Professional Documents
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TECHNOLOGY, PUDUKKOTTAI
1
UNIV.
UNIT PLANNED
UNIT TITLES ALLOTED TEACHING AIDS
NO. HOURS
HOURS
1 VEHICLE STRUCTURE AND ENGINES 9 9 PPT, SMART BOARD, VIDEOS, FIELD VISIT
LECTURE PLANNED
TOPICS TLP NO. TEACHING AIDS
HOUR HOURS
• Transmission
– Conventional vehicles with manual transmission, e.g.
car with 5 gears.
– Semi-automatic
– Automatic : In automatic transmission, gears are not
required to be changed manually. It is automatically
changes as per speed of the automobile.
1.2 Classification of Vehicles
• Position of Engine
– Engine in Front :Most of the vehicles have engine in
the front. Example : most of the cars, buses, trucks in
India.
– Engine in the Rear Side: Very few vehicles have engine
located in the rear. Example : Nano car.
LECTURER HOUR – 2
1.3 Vehicle construction and
Different layouts
1.3 Vehicle construction and
Different layouts
1.3 Vehicle construction and
Different layouts
LECTURER HOUR – 3
1.3 Vehicle construction and
Different layouts
• It contains the source of power, i.e. engine, the frame,
which supports the engine, wheels, body, transmission,
the braking system and the steering. It also gives support
to suspension system and springs.
Introduction….
Chassis is the significant structure of an
automobile
A skeletal frame with various mechanical
parts like engine, tires, brakes, steering and
axle assemblies
Usually made of a light metal or composite
plastic which provides strength needed for
supporting vehicle components and load on it
• Chassis is a French term and was initially used to denote
the frame parts or Basic Structure of the vehicle. It is the
back bone of the vehicle.
• A vehicle with out body is called Chassis. The
components of the vehicle like Power plant, Transmission
System, Axles, Wheels and Tyres, Suspension, Controlling
Systems like Braking, Steering etc., and also electrical
system parts are mounted on the Chassis frame.
Types of chassis….
Most SUVs , classic cars ,lincoln town car, ford crown victoria
etc…..
Backbone chassis
Has a rectangular tube like a backbone and
simple in structure
made of glass fibre is used for joining front
and rear axle and responsible for the strength.
Space within structure used for positioning
drive shaft in case of rear wheel drive.
Drive train, engine and suspensions are
connected at the ends of the chassis
Strong enough for smaller sports
cars and most space saving other
than monocoque chassis
Audi
1.4 Chassis
• It is the main mounting for all the components including
the body. So it is also called as Carrying Unit.
Classification of a vehicle chassis is based on the
position of the engine on the chassis.
1. Full forward
2. Semi Forward
3. Engine at centre
4. Engine at the back
5. Conventional chassis
Chassis of a Truck
Chassis of a Truck
Rear wheel Drive:
Good traction obtained while climbing the hill.
Good distribution of braking force.
Large bulge in the region of gear box and due to
propeller shaft.
-Lighter in weight, because the driveshaft is
shorter, meaning better fuel economy.
-No floor hump in the passenger compartment, for
the same reason.
-Less weight in the drive train overall, resulting in
even more fuel economy.
1.4 Chassis
FUNCTIONS OF THE CHASSIS FRAME:
1. To carry load of the passengers or goods carried in the
body.
2. To support the load of the body, engine, gear box etc.,
3. To withstand the forces caused due to the sudden
braking or acceleration
4. To withstand the stresses caused due to the bad road
condition.
5. To withstand centrifugal force while cornering
LECTURER HOUR – 4
It is the foundation on which the power plant
and the body are carried and which in turn is
supported on the wheels through axles and
springs
Cross Section of Frame:
a.Channel Section - Good resistance to bending
b.Tabular Section - Good resistance to Torsion
c.Box Section - Good resistance to
both bending
and Torsion
•Carbon - 0.25-0.35%
•Manganese -0.35-0.725%
•Silicon -0.30% (maximm)
•Nickel -3%
•Phosphorous -0.05% (max.)
•Sulphur -0.5% (max)
1.5 Frame and body
• Frame: It is made up of long two members called side
members riveted together with the help of number of
cross members.
• TYPES OF CHASSIS FRAMES:
• There are three types of frames
– Conventional frame
– Integral frame
– Semi-integral frame
1.5 Frame and body
• Conventional frame: It has two long side members and
5 to 6 cross members joined together with the help of
rivets and bolts.
Conventional Semi Integral
Integral
1.5 Frame and body
• Integral Frame: This frame is used now a days in most
of the cars. There is no frame and all the assembly units
are attached to the body. All the functions of the frame
carried out by the body itself. Due to elimination of long
frame it is cheaper and due to less weight most
economical also. Only disadvantage is repairing is
difficult.
1.5 Frame and body
• Semi - Integral Frame: In some vehicles half frame is
fixed in the front end on which engine gear box and
front suspension is mounted. It has the advantage when
the vehicle is met with accident the front frame can be
taken easily to replace the damaged chassis frame. This
type of frame is used in FIAT cars and some of the
European and American cars.
1.5 Frame and body
• VARIOUS LOADS ACTING ON THE FRAME:
– Short duration Load - While crossing a broken patch.
– Momentary duration Load - While taking a curve.
– Impact Loads - Due to the collision of the vehicle
– Inertia Load - While applying brakes.
– Static Loads - Loads due to chassis parts.
