B V B COLLEGE OF ENGINEERING AND TECHNOLOGY

2012-2013

DEPARTMENT OF AUTOMOBILE ENGINEERING

VEHICLE BODY ENGINEERING COURSE PROJECT REPORT ON “FIAT PUNTO”

BY:

KAVYA M BHAT 2BV09AU020

H S SAMPATHKUMAR 2BV09AU048

DEVENDRA JAIN 2BV09AU016

VBE COURSE PROJECT

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TECHNICAL SPECIFICATION

OUTFITS ACTIVE - DYNAMICENGINE 1.2 - 8V – 65 bhpNo. of cylinders, arrangement 4, in line, front transverseNo. of valves 2Bore x stroke (mm) 70.8 x 78.9Capacity (cc) 1242Environmental compatibility EURO 4Emissions control EOBDCompression ratio 11:1Max. power output: bhp-EC (kW-EC) 65 (48)at rpm 5500Peak torque: kgm-EC (Nm-EC) 10.4 (102)at rpm 3000Timing (control) 1 OHCwith mechanical tappetsFuel feed MPI electronic sequential phasedIgnition Static with digital electronic controlTRANSMISSIONDrive frontClutch control hydraulicGearbox, no. of speeds 5Ratios:

1st 3.909 : 1

2nd 2.158 : 1

3rd 1.480 : 1

4th 1.121 : 1

5th 0.921 : 1

6th / Reverse 3.818 : 1Gearbox family C514Final drive 4.071STEERINGType rack and pinionwith electric driveTurning circle (m) 10BRAKES - D (disc) - T (drum)Front: (mm) D257 x 22 (ventilated)Rear: (mm) T203SUSPENSION

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Front independent MacPherson,telescopic dampers, anti-roll bar withspherical joint linksRear torsion axle and crossbeam.Telescopic hydraulic dampersMEASUREMENTSWheelbase (mm) 2510Front/rear track* (mm) front 1473 - rear 1466

DEVELOPMENT OF FIAT PUNTO

The Fiat Grande Punto is a car manufactured by the Italian automaker Fiat. It was unveiled on 5 May 2005 and replaced by the Punto Evo in 2010. The car is manufactured in Italy, in Brazil from 2007, and in India from 2008. This model is at its third facelift. After the Fiat Grande Punto and Fiat Punto Evo, the 2012 third version is simply called Fiat Punto.

Grande Punto (2005–2009)

The third generation Fiat supermini to bear the name Punto, codenamed Project 199, the Grande Punto was unveiled at the 2005 Frankfurt Motor Show and went on sale later that year. Styled by Giugiaro, the car is based on the Fiat-GM Small platform. Whilst the model shares some of its name with the previous Punto, a large number of its components are new, including a new chassis and body shell.

The engines are the Fiat 1.2 8v Fire (65 PS), a new 1.4 8v Fire (77 PS) and the 1.4 16v StarJet (95 PS). Four MultiJet diesel engines are also available: two 1.3 16v units (75 PS (55 kW) and 90 PS (66 kW), the latter with a variable geometry turbocharger) and two 1.9 with 120 PS (88 kW) and 130 PS (96 kW), all of them with diesel particulate filter. The 1.9 diesel was replaced with the new 1.6 MultiJet starting the end of 2008.

All the engines are Euro IV compliant. In 2007, a new 1.4 16v T-Jet turbocharged petrol engine, 120 PS (88 kW), became available. At the 2007 Frankfurt Motor Show, Fiat introduced 155 PS (114 kW) an Abarth version by Abarth & C S.p.A.. It was branded as an Abarth rather than Fiat.[8] The car's nose, headlights and front grill look reminiscent of the Maserati Coupé (both were designed by Giorgetto Giugiaro of ItalDesign).

In Australia, Fiat introduced the Grande Punto in mid-2006, sold only as the Punto; it is the first Fiat to be sold in Australia since 1989. Shortly after its launch the car, powered by the 1.3 90 PS (66 kW) diesel engine, was recognized as the most economical on the market.

