Chassis

• It is a French term initially used to denote the frame of a

vehicle

• It is now extensively used to denote the complete vehicle

except body

1
 Layout of Chassis

Fig: 1 2
 Layout of Chassis

Fig: 2 3
 Layout of Chassis

Lorry chassis
Fig: 3 4
 Layout of Chassis

• For light vehicles of mono construction types laming body

integral with frame

• The chassis contains 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 components including the

body

5
 Layout of Chassis

• It is also known as carrying unit

• The chassis is subdivided into the running gear and the

power

• The running gear includes the frame, steering system,

suspension system, brakes, wheels and tyres

6
 Layout of Chassis

• The power plant include the engine assembles and

power transmission assembles

• The electrical system is the part of both chassis and

body

7
Components of Chassis

• Engine and the Radiator

• Transmission system
• Suspension system
• Steering system
• Braking system
• Fuel tank
• wheels

8
 Engine

Fig: 4 9
 Engine

• It is the main power source to move the vehicle

10
 Radiator

• It is a component of the

engine cooling system.

• It dissipate the engine

heat from the coolant to

the atmosphere

Fig: 5 11
 Transmission System

Fig: 6

12
 Transmission System

• The main purpose of the transmission system is to

transmit the power from engine to the road wheels

13
 Quiz

frame
1. Initially chassis was used to denote _________ of a

vehicle.

Carrying unit
2. The chassis is also known as __________ ____.

Engine is the main power source to move the vehicle.

3. ________

14
What is the main function of Brakes ?

15
Braking System

16
 Braking System

Fig 1
17
 Braking System

• The main function of braking system is to stop or slowdown the vehicle in the

shortest possible distance

18
 Braking System

Types

• Mechanical brakes

• Hydraulic brakes

• Vacuum brakes

• Air brakes

• Electrical brakes

19
Fuel Tank

20
 Fuel Tank

Fig 2 21
 Fuel Tank

• It is attached to the frame at the rear of the vehicle.

• Its capacity ranges from 70-120 litres.

• The filler neck of the tank is closed by a cap.

• A drain plug is provided at the bottom for emptying the tank

22
Wheels

23
 Wheels

• To move the vehicle

• To support the weight of the

vehicle

Fig 3 24
 Quiz
stop the
1. The main function of the braking system is to ______ or __________
vehicle.
slow down

2. The capacity of the fuel tank used in heavy vehicles is ___________.

3. The function of lts

70 to 120 the wheel is to ________ vehicle.

move the

25
How to chassis are classified ?

26
Classification

27
 Classification of Chassis

According to

• Location of the engine

• Number of wheels fitted

• Number of driving wheels

28
 Classification of Chassis
According to location of the engine

• Full forward chassis

• Semi-forward chassis

• Bus chassis

• Engine in front

• Engine at center

• Engine at rear

29
 Full forward Chassis

• In Full forward chassis the engine is located out side the

driver cabin

e x : passenger cars, old Tata Trucks

30
 Full forward Chassis

Fig 1
31
 Full forward Chassis

Disadvantage

• The driver is not able to see just in front of the vehicle

because his seat is far enough from the front wheels

32
 Semi forward Chassis

• In semi forward chassis, half portion of the engine is in

the driver cabin and the remaining half is out side the
cabin

ex : standard cars, Tata SE Trucks

33
 Semi forward Chassis

Fig 2 34
 Semi forward Chassis

Advantage

• It provides better visibility of road to the driver

35
 Bus Chassis

Fig: 3
36
 Bus Chassis

• The whole engine is fitted in the driver cabin.

• The driver seat is just above the front wheel.

37
Bus

Fig: 4

38
 Bus Chassis

Advantage:

• Driver can see the full front road right from the front
wheel.

39
 Quiz

out side of
1. In full forward chassis the engine is located _______
driver’s cabin.

half portion of the engine is in

2. In semi forward chassis ______
the driver’s cabin.

Passenger car is the example of full forward chassis

3. _____________

40
 Quiz

1. Full forward chassis (b ) a) French term

2. Semi forward chassis (c ) b) Passenger car

3. chassis (a ) c) Tata SE series

41
Chassis: Engine in Front

Fig: 1

42
 Engine in Front

• The engine is fitted in front portion of chassis

• The drive is given to front wheels only

ex : Matador vehicle

43
Engine In Front Chassis

Fig: 2

44
 Engine at Centre Chassis

Fig 3

45
 Engine At Centre Chassis

• The engine is fitted at the centre of the chassis

ex : Delhi transport buses

46
Engine at Centre Chassis ( D T C Buses )

Fig 4
47
 Engine at Centre Chassis

Advantage

• Full space of chassis floor for use.

48
 Engine at Rear Chassis

Fig 5

49
 Engine at Rear Chassis

• The engine is fitted at the back portion of the chassis

ex : VOLVO BUS

50
 Engine at Rear Chassis

Advantages

• Does not require long propeller shaft

• Gear box and differential are combined in one unit

51
 Quiz

1. In bus chassis the engine is fitted _______

inside of driver’s
cabin.

drive is given to the front

2. In engine at front chassis the_____
wheel.

Passenger car is the example of full forward chassis

3. _____________

52
 Quiz

Volvo bus
4. ___________ is the example of engine at rear chassis.

DTC bus
5. __________is the example of engine at centre chassis.

