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AUTOMOTIVE MECHANICS & IC ENGINESAutoNEXWorkshop on: Venue: GGI, KhannaDate: 24-25 Feb 20121CHASSISSKELETON OF AUTOMOBILE TYPES OF CHASSISLADDER FRAME CHASSISTUBULAR SPACE FRAME CHASSISMONOCOQUE FRAME CHASSISULSAB MONOCOQUE BACKBONE FRAME CHASSIS ALUMINIUM SPACE FRAME

3Ladder Chassis

AC Cobra's chassis. Two longitudinal rails interconnected by several lateral and cross bracesAdvantage:Not much advantage these days.it is easy to buildcheap for hand buildProves good for SUVs.Disadvantage:Since it is a 2 dimensional structure, torsional rigidity is very much lower especially when dealing with vertical load or bumps.Who use it ?Most SUVs, classic cars, Lincoln Town Car, Ford Crown Victoria etc. PRO-E DESIGN OF LADDER FRAME CHASSIS

6TUBULAR SPACE FRAME

3 dimensional design High-end sports cars adopt tubular space frame to enhance the rigidity / weight ratioTubes are welded together and forms a very complex structureTUBULAR SPACE FRAME PRO-E DESIGN

8 3D-MAX DESIGN

9Advantage:Very strong in any direction. (compare with ladder chassis and monocoque chassis of the same weight)Disadvantage:Very complex, costly and time consuming to be built. Impossible for robotised production. Besides, it engages a lot of space, Raise the door sill and result in difficult access to the cabin.Who use it ?All Ferrari before the 360M, Lamborghini Diablo, Jaguar XJ220, Cater ham, TVR etc.MONOCOQUE

Monocoque is a one-piece structure which defines the overall shape of the carThe floorpan, which is the largest piece, and other pieces are press-made by big stamping machinesChassis is actually made by spot welding several pieces togetherSpot Welding

Metal sheets welded by applying pressure and heatLocalized heating is doneCopper electrodes usedE=I^2Rt

BRIEF TERMINOLOGYMULTI POINT STRUT BARFENDER BARANTI ROLL BARMONOCOQUETUBULAR SPACE LONGERON RH,LH

14ULSAB Monocoque

Ultra Light Steel Auto Body (ULSAB)It has the same structure as a conventional monocoque It differs from its donor is in minor details - the use of "Hydroform" parts, laser welding and sandwich steelAdvantage:Stronger and lighter then conventional monocoque without increasing production cost.Disadvantage:Still not strong or light enough for the best sports cars.Who use it ?Opel Astra, BMW 3-seriesBACKBONE CHASSIS

A strong tubular backbone (usually in rectangular section) connects the front and rear axle and provides nearly all the mechanical strengthIt's strong enough for smaller sports cars but not up to the job for high-end onesBACKBONE FRAME CHASSISBackbone chassis is a type of an automobile construction chassis that is similar to the body-on-frame design.

Instead of a two-dimensional ladder type structure, it consists of a strong tubular backbone (usually rectangular in cross section) that connects the front and rear suspension attachment areas. A body is then placed on this structure.

It is basically employed in mainly two wheel vehicles like bicycles, motorbikesetc 18CAD DESIGN OF BACKBONE FRAME CHASSIS

19Advantage:Cheap for mass production. Inherently good crash protection.Space efficient.Disadvantage:Heavy. Impossible for small-volume production.Who use it ?Nearly all mass production cars, all current Porsche.

21Advantage:Stong 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.Who use it ?Lotus Esprit, Elan Mk II, TVR, Marcos. ALUMINIUM SPACE FRAMEASF is intended to replace conventional steel monocoque mainly for the benefit of lightness.

Consists of extruded aluminum sections, vacuum die cast components and aluminum sheets of different thicknessesIt's quite complex and production cost is far higher than steel monocoqueAdvantage:Lighter than steel monocoque. As space efficient as it.Disadvantage:Still expensive for mass productionWho use it ?AudiCARBON-FIBER MONOCOQUE

Carbon Fiber is the most sophisticated material using in aircrafts, spaceships and racing cars because of its superior rigidity-to-weight ratio.Most so-called "supercars" use carbon-fiber in body panels only.Kevlar is the most rigidity to weight used in motor industry due to its highest rigidity-to-weight ratio.

SOLAR CAR CHASSIS