It was launched in Mexico in November 2006. The Grande Punto is placed above the Fiat Palio in the Mexican Fiat car lineup. Initially it was sold with the 1.4 16v StarJet 95 PS (70 kW) engine with 6-speed manual gearbox in 5-door Dynamic and 3-door Sport trims. In December 2007, the 1.4 16v T-Jet 120 PS (88 kW) variant was launched. The Italian-made Grande Punto has already been launched in Chile and the Dominican Republic in petrol and diesel versions.

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The Grande Punto also went on sale in South Africa in 2006, replacing the previous generation.

In the rest of South America, the Brazilian-built Grande Punto (called only Punto) was launched in August 2007. Codenamed Project 310, it is produced in the factory of Betim, Minas Gerais, Brazil. The chassis is an adaptation of the Fiat Palio, a lower cost compact. Levels of safety were not maintained (airbags and ABS are optional on lower trim levels, and the highest one has only two airbags as standard), but the ride comfort is said to be the same. The five-door version is the only one available in the Brazilian line, and there are no plans for a two-door version (in Brazil, two-door vehicles are only accepted for cheaper cars). The engines available at launch were the 85 PS (63 kW) 1.4 Fire 8v and the 115 PS (85 kW) 1.8 Family 1 X18XE engine that comes from GM-Fiat/Powertrain, and later the 1.4 Fire 16v TurboJet, also available for the Linea. For the 2011 model, there were added the new E.torQ engines 1.6 16v and 1.8 16v. Produced by Fiat Powertrain Technologies, they were based on the discontinued Tritec engines. All non-Turbo petrol models produced in Brazil are flex-fuel.

Grande Punto was launched in India during the Delhi Auto Expo in January 2008, with sales starting in June 2009. The Indian market Punto is manufactured by the Fiat-Tata Motors joint venture Fiat India Automobiles Ltd (FIAL) in a new plant in Ranjangaon, Maharashtra.

A related sedan car, the Fiat Linea, was launched in early 2007 to replace the aging Fiat Marea. It is built on an extended version of the Grande Punto's chassis, with a total length of 4,600 mm (181.1 in), making it part of the superior small family car segment.

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CALCULATION OF DRAG COEFFICIENT AND ROLLING RESISTANCE

Calculation of Frontal Cross Sectional Area (A)

Overall height of the vehicle = 1.490m

Overall width of the vehicle = 1.473 m

Ground clearance = 0.185 m

Therefore A = (Overall height-Ground clearance) ×Overall width

A = (1.490-.185) ×1.473

A =1.922mm 2

Velocity of the vehicle (v) = 160 kmph = 44.44 mph

Maximum power of the vehicle(P) = 65 bhp

Maximum speed of the engine(N) = 5500 rpm

Radius of the tyre (r) = 0.24m

gear ratio = 3

transmission efficiency = 0.90

Torque available at crankshaft (T) = (HP*5252)/N lbft

= (65*5252)/5500

= 62.06 lbft (1 lbft = 0.138kgm)

= 8.56 kgm

Torque available at wheels (Tw) = T*gear ratio*transmission efficiency

= 8.56*3*0.9

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= 23.12 kgm

Total tractive effort available at wheels (P) = (Tw/r)*g

= (23.12/0.24)*9.81

= 944.703 N

Total tractive effort available at wheels (P) =1.35*( ρA v2∗Cx /2)

Coefficient of air resistance (Cx) = (P∗2)/ (1.35∗ρA v2)

= (944.703∗2)/(1.35∗1∗1.922∗(44.44 )2)