53
 Quiz

1. Bus chassis (c ) a) Matador van

2. Engine in front (a ) b) Passenger car

3. Full forward chassis ( ) c) Engine inside driver

b
cabine

54
How the chassis are classified?

55
 Classification

According to the number of wheels fitted and

number of driving wheels

• 4 x 2 drive chassis vehicle

• 4 x 4 drive chassis vehicle

• 6 x 2 drive chassis vehicle

• 6 x 4 drive chassis vehicle

56
 4 x 2 Drive Chassis Vehicle

• It consists of 4 wheels out of which 2 wheels are the

driving wheels

57
4 x 2 Drive Chassis Vehicle

Fig. 1
58
4 x 2 Drive Chassis Vehicle

Fig. 2
Fig. 2
59
4 x 4 Drive Chassis Vehicle

Fig. 3
60
 4 x 4 Drive Chassis Vehicle

• It consists of 4 wheels and all of them are the

driving wheels

61
4 x 4Drive Chassis Vehicle

Fig. 4
62
 6 x 2 Drive Chassis Vehicle

• It consists of 6 wheels out of which 2 wheels are the

driving wheels

63
6 x 2 Drive Chassis Vehicle

Fig. 5
64
6 x 2 Drive Chassis Vehicle

Fig. 6
65
 6 x 4 Drive Chassis Vehicle

• It consists of 6 wheels out of which 4 wheels are

the driving wheels

66
6 x 4 Drive Chassis Vehicle

Fig. 7
67
6 x 4 Drive Chassis Vehicle

Fig. 8
68
 Quiz

1. In 4 x 2 drive chassis vehicle _______

Two are the driving
wheels.

2. In 4 x 4 drive chassis vehicle _____

All are the driving wheels.

69
 Quiz

• Two
3. In 6 x 2 drive chassis vehicle ______are the driving

wheels

• Four
4. In 6 x 4 drive chassis vehicle _______are the driving

wheels

70
Frame

Figure 1
71
Frame

Figure 2
72
Frame

Figure 3

73
 Frame
• It is the main part of the chassis on which the remaining
parts of the chassis are mounted

• It is a rigid structure to hold all the major part together

• It is the foundation for carrying the engine and the body

of the vehicle as well as steering, power train etc , by
means of springs, axles, rubber pads etc

74
 Frame

• The frames are made of box, tubular channels or U –

shaped section, welded or riveted together

• In order to make them rigid to with stand the shocks,

blows, twists and vibrations

75
 Frame
• The engine is usually supported at three or four places
by providing rubber pads or washers between support
legs on the engine and the brackets on the frame

• Generally the engine is mount in the forward end of the

frame is connected to transmission system to form
power assembly

76
 Frame

• At the rear end of the frame rear axle housing is attached

through the rear spring

• The wheel assembly supports the frame

• The petrol tank is fastened to the rear side of the frame

• The steering system has some parts bolted to the frame

and some to the body

77
There are two types frame constructions
commonly in use
They are
- Conventional type of frame
- Integral type of frame

78
• It curves upwards at the rear of provide space for the
rear springs and to provide space for turning of the front
wheels when steered it is tapered at the front

79
Layout of Frame

Figure 4
80
 Layout of Frame

• It contains two longitudinal members A and cross

members B

• It is upswept at the front and rear to accommodate the

movement of axles due to springing

• It also keeps the chassis height low

81
 Layout of Frame

• It is narrowed down at the front to have better steering

lock, which gives a smaller turning circle

• C are brackets supporting the body

• E1 are dumb irons to act as bearings for spring

shackles

• They also take bumper brackets

82
 Layout of Frame

• E are brackets for mounting the springs

• The extension of the chassis frame ahead of the front

axle is called front over hang

• The extension of the chassis frame beyond the rear axle

is called rear over hang

83
 Quiz

1. Frame is the _______

Skelton of the vehicle.

2. The engine is mounted in theforward

______end of the frame.

rear side of the frame.

3. The petrol tank is fastened to the ____

4. The ______________supports
wheel assembly the frame

84
 Quiz

5) The frame is connected to transmission system to form

Power assembly
_______________

6) The extension of the chassis frame a head of the front

Front over hang
axle is called _________________

7)The extension of the chassis frame a head of the rear

Rear over hang
axle is called ______________

85
 Quiz

1. Frame is a

a) rigid structure
b) not a structure
c) complete vehicle
d) none of the above

86
 Quiz

2) In the frame generally engine is mounted

a) on the side
b) below the frame
c) on the forward
d) none of the above

87
 Car Frame

Fig.1
88
 Car Frame

• The above figure shows the box section type of car

frame which had been predominantly used in the
Plymouths designs

• This need not be as deep as the channel section for the

same strength

89
 Car Frame
• Hence this section permits a lower floor level and

ultimately lower center of gravity

• It also allows sufficient freedom to designers for the lay

out of under body assemblies and running gear

90
 Car Frame

• In case of cars having convertible bodies, an x –

member is added into this frame for providing torsion

rigidity

91
 X – Member Type Car Frame

Fig.2 92
 X – Member Type Car Frame
• The above figure shows an x – member type of car
frame

• This type of frame is advantageous from the torsional

rigidity point of view

• How ever, some difficulty is experienced for laying the

under body parts of the vehicle

93
 Truck Frame

Fig.3
94
 Truck Frame
• Truck frames are made of uniform width from end to end

• The longitudinal members are made of channel sections

• It will be seen from the end , that the longitudinal

members have maximum section at the middle and it
decreases towards the ends

95
 Truck Frame
• Generally, cross – members are located under the
radiator and engine

• Another cross – members is provided at the middle of

the frame to act as support for the central bearing the
propeller shaft

• Cross – members are also provided near the front and

rear of the supporting brackets of the rear spring
assembly

96
 Truck Frame
• They are essentially required to take care of the twisting
moment imposed by the springs on the longitudinal
members of the frame

