Body-Frame Construction

Separate body and frame The frame carries all the structural load

Integral Construction

Chassis and body are separately built Chassis and body are welded together to form a single unit Historically, a step towards unitized body Chassiless Construction

Chassis and body can not be discerned from one another, a.k.a Unitized body The body design is more complex The body provides structural support

Spot welding is extensively used in unitized body Bolts can be used in low stress areas Advantages of the unitized body: o Higher strength and stiffness due to deeper panels and more flanges o Higher torsional stress due to the higher enclosed area

Front End Spider

1- Long rail outer 2- Long rail inner 3- Long rail extensions 4- Torque box - front 5- Long rail rear 6- Torque box - rear 7- #1 Cross member 8- Lower tie bar 9- Lower tie bar extension 10- Upper tie bar 11- Upper tie bar extension

Engine Compartment

1- Engine compartment side panel sub-assembly 2- Front end spider sub-assembly 3- Dash and toe pan 4- Plenum sub-assembly

Plenum

1- Plenum panel 2- Upper shroud panel 3- Cowl bar

Front Compartment Pan

1- Front compartment pan 2- Front seat anchor cross member

Rear End Spider

1- Rear long rail 2- Rear cross bar - front 3- Rear cross bar - rear 4- Rear torque box - lower

Rear Compartment Pan

1- Rear compartment pan 2- Rear end spider sub-assembly

Front & Rear Compartment Pans

1- Front compartment pan sub-assembly

2- Rear compartment pan sub-assembly 3- Rocker inner panel 4- Front torque box upper 5- Rear torque box upper

Body Side Frame (Sedan)

1- Engine compartment rail outer upper 2- Body side ring outer panel 3- Front body hinge pillar reinforcement 4- Center pillar reinforcement 5- Center pillar inner panel 6- Front body hinge pillar & engine compartment rail inner panel 7- Rear quarter to rear compartment pan filler 8- Rear quarter inner panel 9- Roof side rail inner 10- Rear quarter outer panel to rear end panel filler

Rear End Cross Body Parts

1- Rear seat back panel 2- Rear seat back panel reinforcement 3- Rear seat back panel to back window panel 4- Rear seat back panel to back window panel reinforcement 5- Rear end panel

Cross Car Parts at Roof

1- Windshield header 2- Roof bow 3- Backlight header 4- Roof outer panel

Criteria

Rigidity

High torsional and bending rigidity Must minimize the elastic deformation of the apertures o Doors o Hood o Trunk Rigidity must be balanced with the vibrational characteristics Vibrational Characteristics

Must consider the body and its components Causes of vibration o Wheels & Suspension o Powertrain o Wind Natural frequency tuning o Creasing of walls o Sheet metal thickness o Cross sections Operational Integrity

Alternating stresses can cause damage o Cracks o Weld failure Alternating stresses caused by o Road conditions o Driving conditions Certain body areas are more susceptible o Engine mounts o Suspension/steering mounts Crash Worthiness

Protection of the occupants and vehicle interior in high speed collisions Kinetic energy must be absorbed via controlled body panel deformation Ease of Repair

Easy replacement of body parts o Most susceptible to damage o Most susceptible to wear Easy access to interior panels Easy access to bolts and joints Feature lines for repainting the individual panels Materials

Sheet steel o 0.6 to 3.0 mm gage o Possesses ideal properties stiffness strength ductility formability availability

cost

High-Strength Low-Alloy Steel (HSLA) o Used for highly stressed areas o Allows for reduction in thickness Aluminum o Primarily used for weight reduction (1/3 of steel) o Used for hoods, trunk lids, roofs o Not very economical (~ 3x the cost of steel) o In common use among German luxury vehicles o Aluminum alloys can surpass steel in mechanical properties Plastics o Used in a limited number of components Load bearing components use reinforced thermoplastics Energy absorbing components use polyurethane and polypropylene Body components (e.g. roof, door) use polypropylene, polyethylene, polycarbonates o May present cost, weight, and durability benefits Safety

Protection for multiple purposes o Occupants o Pedestrians o The vehicle Exterior body o Body deformation o Body shape

Injury Risk Factors

Exterior body safety factors o Moveable lamps o Moveable mirrors o Recessed door handles

Interior body panels o Add rigidity A, B, C pillars Floor panels o Control deformation behavior Inner hood panels crush initiators Side member crush direction Aerodynamics