= 0.368

Trials in Direction 1 Trials in Direction 2

Time V1 V2 V3 V4 V avg

sec kph kph kph kph kph

0 70 70 70 70 70.0

10 61 60 61 60 60.5

20 52 52 52 51 51.8

30 44 44 43 43 43.5

40 37 37 37 37 37.0

50 32 32 32.5 31 31.9

ρ = 1.22kg/m3

A= 1.922 m2

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g= 9.81 m/s2

m= 1050kg

0 10 20 30 40 50 60 70 800.00

5.00

10.00

15.00

20.00

25.00

Vehicle Velocity vs Time

Actual

Model

Time [sec]

Vel

oci

ty [

m/s

]

time V actual V model F a Error^2 time

sec m/s m/s Newton’s m/s^2 sec

0 19.44 19.44 417.2116 0.278141 0.00000 0

5 18.05374 381.1215 0.254081 5

10 16.81 16.78333 350.493 0.233662 0.00049 10

15 15.61502 324.2977 0.216198 15

20 14.38 14.53403 301.743 0.201162 0.02529 20

25 13.52822 282.2094 0.18814 25

30 12.08 12.58752 265.2077 0.176805 0.25421 30

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35 11.7035 250.3465 0.166898 35

40 10.28 10.86901 237.3106 0.158207 0.34956 40

45 10.07797 225.8433 0.150562 45

50 8.85 9.325163 215.7345 0.143823 0.22184 50

Sum of error^2 (minimize by changing Cd & Crr) = 0.0832

Drag co-efficient Cd= 0.401

Coefficient of rolling resistance Crr =0.013

Calculation for blind area

At normal position of driver seat

Blind area at right A piller 05deg

Blind area at right B piller 09deg

Blind area at right C piller 05deg

Blind area at left A piller 04deg

Blind area at left B piller 04deg

Blind area at left C piller 03deg

Total blind area 30deg

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ERGONOMICS

INTERIORSThe Grande Punto is surprisingly roomy and comes with inspiring dual-tone interiors. The height adjustable driver's seat, the comfortable position of the pedals, the alignment of the tiltable steering and the full, dominant view of the road makes driving a bold new experience.While the passengers at the back can sink into well-shaped seats and slip away into a world of comfort.• Dual-tone dashboard and interiors• Automatic climate control• AC adapted for tropical climate with pollen filter• Electrically controlled outside rear-view mirrors• Remote foldable key• Easy to find ignition facing the driver• 60:40 split seats for customized storage space

Comfort features: The interiors of Fiat Grande Punto are no less. The convenience and comfort

level in this hatchback is high and classy. The dual tone dashboard adds more charm to the

interiors of the car. The steering wheel and gearshift knob has been wrapped in leather, while

the comfy positioning of the pedals makes the driving quite easy and hassle free. The hatchback

features power tilt steering with power windows. The audio controls are mounted on the

steering wheel makes the journey quite entertaining and the audio player with FM radio with

speakers is impressive. The air conditioner in Fiat Grande Punto comes with automatic climate

control and pollen filter in the top trim variant. The hatchback also has automatic foldable key,

relaxing seats and ample of luggage storage space

Colors

Fiat Grande Punto is offered in numerous color shades, which define class with elegance. The color range available for Punto comprise of Medium Grey, Minimal Grey, Electric Blue, Exotica Red, Hip Hop Black and Bossa Nova White. All these colors ensure to make your Fiat Grande Punto look more stylish and elegant than before.

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SAFETY SYSTEMS

Active Safety Systems

Dual stage front airbags with Early Crash Sensors ABS with EBD 3 point ELR seatbelts with pretensioners and load limiters Adjustable rear headrests Seatbelts for all rear seat passengers

Passive safety Crash Severity Algorithm (CSA) to recognize the severity of impact and deploy the dual

front airbags accordingly Early Crash Sensor (ECS). Unlike the traditional system, this allows airbags to unfold

completely before the occupants can hurtle towards the steering wheel Fire Prevention System cuts off fuel supply to the engine in case of collision and

minimises risk of fire Fiat Code System (FCS) uses Immobilizer with Rolling Code to provide protection

against theft. Crumple zones Collapsible steering column High tensile steel frame Engine protection plate