• The frame consists of pressed steel side members and

cross members secured together by cold squeezed
diverts

97
 Truck Frame
• The side members are formed in deep channel section
tapers towards front and rear ends

• The cross members are of flanged U – box sections

constructions

98
 Quiz
1. The box section type of car frame is predominantly
Plymouth design
used in the _______________

2. The box - section type car frame has good

Beam strength
_____________

3. The box – section is quite suitable for the

Long body brackets
___________________

99
 Quiz

4. The box – section type permits a ________________

Lower floor level

5. The box – section type permits a

Lower centre of gravity
___________________

6. The box – section allows sufficient freedom to

Under body assemblies
designers for the lay out of ____________________

100
 Quiz

7. X – member type of frame is advantageous from the

________________point
Torsional rigidity of view

8. Some difficulty is experienced for laying the under body

x – member frame
parts of the vehicle in case of __________________

101
 Functions of Frame

• Support the chassis components and the body

• carry the weight of the passengers and goods

• withstand static and dynamic loads

102
 Functions of Frame

• With stand the engine and transmission torque

• With stand the bending stresses and twisting due to rise

and fall of the axles

• withstand centrifugal force while cornering

103
 Classification of Frame

Frames are classified into 3 types

• Conventional frame

• Integral frame

• Semi Integral frame

104
 Conventional Frame

Fig: 1 105
 Conventional Frame

Fig: 2 106
 Conventional Frame

Fig: 3 107
 Conventional Frame

• It is non-load carrying frame

• The loads are transferred to the suspension

• It supports the engine and transmission system

• The body is isolated from the frame with the help of rubber
mounts

108
 Conventional Frame

• Frame sections are usually channel or box

• It is widely used in Heavy vehicles

109
 Integral Frame

Fig: 4 110
 Integral Frame

Fig: 5 111
 Integral Frame

• There is no separate frame

• The body and frame are welded together as a single

unite

• Side members are eliminated

112
 Functions of Frame

• Floor is strengthened by cross members and body

• All the functions of the frame are carried out by body

• The body sheets relieve the metal frame work of parts of

the stresses

113
 Integral Frame

Advantages

• The body it self becomes a load carrying beam

• The body is lighter as well as stronger

• It can be assembled very easily

114
 Semi-Integral Frame

• The rubber body mounts used in conventional frame are

replaced by stiff mounts

• A part of the frame load is transferred to the body

structure also

115
 Quiz

1. Conventional frame is Non load carrying frame

______________

unit
2. Integral frame is a _________ frame

Conventional type of frame is widely used in Heavy vehicles

3. ___________

frame has to with stand static and dynamic loads

4. ________

116
 Quiz

1. Conventional frame ( b) a) Support weight of goods

and passengers
2. Semi integral frame (c ) b) Heavy vehicles
3. integral frame (d ) c) Stiff mountings
4. Frame (a ) d) Load carrying

117
 Loads on the Frame
• Weight of the vehicle and passengers, which causes
vertical bending of the side members

• Vertical loads when the vehicle comes across a bump or

hollow

• Loads due to road camber, side wind, cornering force while

taking a turn, which result in lateral bending of side
members

118
 Loads on the Frame

• Loads due to wheel impact with road obstacles may

cause that particular wheel to remained obstructed

while the other wheel tends to move forward, distorting

the frame to parallelism shape

119
 Loads on the Frame

• Engine torque and braking torque tending to bend the side members

• Sudden impact loads during a collision, which may result in a general collapse

120
 Frame Sections

Various cross sections of Frame

• Channel section

• Box section

• Tubular section

121
 Channel Section

• It is mainly used as a side

member due to its bending
stiffness

122
Fig: 1
 Box Section

• It is mainly used as side

and cross member due to
its bending stiffness and
high strength

Fig: 2 123
 Tubular Section

• It is extensively used in
three wheelers, scooters
and metadores

Fig: 3

124
 Materials for Frame

Material : Alloy Steel

Composition
Carbon 0.25%-0.35%
Manganese 0.35%-0.75%
Silicon 0.30%(maximum)
Nickel 3.00%
Phosphorous 0.05%(maximum)
Sulphur 0.50%(maximum)
125
 Defects in Frames

• The side members may be bent

• Cross members may be buckled

• Some rivets may be loose or broken

126
 Quiz

1. C________is
section mainly used as a frame side member.

Box section
2. __________ is mainly used as a frame cross member.

3. _____________
Tubular section is extensively used in three wheelers and
scooters.
3%
4. The percentage of Nickel in frame material is______

127
 Quiz

1. Bending stiffness (b ) a) 0.25 to 0.35 %

2. High strength (c ) b) C section
3. 3 wheelers (d ) c) Box section

4. Carbon (a ) d) Tubular section

128
 Requirements of Automobile Body

1. The body should be light in weight

2. It should have minimum number of components

3. It should have long fatigue life

4. It should have uniformly distributed loud

129
 Requirements of Automobile Body
5. It should promise sufficient space for passengers

6. It should have good access to the engine and

suspension system

7. It should create minimum vibrations when the vehicle

is running

8. It should have minimum resistance to air

130
 Requirements of Automobile Body
9. It should be cheap and easy in manufacturing

10. It should provide clear all – round vision through glass

area

11. It should be attractive in shape and colour

12. It should provide sufficient space for luggage

131
 Requirements of Automobile Body

The body of an Automobile especially a car must

satisfy the following requirements

• Strength

• Stiffness

• Torsional Stiffness

• Space

132
 Requirements of Automobile Body

• Protection against weather

• Resistance to corrosion

• Protection in Accident

• Air drag

• Noise vibration and harshness (NVH) should be in

minimum level

133
 Strength

The body must be strong enough to withstand all types of

forces or loads which it encounters

• Loads and forces encountered by the vehicles will

be discussed

134
 Stiffness

The car is like a beam supported on wheels. It must posses

• Sufficient stiffness to prevent excessive sagging in the

middle

135
Car Bent in the Middle

Fig 1
136
 Torsional Stiffness

The body should be sufficiently rigid so as to resist twisting

on bad roads

137
 Space

• There must be sufficient space for passengers and

luggage

• Leg room must be convenient

• It should have sufficient head room

• In case of trucks body, design should be in such a way

that maximum space is utilized for load carrying purpose

138
Leg Room

Fig 2
139
Head Room Head Room

Fig 3

140
 Air Drag

• The resistance of air to the movement of vehicle

depends upon the body shape
• Resistance increases directly with the vehicle speed

