis include following
Frame,
Front suspension,
Steering mechanism,
Radiator,
Engine, clutch, gearbox,
Propeller shaft,
Rear spring,
Road wheels,
Differential, half shaft, universal joints,
Brakes end braking system,
Storage battery,
Silencer,
Shock absorbers, fuel tank, petrol and hydraulics pipe cables
and some means of mounting these components.
Building a Chassis

2007 FIRST Rookie Workshop

Design Tradeoffs
 Stable vs. Maneuverable

 Accessible vs. Compact

 Strong & Rigid vs. Light

 Safety vs Luxury

 Manufacturability & Affordable vs. Everything

Types of Chassis
 Ladder Frame Chassis
 Space Frame Chassis
 Monocoque Frame Chassis
 Ulsab Monocoque
 Backbone Frame Chassis
 Aluminium Space Frame
 Carbon Fibre Monocoque
 Ladder Frame Chassis
Indicated by its name, looks like a ladder - two longitudinal rails
interconnected by several lateral and cross braces. The longitude
members are the main stress member. They deal with the load
and also the longitudinal forces caused by acceleration and
braking. The lateral and cross members provide resistance to
lateral forces and further increase torsional rigidity.
Advantage
 It doesn’t have much advantage these days. It is easy and
cheap for hand build, that's all.

Disadvantage
 Since it is a 2 dimensional structure, torsional rigidity is
very much lower than other chassis, especially when
dealing with vertical load or bumps.

Most SUVs, classic cars, Lincoln Town Car, Ford Crown

Victoria etc.
 Monocoque Frame Chassis
Monocoque is a one-piece structure which defines the overall shape
of the car. While other chassis types provides only the stress
members and need to build the body around them, monocoque
chassis is already incorporated with the body in a single piece.
Advantage
 Cheap for mass production.
 Inherently good crash protection.
 Space efficient.

Disadvantage
 Heavy.
 Impossible for small-volume production.

Used by nearly all mass production cars, all Porsche.

 Ulsab Monocoque
Basically ULSAB (Ultra Light Steel Auto Body) has the same structure as a
conventional monocoque. What it differs from its donor is in minor details - the
use of "Hydroform" parts, sandwich steel and laser beam welding. It is used in
Opel Astra, BMW 3-series.

Advantage
 Stronger and lighter then conventional monocoque without increasing
production cost.

Disadvantage
 Still not strong or light enough for the best sports cars.
Hydroforming
 Backbone Frame Chassis
Backbone chassis is very simple: a strong tubular backbone (usually in
triangular section) connects the front and rear axle and provides nearly all the
mechanical strength.
Advantage
 Strong enough for smaller sports cars.
 Easy to be made by hand thus cheap for low-volume production.
 Simple structure benefit cost.
 The most space-saving other than monocoque chassis.

Disadvantage
 Not strong enough for high-end sports cars.
 The backbone does not provide protection against side impact or off-set crash.
 Therefore it need other compensation means in the body.
 Cost ineffective for mass production.

Used by Lotus Esprit, Élan Mk II, TVR, Marcos.

 Space Frame

A nodal triangulated truss networks that attempts to distribute all

loads in axial direction so that no part of force is subjected to
harsher bending force.
Used in FSAE competition

Advantages
 Impact protection
 Good weight holding capability
 Provide torsional rigidity
Disadvantages
 Used for compact design
 Complex, costly and time consuming
 Still expensive for mass production
 Aluminum Space Frame
ASF consists of extruded aluminum sections, vacuum die cast
components and aluminum sheets of different thicknesses.
They all are made of high-strength aluminum alloy. At the
highly stressed corners and joints, extruded sections are
connected by complex aluminum die casting (nodes).
Advantage
 Lighter than space frame
Audi claimed A8's ASF is 40% lighter yet 40% stiffer than
contemporary steel monocoque. This enable the 4WD-equipped
A8 to be lighter than BMW 740i.
Used in Lamborghini Countach and Audi
 Carbon Fibre Monocoque

Carbon Fiber is the most sophisticated material used in aircrafts,

spaceships and racing cars because of its superior rigidity-to-
weight ratio.

Advantage
 The lightest and stiffest chassis.
 Provides great safety at high speed

Disadvantage:
 By far the most expensive
 Factors Affecting Cracking

 Incorrect welding procedures (i.e. undercutting, no

preheat, slag inclusions, transverse welding of flanges
etc.).
 Accident damage.
 Overloading of chassis
 Insufficient reinforcement.
 Over length wheelbase.
 Design fault
 STEERING SYSTEM

• Steering is the term applied to the collections of

components,linkages etc.which allow a vehicle to move in the
desired direction.
• An automobile is steered with the help of steered gears and
linkages,which transfer the motion of the hand operated
steering wheel to the front wheels.
 FUNCTIONS OF STEERING

• It helps in turning the wheels to left or right.