Security Features: Remote keyless entry Digital door open indicator with specific door notification Anti-theft engine immobiliser with rolling code Double crank prevention system

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EURO NCAP CRASH TEST:

Adult occupant protection

Frontal impact driver Frontal impact passenger Side impact driver

Child restraints

18 month old Child

Kiddy Lineaccessory, forward facing

3 year old ChildKiddy Mega Base,

forward facing

Safety equipment

Front seatbelt pretensioners

Front seatbelt load limiters

Driver frontal airbag

Front passenger frontal airbag

Side body airbags

Side head airbags

Driver knee airbag

Car details

Hand of drive LHD

Tested model Fiat Punto S60 1.2

Body type 3 door hatchback

Year of publication

2000

Kerb weight 919

VIN from which rating applies

Applies to new Punto

Comments

The Punto gave a strong performance, revealing no areas of real concern. The cabin remained

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stable and could still be opened after the frontal impact. Less good was that the passenger's head hit the facia; this would have been more serious had such an impact happened to the other side of the car. The centre rear seat belt was of a simple two-point lap type that, it has been shown, can cause serious abdominal and spinal injuries. The child restraints had poor instruction labels and did not give very good sideways support: they allowed the dummies' torsos to come out of the seatbelts.

Front impactDamage to the cabin was insufficient to have seriously threatened the occupants. The steering wheel was slightly distorted but there was no evidence of chest contact. The front seat belts were equipped with real-mounted pyrotechnic pre-tensioners and were load limited. However, loadings on the driver's and passenger's chests were relatively high. Fiat intends to fit new front belt pre-tensioners and load limiters from March 2000.

Side impactWhen the Punto was first tested the results showed that the driver ran a high risk of serious chest injury. But the latest results were very good, even without a side airbag, and showed only a small risk of chest injury. This is an impressive performance by a small car that has a well-designed body structure.

Child occupantThe seat for the three-year-old used the adult belt to restrain the dummy. This prevented the head from moving too far forward but gave little support laterally, allowing the child to roll to the right. This, together with there being no seat wing, allowed the head to move outside the restraint and strike the other child seat. The seat's instruction labels were inadequate; some could be removed; others could not be seen when fitting the restraint.

PedestrianThe score comes mostly from protection offered in adult and child head-impact areas. The leg impact sites were unforgiving, but two of them gave little protection.

MATERAILS USED IN VEHICLE:

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1: SteelIn cars, steel is used to create the underlying chassis or cage beneath the body that forms the skeleton of the vehicle and protects you in the event of a crash. Door beams, roofs and even body panels created during auto manufacturing are made of steel on most cars today. Steel is also used in a variety of areas throughout the body to accommodate the engine or other parts. Exhausts are often made from stainless steel, for example.

Steel manufacturing has evolved greatly, so carmakers these days can make different types of steel for different areas of the vehicle that are rigid or that can crumple to absorb different impacts. These innovations in automotive manufacturing help keep you safe on the road.

2: Plastic

Today's cars now use tremendous amounts of plastics in auto manufacturing. They make up about 50 percent of the construction of new cars today. It's not surprising because plastics are durable, cheap to make and can be turned into just about anything.

Car dashboard, gauges, dials, switches, air conditioner vents, door handles, floor mats, seat belts, airbags and many other parts are all made from different types of plastics.

In addition to the dashboard parts, many of the tiny parts inside the engine, such as the handle on the oil dipstick, are also made of plastic. Because of their lightweight nature, plastics are being increasingly used in body structures and in engines during automotive manufacturing.

3: Aluminum

In the world of auto manufacturing, It's being used increasingly in the car world for its lightweight but tough nature. In 2009, aluminum components made up about 9 percent of the weight in most modern vehicles.

Aluminum can be used in automotive manufacturing to create body panels for a lighter, more performance-oriented vehicle. .