141
 Air Drag

• The shape of the body should be such that the air drag is
minimum

• The streamlining of body work becomes an important

factor towards fuel consumption

142
 Streamlining of Cars

• Streamlining is to produce a shape that provides less

resistance to air past, it was also applied to cars push to

increase fuel economy, and increase speed of the

vehicle

• Building a car having a Elliptical profile such that air

flows smoothly over the car without resisting the motion

of the car
143
Flow of air on streamlined car

It offers less resistance to the flow of air

Fig 4
144
 Protection against Weather

• The design of the body must be such that the occupants

and the luggage are protected from bad weather

145
 Protection to Corrosion

The body should be so designed that

• No moisture should be accumulated anywhere which
causes rust

• The material used should also non corrosive

• While painting the body anti rust agents like red oxide
should be coated to prevent from being corroded

146
 Protection Against Accidents

This is very important consideration in body design

The body should be so designed that

• The driver is at maximum ease so that there are least
chance of accidents due to fatigue

• In case of accidents the body must protect the occupants

147
 Quiz

1. _____________ protects passengers during accidents

a) Roof

b) Seat

c) Airbag

d) None of the above

148
 Quiz

2. Streamlining of body causes ________air resistance?

a) More

b) Less

c) No

d) None of the above

149
 Factors influence in buying a vehicle

What does one consider when buying a car ?

• Budget ( cost of the car )

• Mileage ( Fuel Consumption )

• Aesthetic looks

• Comforts

• Special features

150
 Which factor matters most

There may be ‘N’ number of models and brands

available suitable to your budget range. If some of them
are almost have same fuel efficiency then how will you
decide on buying one particular make or model?
• Looks

• Color

• Interior and exterior design

• Seats

• Other special features if any 151

 Which car will you buy

Fig 1 Fig 2 Fig 3

Fig 3 car
because It looks better

152
 Which one will you select

Fig 4 Fig 5

Most of them will go for car in fig 5

Reason for selecting it is color
153
Great Looking Cars

Fig 6
154
Great Looking Cars

Fig 7
155
Great Looking Cars

Fig 8
156
Great Looking Cars

Fig 9
157
Great Looking Cars

Fig 10
158
 One Important difference Between Cars

One will ultimately select a particular brand or make

basing on its looks, color, interior and exterior design,

seats etc

159
 Importance of Automobile Body

• It is the body( shape ) of vehicle, color and interior

comforts dictate’ one to buy a particular model when cost
and fuel efficiency is same among many models

• Color will be a key factor in deciding among same model

• That is the reason why companies produce one

particular colored car more than the others.

• It is clear that body Engineering is an important factor

160
 Quiz

• The important factor which influences in

deciding a particular vehicle model

aesthetic looks
is________________

161
Difference Between A Conventional Bus
And A Car

Can you state the major difference between a bus structure

and a car

• Bus has a Chassis frame on which the body is

attached

• Generally cars will not have a separate frame

162
 Classification of Body

• There are many types of vehicles being manufactured

and used

• Types of classification of body is done as below

They are

1) with respect to frame

2) with respect to material used

3) with respect to specific purpose or functional design

163
 Classification of Automobiles Based on
Frames

Automobiles can be classified into two groups with

respect to frames

They are

1)Framed Construction (conventional)

2)Frame less construction ( Uni-body or unitized )

164
 Framed Construction (conventional)

• There is a conventional pressed steel frame on which all

mechanical assemblies and parts are attached and the

body is superimposed on the frame

165
Framed Construction Vehicle

body

frame

Fig 1
166
 Merits of Framed Construction

• Higher strength

• Variants can be easily produced using same chassis

frame

• Repair cost is less in case of accidents

• Top less cars can be easily produced

167
 Demerits of Framed Construction

• Heavier because of frame, causing more fuel

consumption

• Cost of production is more because of frames

• Due to frame the CG point of vehicle is in higher

position.

• Thus Stability decreases

168
 Unitized Construction

• It is also called integral construction

• There is no separate frame

• Body structure is so designed to combine the functions

of frame and body

• Units normally attached to frame are attached to body

169
 Frameless Vehicle

Typical unibody construction. (Courtesy of Toyota Motor Corp.)