• It converts the rotary movement of the steering wheel into an angular turn of
the front wheels.
• It multiplies the effort of the driver by leverage in order to reduce the effort to
turn the wheels.
• It absorbs a major part of the road shocks thereby preventing them to get
transmitted to hands of the driver.
RACK AND PINION
WORM AND ROLLER
 BRAKE

Abrake is a
mechanical
device which
inhibits
motion.
 WORKING OF
•
BRAKES
A COMMON MISCONCEPTION ABOUT BRAKES IS THAT BRAKES
SQUEEZE AGAINST A DRUM OR DISC, AND THE PRESSURE OF THE
SQUEEZING ACTION SLOWS THE VEHICLE DOWN. THIS IS IN FACT A
PART OF THE REASON FOR SLOWING DOWN A VEHICLE.
• ACTUALLY BRAKES USE FRICTION OF BRAKE SHOES AND DRUMS TO
CONVERT KINETIC ENERGY DEVELOPED BY THE VEHICLE INTO HEAT
ENERGY.
• WHEN WE APPLY BRAKES, THE PADS OR SHOES THAT PRESS AGAINST THE
BRAKE DRUMS OR ROTOR CONVERT KINETIC ENERGY INTO THERMAL
ENERGY VIA FRICTION.

THUS BRAKES ARE ESSENTIALLY

A MECHANISM TO CHANGE
ENERGY TYPES
 TYPES OF BRAKES

 MECHANICAL
BRAKES
• DRUM BRAKES
• DISC BRAKES
 HYDRAULICBRAKES
 POWER BRAKES
• AIR BRAKES
• AIR HYDRAULIC
BRAKES
BRAKE SYSTEM COMPONENTS
 HYDRAULIC BRAKES

 Hydraulics is the use of a liquid under

pressure to transfer force or motion, or to
increase an applied force.

 The pressure on a liquid is called

HYRAULIC PRESSURE.

 And the brakes which are operated by

means of hydraulic pressure are called
HYDRAULIC BRAKES.

 These brakes are based on the principle

of Pascal’s law.
 PASCAL’S LAW

 The pressure exerted

anywhere in a mass of
confined liquid is
transmitted undiminished
in all directions throughout
the liquid.

 Applied in hydraulic
lifts, hydraulic brakes
 MASTER CYLINDER IN ACTION

 When we press the brake pedal, it pushes on primary

piston through a linkage.

 Pressure is built in the cylinder and the lines as the

brake pedal is depressed further.

 The pressure between the primary and secondary

piston forces the secondary piston to compress the
fluid in its circuit.

 If the brakes are operating properly, the pressure wll

be same in both the circuits.

 If there is a leak in one of the circuits, that circuit will

not be able to maintain pressure.
MASTER CYLINDER
 USE OF LIQUIDS INSTEAD OF GASES

 Liquids are used in hydraulic systems because

liquids are incompressible.

 If
we use a gas, on increasing the pressure, the gas
will be compressed into a smaller volume due to
which there will be no transmission of force or
motion.
 ADVANTAGES OF HYDRAULIC BRAKES

 Equal braking effort to all the four wheels

 Lessrate of wear (due to absence of joints compared

to mechanical brakes)

 Force
multiplication (or divisions) very easily just by
changing the size of one piston and cylinder relative to
 DISADVANTAGES OF HYDRAULIC
BRAKES

 Evenslight leakage of air into the breaking

system makes it useless.

 Thebrake shoes are liable to get ruined if the

brake fluid leaks out.
 DISC BRAKES

 In a disc brake, the fluid from

the master cylinder is forced
into a caliper where it presses
against a piston.

 The piston in turn squeezes two

brake pads against the disc
(rotor), which is attached to
wheel, forcing it to slow down or
stop.
 DISC BRAKE AND BRAKE OF A BICYCLE

 Similarto a bicycle brake where two rubber pads run

against the wheel rim creating friction.

 But in a disc brake, the brake pads squeeze the rotor

instead of the wheel, and the force is transmitted
hydraulically instead of through a cable.
 DRUM BRAKES

 The
drum brake has a metal
brake drum that encloses
the brake assembly at each
wheel.

 Twocurved brake shoes

expand outward to slow or
stop the drum which
rotates with the wheel.
 WORKING OF DRUM BRAKES

 Drum brakes work on the same principle as

the disc brakes.

 Shoes press against a rotating surface.

 In this system that surface is called a drum.

 Drum brake also has an adjuster

mechanism, an
emergency brake mechanism and lots of
springs.

 The shoes are pulled away from the drum by

the springs when the brakes are released.
DISK BRAKE AND DRUM BRAKE
 SOME MORE POINTS

 Most modern cars have disc brakes on front wheels and drum brakes
on rear wheels and some wheels have disc brakes on all four wheels.

 To increase safety, most modern car brake systems are broken into
two circuits, with two wheels on each circuit.