Wheels are also often made out of aluminum.

In addition, more automakers are switching from traditional iron blocks for engines to aluminum construction. It tends to be not quite as durable as iron, but its lighter weight means a big boost in performance.4: Rubber

Automotive manufacturing is the driving force of the rubber industry, as about 75 percent of the world's natural rubber production is used to make tires for vehicles. The rubber tire protects the

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rest of the wheel and its internal parts from wearing down, which can be good for fuel mileage and road safety.

In addition to the all-important tires, parts such as wiper blades, engine mounts, seals, hoses and belts are also made from rubber. As with plastic, it's a very durable, cheap and flexible material that has a wide array of uses in automobiles.

5: Glass.

Glass is used in many areas of your car. Obviously, its primary use is to create windshields so you can see properly while remaining safe from any airborne objects. It's also used to create rear and side-view mirrors to boost your view of what's around you while driving. In addition, its cousin fiberglass is also commonly used in auto manufacturing as an insulation material on cars.

However, as technology advances, glass is also being used to create more innovative parts on cars. For example, it can be used to create navigation screens and lenses for back-up cameras to allow drivers to have an even better view of what's behind them.

6: copper.

Steering wheel - must be a very hard material such as steel and pliable for your hands - rubber with a plastic coating to protect the rubber.

7: Lead.

Lead plates and sulphuric acid the liquid that circulates around the plates makes the best known vehicle storage battery which lasts 5 to 7 years before.

8: fiber.Manufacturing and styling of interiors and seats.

SUSPENSION SYSTEM:

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The front axle comes with independent Wheel, Suspension with McPherson Struts, Helical Springs, Double Acting Telescopic Dampers with Stabilizer Bar, while the rear axle has Torsion Beam, Helical Springs, and Double Acting Telescopic Dampers.

1. McPherson Strut with Stabilizer Bar (front)

Although it is a popular choice due to its simplicity and low manufacturing cost, the design has a few disadvantages with regards to the quality of ride provided and how it affects the handling of the car. Geometric analysis shows it cannot allow vertical movement of the wheel without some degree of either camber angle change, sideways movement, or both. It is not generally considered to give as good handling as a double wishbone suspension, because it allows the engineers less freedom to choose camber change and roll center. Another drawback is that it tends to transmit noise and vibration from the road directly into the body shell, giving higher noise levels and a "harsh" feeling to the ride compared with double wishbones, requiring manufacturers to add extra noise reduction or cancellation and isolation mechanisms. Also, because of its greater size and robustness and greater degree of attachment to the vehicle structure, when the internal seals of the shock absorber portion wear out replacement is expensive compared to replacing a simple shock absorber.

2. Torsional Beam Axle(rear)

A torsion beam suspension is a vehicle suspension similar to a trailing arm suspension but where both trailing arms are connected by a beam.In contrast to a torsion bar suspension, the main weight bearing springs are usually coil springs, either mounted over the shock absorbers or independently from them. Obviating anti-roll bars, the central torsion beam allows for a limited degree of freedom of each wheel when forced.

This semi-independent suspension has been very widely used for decades by the great majority of compact European and Japanese front wheel drive cars up to Golf-size. It is cheap to design and manufacture, compact with little boot space intrusion, and although ride and handling are theoretically inferior to more sophisticated designs

DAMPERS:

Mechanical energy is converted to heat in a vibrating systemDamping – dynamic load is reduced, displacement is reduced and fatigue life is improvedDynamic dampers are those which reduce dynamic load, displacement and improve fatigue life without converting mech. Energy to heat. They reduce the amplitude of systems vibrating at constant frequency.It consists of comparatively small mass with a spring, which would be tuned to have the damper vibrate at the same frequency as the disturbing force. The main mass will stop vibrating because the motion of the dynamic damper will always be equal and opposite to the motion of the disturbing force. The net force acting on the main mass would be in effect be reduced to zero.

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