Fig.2
170
 Merits of Unitized Construction

• Reduced weight and consequent saving in fuel

• Lower manufacturing cost because of the absence of

frame

• During collision the body crumbles thereby absorbing the

shock due to impact. Passengers are protected from
impact

• Lower body position may be obtained. Results in

increased stability of the vehicle 171
 Demerits of Unitized Construction

• Reduction of strength and durability

• Economical only if frameless construction is adopted in

mass production

• Increased cost of repairs in case of damage to body

during accidents

• Topless cars are difficult to design with the frameless

construction
172
Classification of Automobiles based on Materials
used in Body Construction

• Wooden construction

• All metal construction

• Composite construction

• Plastics

• New age material like carbon fiber

173
 Wooden Construction

• All timber construction for automobile bodies was

discarded long back

174
 Draw Back of Wood as Body Material

Wood is now virtually obsolete in vehicle body

construction as single material because of following
reasons

1) high manual labor required

2) costly

3) shorter life

175
 Type of Wood used in Body Work

• However wood is still used along with other materials in

the manufacturing of Automobiles

• Soft wood like Pine, spruce are used for floor board of
bus and trucks

• Ash and beech are used for body frame work

176
• The hard wood such as oak, chest nut are used in
making complicated structural elements

• Special species of timber such as walnut, acacia

mahogany are used for dash board finishes in luxury
vehicles

177
 Quiz

1. What is FRP?
Fiber reinforced plastic

2. What is GRP?
Glass reinforced plastic

178
Quiz

1. Framed construction vehicle has more stability factor than

frameless construction vehicle
True
False
2. Which of the following vehicle is frameless construction
a) Minitruck
b) Car
c) Bus
d) None of the above

179
Quiz
1. Bus chassis frame on which the body is
________
Attached
2. Separate frame
Conventional cars will not have any_______________

3. In framed construction, the repair ________________

Cost will be less
in case of accidents

180
Quiz

4. In unitized construction there is

No separate frame
__________________

5. obsolute
Wood is now virtually _______________ in vehicle
body construction.

6. Frame less construction is economical only if is

Mass production
adopted in _________________

181
 All Metal Construction

• All steel construction is adopted for mass production of

bodies

• Sheet steel is shaped into different parts of body as per

design

• Parts such as roof, scuttle, doors are made of sheet

steel

182
 All Metal Construction

• The steel normally used is a low carbon steel of about

0.8 percent. Low carbon steel is a good welding material

• Copper or nickel and chrome are often added to improve

anticorrosive properties of the sheet steel

• Cheap when compared to wood and it has longer life

than wood

• It can be machined easily into any shapes

183
 Aluminum Alloy

• This metal is widely used in automobile body

construction in place of sheet steel

• It is used in body construction both as castings and for

sheet metal fabrication

• The additions to aluminum alloy are magnesium, nickel,

and silicon

184
 Aluminum Alloy

• The mechanical properties of aluminum alloy depends

on heat treatment and ageing

• It weighs less than sheet steel

• It has good anti corrosive properties

185
Aluminum Alloy Sheets

Fig 1

186
 Composite Construction

• Composite construction is one in which metal wood,

plastics are together used in the construction of body

work

• Today's trucks and buses uses all three materials

187
 Plastics

The introduction of plastics into the field of body work as

given the following advantages

1) Easier in making, more delicate styling especially for

interior

2) Cost effective

3) Corrosion free

188
 Plastics

4) Non absorbent nature of material so can be cleaned with

soap and water

5) Precession moulding is possible

6) Immune from acids and alkalies

189
 Fiber Reinforced Plastics

Cars are being manufactured entirely using FRP or GRP

(glass reinforced plastic)

They have the following advantages

• Less in weight so fuel efficient

• Will not corrode

• Have enough strength because of fiber reinforcement

• Color is introduced during manufacturing of raw

material itself 190
Car Body Made of FRP

Fig 2
191
 Various Plastic Parts

Fig 3 Fig 4

192
FRP Sheets

Fig 5
193
GRP Sheets

Fig 6
194
 Limitations of FRP

• Will be economical only if mass produced

• Cars made of metal looks better than plastics

• Though it is not widely used as single material for

making vehicles it is however today's car has more parts

made of plastics

195
 Future Materials

• Carbon fiber (also sometimes called graphite fiber) is a

material consisting of long thin sheets of graphite-like
carbon, packed to form a fiber

• It is commonly used in composite materials such as

carbon fiber reinforced plastic (which is often also called
carbon fiber)

196
 Future Materials

• It has the highest specific tensile strength of all the

reinforced materials (composite materials), and it has a
high strength to weight ratio and low coefficient of
thermal expansion

• It is now used as a body material in racing cars owing to

its low weight high strength factor

• Future vehicles will me made of this material

197
Carbon Fiber Sheets

Fig 7
198
 Quiz

1. What is FRP?
Fiber reinforced plastic

2. What is GRP?
Glass reinforced plastic

199
Quiz

1. Framed construction vehicle has more stability factor

than frameless construction vehicle
True
False
2. Which of the following vehicle is frameless
construction
a) Minitruck
b) Car
200
c) Bus
 Classification of Automobile Body
Based on Functional Design

• Functional design is of primary importance in the vehicle

body building

• The purpose factor gives the approximate shape size

and the layout of vehicle

201
 Classification of Automobile Vehicle Bodies
Based on Functional Design
All vehicles are classified into three groups based
on functional design
They are