Minimize drag Maximize down force Minimize side force Minimize wind noise Minimize vibration BIW (BODY IN WHITE)/BODY SHELL/BLUE BUCK BIW is an assemblage of all welded sheet metal panels as before going for primingand painting.There are two kinds of BIW Structures in use:1 . M o n o c o q u e B o d y s t r u c t u r e 2 . F r a m e m o u n t e d B o d y s t r u c t u r e In monocoque body, chassis is in built in the BIW itself and there is no separatechassis. Wheels are directly mounted to the BIW with the help of suspension system.In Frame mounted body, body is mounted on a separate chassis/frame and thewheels are mounted on the chassis and not to the body.BIW structure can be divided in following substructures: UNDERBODY STRUCTURE FRONT END STRUCTURE BODY SIDE STRUCTURE CLOSURES ROOFAn UNDERBODY Structure consists of following major panels: DASHPANEL FRTFLOOR RISER REAR FLOOR REAR WHEEL HOUSEFRONT END structure consists of following major panels: PLENUMPANEL FRTWHEELHOUSE/FENDER WINGPANEL COWL UPPER TIE BAR LOWER TIE BAR BODY SIDE structure consists of following major panels:

A-PILLAR B-PILLAR C/D PILLARS RINGPANEL QUARTERPANELS DRIP RAILS/GUTTERSCLOSURES consists of following major panels: ALLDOORS HOOD/BONNETROOF structure consists of following major panels: ROOF HEADERS BOWSDash panel provides a partition between engine and the driver/passenger cabininsidecar.FRT FLOOR provides a base for seats mounting and provides partition betweentransmission/propeller shaft/ground and the cabin.Riser connects Front floor to Rear Floor by providing a level difference.Rear Floor is the floor on the Rear of the car and provides a partition from groundalso provide base for Rear seat mounting.A floor assembly consists of Sills/bars for mtg on frame in case of frame mountedconstruction and in case of monocoque construction long members/cross membersare welded.Note: Where there are three row seats one more floor panel is connected to the frontfloor called Centre floor and the second row seat is mounted on the center floor.Plenum is a chamber located between the throttle body and the runners of theintake manifold, used to distribute the intake charge evenly and enhance enginebreathing. The greater volume of gas in this enclosed area is under greater pressurethan the surrounding container.Panel below windshield connecting the dash panel to cowl, also provides basefor cross car beam (CCB)/Instrument panel (IP) mounting.Frt Wheel house or Fender is an encasement around the Frt wheel.Wing panel are the outer most side panel in the front. Cowl is the portion of the body bounded by the front fenders, the base of thewindshield, and the rear edge of the hood.Upper tie bar is the upper panel in front connecting the two sides (RH/LH) of Frontstructure.Lower tie bar is the lower panel in front connecting the two sides (RH/LH) of Frontstructure.Pillars are the support to the roof, i.e. connecting panels between roof & lower bodypanels.A-Pillar is the front most support to Roof.BPillar is the second support to the roof and situated on the locking side of theFrontdoor.C-Pillar is the Rear most support to roof in case of a two row seats car, OR thirdsupport to the roof.D-pillar is the forth support to the roof and usually on the rear side of quarterpanel.Ring panel is a structure panel connecting the rear portion of the body to front, andconstitutes a big part in side structure.Quarter panel is rear most panel of a body side structure.Drip rails/Gutters is an exposed channel applied to the roof over the side windows todirect water away from the windows and to cover structural welding.Header is the structural member above the windshield at the juncture with theforward edge of the roof panel.Hood is a hinged panel providing access to the engine compartment. Some other terms used for BIW: Backlight: The window across the rear of any automobile, regardless of body style.Some times called back window. Beltline: The line established by the upper edge of the car lower body at the glassopenings, as seen from the side. Blind Quarter: An unusually wide C pillar of roof quarter, tending to enclose rear seatarea. Catwalk: A depressed surface, usually between a fender and a raised area of the hood or deck.

Convertible Boot: A covering, usually held in place with snap fasteners, over the folded-down soft top. Convertible Stack: That part of a convertible top, which projects above the beltline of deck when the top is folded down. Decklid: A hinged panel providing access to the luggage compartment. Greenhouse: The upper body of an automobile; the structure above the beltline glass,roof, and supporting members. Hardtop: A term applied to any fixed roof with retracting window glass and no exposedB or middle pillar. Lower Back Panel: Portion of body sheet metal below rear edge of deckled. Rocker Panel: The sheet-metal surface below the door opening, running between frontand rear wheel openings. Sedan: Two-door or four-door car having stationary window frames in its doors. Tunnel: The hump in the floor pan that provides clearance for the drive shaft on rear wheel drive vehicles. Upper Back Panel: Portion of body sheet metal between backlight and deckled.

Common terms used for sheet metal technology:Blank: Blank is the trimmed sheet to the required shape for further operations. Operationis called as blanking.Drawing: making a cup shape is called drawing operation, material thinning takes placein the operation normally and the allowed thinning is around 15%.Forming: this refers to bending of sheet metal to desired shape.Punching: this refers to making holes/any shape cutout in sheet metal.Trimming: this refers to trim the outer periphery, usually after forming or drawingoperation.