 If a fluid leak occurs in one circuit, only two of the wheels will loose
their
brakes and the car will still be able to stop when we press the break
 BRAKE FLUIDS

 One of the important characteristics of

brake fluid is its BOILING POINT. Hydraulic
systems rely on incompressible fluid to
transmit force.

 Liquids are generally incompressible while

gases are compressible.

 If the break fluid boils (becomes a gas), it

will loose most of its ability to transmit
force.

 This may partially or completely disable

he brakes.
TYPES OF BRAKE FLUIDS

DOT
GLYCOL 3
BASED
(ABSORB
WATER) DOT
FLUID 4
S
SILICON BASED
(DOESN’T DOT
ABSORB 5
WATER)
 PRECAUTIONS

 As a DOT 3 or DOT 4 brake fluid absorbs water, its boiling point

decreases. It can absorb water from air, that is why we should avoid
opening the car’s brake fluid reservoir and the container of the brake
fluid should be tightly sealed.

 Also DOT 3 and DOT 4 brake fluids eat paint.

 None of the different types of brake fluids should be mixed. They can
react
badly with each other and corrode the brake system.
IC ENGINES
 Types of IC Engines

• According to the basic engine design

1. Reciprocating engine
2. Rotary engine
• According to method of ignition
1. Spark ignition engine
2. Compression ignition engine
• According to the number of strokes per cycle
1. Two stroke
2. Four stroke
3. Six stroke
RECIPROCATING ENGINE
Rotatory engine
• According to the type of fuel
1. Petrol engine
2. Diesel engine
3. Gas engine
• According to the cycle of operation
1. Otto cycle engine
2. Diesel cycle engine
3. Dual cycle engine
• According to the number of cylinders
1. Single cylinder
2. Multi cylinder
• According to the arrangement of the cylinder
1. Horizontal engine
2. Vertical engine
3. V-shaped engine
4. Radial engine
5. W-shaped engine
• According to the method of cooling
1. Air cooled engine
2. Water cooled engine
VERTICAL ENGINE
HORIZONTAL ENGINE
V – SHAPED ENGINE
RADIAL ENGINE
W - SHAPED
 Spark Ignition
• The combustion process of the air-fuel mixture is ignited by a spark from a spark
plug and fuel is burnt in the combustion chamber.
• It uses Petrol as fuel.
• Compression ratio is less.
76
 Compression Ignition
• It uses the heat of compression to initiate ignition and burn the fuel that has been
injected into the combustion chamber.
• It uses Diesel as fuel.
• Compression ratio is more.
 4 STROKE ENGINE
• Suction Stroke
• Compression Stroke
• Power Stroke
• Exhaust Stroke
 Valves
• There are 2 type of valves - a) Inlet Valve
b) Exhaust Valve
• The valve which allows mixture into the cylinder is the inlet valve; the one through
which the spent gases escape is the exhaust valve.
• They are designed to open and close at precise moments, to allow the engine to run
efficiently at all speeds.
 Valve Timing
The valve timing is the precise timing of the opening and closing of the valves.

The 4-stroke cycle

1 = TDC
2 = BDC
A: Intake 
B: Compression 
C: Power 
D: Exhaust
 Valve Train
It is a device that controls the operation of the valves, in which a sequence of components
transmits motion throughout the assembly. A traditional reciprocating internal combustion
engine uses valves to control air and fuel flow into and out of the cylinders, facilitating
combustion.
 Engine Balancing
For complete balancing we have to Balance -

• Rotating Mass
• Reciprocating Mass
• Firing Forces
 ENGINE COOLING

• Air Cooling

• Oil Cooling

• Water Cooling
ENGINE COOLING PARTS
 Superchargers
It is a type of air compression device powered by the engine
crankshaft. It is a way of increasing engine power by forcing
more air into the cylinder so that more power can be produced
from each power stroke
 Turbochargers

A turbocharger is a supercharger that is driven by the engine's exhaust gases, by means

of a turbine. It consists of a two piece, high-speed turbine assembly with one side that
compresses the intake air, and the other side that is powered by the exhaust gas
outflow.
.
FUEL SUPPLY SYSTEM
 SPARK PLUG
• It is a device for delivering electric current from an ignition system to the
combustion chamber of a spark-ignition engine to ignite the compressed fuel/air
mixture by an electric spark, while containing combustion pressure within the
engine.
 CARBURETOR

• It is a device that blends air and fuel for an internal combustion engine.
 Carburetors have five different circuits

• Main circuit - Provides just enough fuel for fuel-efficient

cruising.
• Idle circuit - Provides just enough fuel to keep the engine idling.
• Accelerator pump - Provides an extra burst of fuel when the
accelerator pedal is first depressed, reducing hesitation before
the engine speeds up.
• Power enrichment circuit - Provides extra fuel when the car is
going up a hill or towing a trailer.
• Choke - Provides extra fuel when the engine is cold so that it
will start.
 FUEL INJECTOR
It is a device used for injecting fuel in IC engine
in atomized form.
FUEL INJECTOR
94