1) Private body type

2) Commercial body type

3) Special body type

202
 Private Body Type
In case of private class automobiles importance is given to
the following items while designing

• Accommodation of persons

• Comforts to the persons accommodated in the vehicle

• Space and seat

• Lighting

• Ventilation

• Luggage space

203
Some Models of Private Class Automobiles

Many models of vehicles are manufactured in this type

Some of them are

• Saloon or sedan

• Convertibles

• Coupe

204
Some Models of Private Class Automobiles

• Limousine

• Estate car

• Sports utility vehicle

• Multi passenger vehicle

• Van or minibus

205
 Saloon or Sedan

• A car seating four or more with a fixed roof that is

full-height up to the rear window

• Sedans can have 2 or 4 doors

• This is the most common body style

• It normally has seats for 4 passengers

206
Saloon or Sedan

Fig 1
207
 Convertibles

• A body style with a removable or retractable roof and

rear window

208
Convertibles

Fig 2
209
 Coupe

• A 2-door, 2- or 4-seat car with a fixed roof

• Its doors are often longer than those of an equivalent sedan

• and the rear passenger area smaller

• the roof may also be low

• Originally, a coupé was required to have only one side

window per side, but this consideration has not been used
for many years

210
Coupe

Fig 3
211
 Limousine

• By definition, a driver-driven car with a (normally glass-

windowed) division between the front seats and the rear

• It has some times 3 doors on each side of the vehicle

• It has luxurious facilities

• It is custom built as per individual requirements

• It has very comfortable seating arrangements

212
Limousine

Fig 4
213
Seating Arrangement inside a Limousine

Fig 5
214
 Estate or Station Wagon

Station wagon

• A car with a full-height body all the way to the rear; the

load-carrying space created is accessed via a rear door

or doors. Sometimes shortened to just wagon

• It is used for long tours

• It has a large luggage place

215
Estate or Station Wagon

Fig 6
216
 Multi Purpose Vehicle

• Multi-purpose vehicle, a large car or small bus designed

to be used on and off-road and easily convertible to

facilitate loading of goods from facilitating carrying

people

217
Multi Purpose Vehicle

Fig 7
218
 Sports Utility Vehicle (4x4) (4WD)

• A four-wheeled vehicle with a drivetrain that allows all

four wheels to receive power from the engine

simultaneously

• Derivative of off-road or four-wheel drive vehicles but

with car-like levels of interior comfort and drivability

219
Sports Utility Vehicle

Fig 8
220
 Van or Minibus

• Designed to carry fewer people than a full-size bus,

generally up to 16 people in multiple rows of seats

Passenger access in normally via a sliding door on one

side of the vehicle. One example of a van with a minibus

version

221
Van or Minibus

Fig 9
222
 Sports Car
• Sports car is not the car which is used in race tracks like
FORMULA 1 cars

• It is used on roads for thrill purpose

• It has two doors

• It has normally 2 seats

• It has a very powerful engine and other features used in

racing cars

• It has very quick acceleration

223
 This is not the example for sports car

It is a racing car Fig 10

224
Sports Car

Fig 11
225
 Hatchback

• Identified by a rear door including the back window that

opens vertically to access a storage area not separated

from the rest of the passenger compartment. May be 2

or 4 door and 2 or 4 seat

226
Hatchback

Fig 12
227
 Quiz

1. Saloon consists of ___________no

2 to 4 doors of doors and

seats to ________
4 no of passengers

2. partition
Limousine has a ___________ between driver and

passenger compartment

228
 Commercial Vehicle Types

• There are two main type of vehicles in this segment

They are

1) Trucks

2) Buses

• In all the above cases the size of the body for the vehicle

is brought out strictly as per prescribed road rules

229
 Trucks

Following points should be considered while designing trucks

• Pay load

• Convenience in loading and unloading

• payload should be protected from atmospheric effects

• They are constructed either open trucks or closed vans

230
 Trucks

• For transportation of large articles trucks with raised roof

are used

• For ease of loading side doors can be of sliding or

removable type

• Open trucks can be made with lowered or raised floors

231
 Types of Trucks

• Normal control with lowered load carrying platform

• Forward control with flat floor

• Tipper

• Articulated trucks

232
 Normal Control Trucks

• In normal control trucks engine is placed in front of

drivers cabin

• Draw back of this type is that the space for carrying load

decreases

233
Normal Control Trucks

Fig 1
234
 Fully Forward Truck

• The engine in this case is placed in the cabin next to

driver or below the drivers cabin

• The space for payload can be increased with this type of

arrangement

235
Fully Forward Control Truck

Fig 2
236
Truck Type Based on Engines Position

Fig 3
237
Some types of trucks

238
Articulated Trucks

Fig 4
239
Tippers

Fig 5
240
Stack and Rack

Fig 6
241
Semi-trailer Truck

Fig 7
242
Special Purpose Trucks

Fig 8
243
Special Type of Trucks

Fig 9
244
Special Type of Trucks

Fig 10
245
Special Type of Trucks

Fig 11
246
 Another Way of Classifying Trucks

Trucks can be classified basing on

• Their load carrying capacity

247
 Quiz

1. In normal control trucks engine is placed in front of

Drivers cabin
_______________

The engine
2. In fully forward truck ___________ is placed in the
drivers cabin
cabin next to the _____________

248
 Buses

• Passenger carrying buses classified by the average

distance traveled
• There are four types of buses based on distance
traveled

1) town buses

2) suburban buses

3) Intercity coaches

4) touring coaches
249
 Town Buses

• Used for short distance ( 20 to 40 kms)

• Have large standing place

• At least two wide doors

• Lower entry and exit platforms

• Hard seat covers

250
 Suburban Buses

• Used for transportation of passengers from one town to

other (within 40-100km range )

• Have reasonably comfortable seats

• One door is sufficient

• Space should be provided to place luggage

251
 Intercity Coaches

• Used for long distance ( more than 200kms)

• Have comfortable seats

• Under floor luggage space

• Roof racks for luggage's

252
 Touring Coaches

• Have very comfortable reclining seats

• Toilets, air-conditioning, television are provided

• Additional windows in the roof are used to improve

visibility for the passengers

• under floor Spacious luggage compartments

• Elaborate thermal and acoustic insulations

• Large glassed windows

253
 Another Method of Classifying Buses

According to the seating capacity buses can be classified

into

• Micro bus 8-15 passengers

• Small coaches for long distance 16-30 passengers

• Medium coaches f0r long distance 31-45 passengers

• Medium buses for towns 41-60 passengers

• Large coaches for long distances 46-60 passengers

• Large buses for towns 61-80 passengers

254
 Classic Bus

Obsolete now Fig 1

255
Double Decker Bus

Fig 2
256
Double Decker Bus

Fig 3
257
 Double Decker Bus

• A double-Decker bus is a bus that has two levels

• Double-Decker long-distance coaches are in widespread

use around the world,

• Double-Decker city buses are less common

258
 Double Decker Bus

• Double-Decker buses are popular in some European

cities and in some parts of Asia, usually in former British
colonies

• Many towns around the world have a few that specialize

in short sight-seeing tours for tourists

259
 Disadvantages of Double Decker

• Less stable

• Consumes more fuel

260
Articulated Buses

Fig 4
261
 Articulated Bus

• Articulated buses are buses of a type with an increased

passenger capacity

• Found almost exclusively in public transportation use

• They are approximately 18 mm (60 ft) long, while regular

buses are 11 to 14 m (35-45 ft) long

262
 Articulated Bus

• To make them nimble enough to safely navigate streets

at their increased length, they are fitted with an extra
axle (set of wheels) and a joint usually located slightly
behind the midpoint of the bus, behind the second axle

• Some models of articulated buses have a steering

arrangement on the rearmost axle which turns slightly in
opposition to the front steering axle, which allows the
vehicle to negotiate turns in a somewhat crab-like
263
fashion
Articulated Bus

• Some buses have two joints, and these are called bi-

articulated buses

• Their seating capacity is around 200 and their length

about 25 m (82 ft)

264
 Main Benefits of an Articulated Bus
Compared with Double Decker
• Rapid simultaneous boarding and disembarkation
through more and large doors

• Much larger passenger capacity (120+ versus 80-90)

• Increased stability due to a lower centre of gravity

• Higher maximum speed

265
 Disadvantages

• Articulated bus is the effective power available to it. It is

common for articulated buses to use the same engine as
non-articulated buses; this leads to a slower speed and
acceleration, due to an increase of weight

• When used in cities with many slopes the vehicle is

prone to overheating

266
Some special types of buses

267
Airport Bus

Fig 5
268
City Bus

Fig 6
269
Luxury Coaches

Fig 7
270
• Buses are classified on the seating capacity

• Buses are also classified on the basis of the traveling

distance

• On the basis of traveling distance buses can be

classified into town bus, suburban bus, Long time bus,
Touring bus

271
 Quiz

1. Among articulated bus and double Decker bus which is

Articulated bus
widely used as bus for city commuter ? _____________

2. Articulated buses can be used in some cities with a

Train net work
____________

3. The main advantage of articulated bus is its

Passenger capacity
_________________

272
 Quiz

• Which of the following is the disadvantages of double

decker bus?

a) More fuel consumption

b) More stable

c) More pickup

d) None

273
 Special Class of Vehicle

• Vehicle used for special works

• Points to be taken care while designing special class

of vehicles:

1)Cruising speed

2)The type of load to be carried

3)Its accessibility on boarding it on the vehicle

274
 Special Class of Vehicle

4) Convenience in easy of unloading

5) Temperature conditions required if perishables are to

be carried

6) Leak proof construction of the body in case of carrying

liquids

275
 Some Examples for Special Class of
Vehicles

1) Ambulance

2) Fire brigade

3) Refrigerated vehicles

4) Tankers

5) Vehicle used by municipalities

276
 Ambulance
• Specially designed vehicle for transportation of patients
or accident persons

Fig 1 Ambulance
277
 Fire Brigade Vehicle
• Special designed vehicle for fire fighting in case of fire
accidents

Fig 2 Fire brigade vehicle

278
Fire Brigade Vehicle

Fig 3 Fire brigade vehicle

279
 Refrigerated Vehicle
• Special vehicle for transportation of sea foods

Fig 4 Refrigerated vehicle

280
 Tanker
• Special vehicle for transportation of liquids

Fig 5 Tanker
281
 Vehicle Used for Carrying Municipal Waste
• Special vehicle for transportation of garbage

Fig 6 Set down skip loader

282
Some types of trucks

283
Articulated Trucks

Fig 4
284
 Loads or Forces Acting on Bodies

The body must be strong enough to withstand all

types of forces
Forces are
• Weight of the car

• Weight of the passengers

• Weight of the luggage

285
 Loads or Forces Acting on Bodies

• Brake forces and

• Side force

• Should also be able to cope with impact loads of

reasonable magnitude

286
 Effect of Loads

• Weight of vehicle itself, weight of passengers and pay

load, side wind force will cause the vehicle to bend

vertical

• Inertia force, and braking force will cause the vehicle

body to twist

• Impact load due to accidents will cause the vehicle body

to crumble, bend and twist 287

• Weight of the car, Weight of the passengers, Weight of
the luggage, Inertia forces, Brake forces and Side force

• Should also be able to cope with impact loads of

reasonable magnitude

288
 Quiz

1. Which of the following is a special vehicle

a) Bus

b) Lorry

c) Ambulance

d) Auto

289
 Quiz

2. Loads acting on the body of vehicle are

a) Weight of the vehicle

b) Weight of the passengers

c) Braking force

d) All of the above

290
 Chassis

• It is a French term initially used to denote the frame

of a vehicle

• It is now extensively used to denote the complete

vehicle except body

291
 Components

• Engine and the Radiator

• Transmission system

• Suspension system

• Steering system

• Brakes

• Fuel tank

• wheels

292
 Classification of Chassis
According to the fitting of the engine

• Full forward chassis

• Semi-forward chassis

• Bus chassis

• Engine in front

• Engine at center

• Engine at rear

293
Full Forward Chassis & Semi Forward Chassis

• In Full forward chassis the engine is fitted out side the

driver cabin

Ex : passenger cars, old Tata trucks

• In semi forward chassis, half portion of the engine

is in the driver cabin and the remaining half is out

side the cabin

Ex : standard cars

294
 Bus Chassis & Engine in Front

• The whole engine is fitted in the driver cabin

• The driver seat is just above the front wheel

• The engine is fitted in front portion of chassis

• The drive is given to front wheels only

Ex : Matador vehicle

295
 Engine At Centre & Engine At Rear

• The engine is fitted at the centre of the chassis

Ex : Delhi transport buses

• The engine is fitted at the back portion of the chassis

Ex : Leyland bus of England

Volkswagen of w Germany

296
 Classification
According to the number of wheels fitted and
number of driving wheels

• 4 x 2 drive chassis vehicle

• 4 x 4 drive chassis vehicle

• 6 x 2 drive chassis vehicle

• 6 x 4 drive chassis vehicle

297
 Frame

• It is the main part of the chassis on which the remaining

parts of the chassis are mounted

• It is a rigid structure to hold all the major parts together

• The engine is mounted in the forward end of the frame

and is connected to transmission system to form power
assembly

298
 Frame

• At the rear end of the frame rear axle housing is attached

• The wheel assembly supports the frame

• The petrol tank is fastened to the rear of the frame

299
Layout of Frame

300
 Functions of Frame

• To Support the chassis components and the body

• To Carry the weight of the passengers and goods

• To Withstand static and dynamic loads

• To Withstand centrifugal force while cornering

301
 Classification of Frame
Frames are classified into 3 types

• Conventional frame

• Integral frame

• Semi Integral frame

302
 Conventional Frame
• It is non-load carrying frame

• The loads are transferred to the suspension

• It supports the engine and transmission system

• The body is isolated from the frame with the help of

rubber mounts

303
 Integral Frame

• There is no separate frame

• The body and frame are welded together as a

single unite

• Side members are eliminated

304
 Semi-integral Frame

• The rubber body mounts used in conventional frame are

replaced by stiff mounts

• A part of the frame load is transferred to the body

structure also

305
 Loads on the Frame

• Weight of the vehicle and passengers

• Vertical loads when the vehicle comes across a bump or
hollow
• Loads due to road camber, side wind, cornering force
• Loads due to wheel impact with road obstacles

• Engine torque and braking torque

• Sudden impact loads during a collision

306
 Frame Sections

Various cross sections

• Channel section

• Box section

• Tubular section

307
 Requirements of Automobile Body

1. The body should be light in weight

2. It should have minimum number of components

3. It should have long fatigue life

4. It should have uniformly distributed loud

308
 Requirements of Automobile Body

5. It should promise sufficient space for passengers

6. It should have good access to the engine and

suspension system

7. It should create minimum vibrations when the vehicle

is running

8. It should have minimum resistance to air

309
 Classification of Body

• There are many types of vehicles being manufactured

and used

• Types of classification of body is done as below

They are :

1) with respect to frame

2) with respect to material used

3) with respect to specific purpose or functional design

310
 Wooden Construction
• All timber construction for automobile bodies was

discarded long back

Draw back of wood as body material

Wood is now virtually obsolete in vehicle body construction
as single material because of following reasons

1) high manual labor required

2) costly

3) shorter life

311
 Type of Wood used in Body Work

• However wood is still used along with other materials in

the manufacturing of Automobiles

• Soft wood like Pine, spruce are used for floor board of
bus and trucks

• Ash and beech are used for body frame work

312
 All Metal Construction

• All steel construction is adopted for mass production of

bodies

• Sheet steel is shaped into different parts of body as per

design

• Parts such as roof, scuttle, doors are made of sheet steel

313
 Aluminum Alloy

• This metal is widely used in automobile body construction

in place of sheet steel

• It is used in body construction both as castings and for

sheet metal fabrication

• The additions to aluminum alloy are magnesium, nickel,

and silicon

314
 Fiber Reinforced Plastics
Cars are being manufactured entirely using FRP or
GRP ( glass reinforced plastic)
They have the following advantages

• Less in weight so fuel efficient

• Will not corrode

• Have enough strength because of fiber reinforcement

• Color is introduced during manufacturing of raw

material itself

315
 Classification of Automobile Vehicle Bodies
Based on Functional Design
All vehicles are classified into three groups based
on functional design
They are

1) Private body type

2) Commercial body type

3) Special body type

316
Some Models of Private Class Automobiles

Many models of vehicles are manufactured in this type

Some of them are

• Saloon or sedan

• Convertibles

• Coupe

317
Some Models of Private Class Automobiles

• Limousine

• Estate car

• Sports utility vehicle

• Multi passenger vehicle

• Van or minibus

318
 Types of Trucks

• Normal control with lowered load carrying platform

• Forward control with flat floor

• Tipper

• Articulated trucks

319
 Town Buses

• Used for short distance ( 20 to 40 kms)

• Have large standing place

• At least two wide doors

• Lower entry and exit platforms

• Hard seat covers

320
 Another Method of Classifying Buses

According to the seating capacity buses can be classified into:

• Micro bus 8-15 passengers

• Small coaches for long distance 16-30 passengers

• Medium coaches f0r long distance 31-45 passengers

• Medium buses for towns 41-60 passengers

• Large coaches for long distances 46-60 passengers

• Large buses for towns 61-80 passengers

• Very large buses for towns over passengers

321
 Loads or Forces Acting on Bodies
The body must be strong enough to withstand all
types of forces

Forces are
• weight of the car

• Weight of the passengers

• Weight of the luggage

322
 Loads or Forces Acting on Bodies

• Brake forces and

• Side force

• Should also be able to cope with impact loads of

reasonable magnitude

323