– Over Loads - Beyond Design capacity.
1.5 Frame and body
• The Automobile bodies are divided in two groups
– Passenger body
– Commercial body
1.5 Frame and body
1.5 Frame and body
• REQUIREMENTS OF BODIES FOR VARIOUS TYPES OF
VEHICLE:
• The body should be light.
• It should have minimum number of components.
• It should provide sufficient space for passengers and
luggage.
• It should withstand vibrations while in motion.
• It should offer minimum resistance to air.
1.5 Frame and body
• REQUIREMENTS OF BODIES FOR VARIOUS TYPES OF
VECHILE:
• It should be cheap and easy in manufacturing.
• It should be attractive in shape and colour.
• It should have uniformly distributed load.
• It should have long fatigue life.
• It should provide good vision and ventilation.
LECTURER HOUR – 5
1.6 Vehicle Aerodynamics
Aerodynamics is itself a part of fluid dynamics, which is
the study of the properties of a solid object displace a
fluid such as air.
For the performance of a typical passenger car,
aerodynamics is an important consideration in the
achievement of maximum fuel economy, as well as in
creating auto body styling that is visually appealing.
1.6 Vehicle Aerodynamics
• Terms to Know- Aerodynamics
– Fluid
– Mass
– Aerodynamics
– Drag
– Lift
– Rear Suction
– Down Force
– Frontal Area
1.6 Vehicle Aerodynamics
• Air-
– Is a type of fluid such as water that can be directed or
displaced;
– Has mass and is measured in terms of pressure;
– Applies direct and frictional forces to objects in
motion
1.6 Vehicle Aerodynamics
One should be aware of four aerodynamic principles
• Drag
• Lift/Down Force
• Drag Coefficient
• Frontal Area
1.6 Vehicle Aerodynamics
• Drag is a combination of two forces that will work against
the acceleration of your car.
– Frontal Pressure occurs when tiny molecules of air hit
the front of your car and is forced away to make room
for other molecules to hit it.
– Rear Suction occurs when an empty pocket of air is
created in the back of your car resulting in a vacuum
cleaner effect that tries to pull your car backward.
1.6 Vehicle Aerodynamics
• Lift and Down Force
• Lift is similar to rear suction in that a thin empty pocket
occurs as air passes over a flat surface causing the car to
lift.
• Down Force is due to high pressure in curved surfaces
that causes the car to be pushed down.
• Drag Coefficient
• Drag Coefficient is a way of expressing how slippery a car.
• The drag coefficient (CD) is a measure of the vehicle's
aerodynamic efficiency.
1.6 Vehicle Aerodynamics
• Frontal Area
Frontal Area is the total of all surfaces in the front of
your vehicle which cause drag.
Area = Length x Width
1.6 Vehicle Aerodynamics
1.6 Vehicle Aerodynamics
LECTURER HOUR – 6
INTRODUCTION
◦ An Engine is a device which transforms the
chemical energy of a fuel into thermal energy
and uses this thermal energy to produce
mechanical work.
◦ Engines normally convert thermal energy into
mechanical work and therefore they are called
heat engines.
◦ Heat engines can be broadly classified into :
i) External combustion engines ( EC
Engines)
ii) Internal combustion engines ( IC
Engines )
HISTORY
◦ Internal combustion engines date back to 1876 when Otto first
developed the spark- ignition engine and 1892 when Rudolf
Diesel invented the compression-ignition engine.
◦ Since that time these engines have continued to develop as our
knowledge of engine processes has increased, as new
technologies became available, as demand for new types of
engine arose, and as environmental constraints on engine use
changed.
◦ Internal combustion engines, and the industries that develop and
manufacture them and support their use, now play a dominant
role in the fields of power, propulsion, and energy.
CLASSIFICATION OF HEAT ENGINES
Heat
Engines
Intake: This stroke of the piston begins at top dead center (T.D.C.) and ends
at bottom dead center (B.D.C.). In this stroke the intake valve must be in the
open position while the piston pulls an air-fuel mixture into the cylinder by
producing vacuum pressure into the cylinder through its downward motion.
Compression stroke
Compression: This stroke begins at B.D.C, or just at the end of the suction
stroke, and ends at T.D.C. In this stroke the piston compresses the air-fuel
mixture in preparation for ignition during the power stroke (below). Both the
intake and exhaust valves are closed during this stage.
Working stroke
Power: This is the start of the second revolution of the four stroke cycle.
At this point the crankshaft has completed a full 360 degree revolution.
While the piston is at T.D.C. (the end of the compression stroke) the
compressed air-fuel mixture is ignited by a spark plug (in a gasoline
engine) or by heat generated by high compression (diesel engines),
forcefully returning the piston to B.D.C. This stroke produces mechanical
work from the engine to turn the crankshaft.
Exhaust stroke
Exhaust: During the exhaust stroke, the piston once again returns from
B.D.C. to T.D.C. while the exhaust valve is open. This action expels the
spent air-fuel mixture through the exhaust valve.
Working Process of 4-stroke engine
Applications of IC Engines
I.C. engines have many applications, including:
Road vehicles(e.g. scooter , motorcycle , buses
etc.)
Aircraft
Motorboats
Small machines, such as lawn mowers,
chainsaws and portable engine-generators
Advantages of IC engine
An internal combustion engine is compact and
lighter.
An internal combustion engine can be started
immediately.
An internal combustion engine is quite safe to
use.
An internal combustion engine has higher
efficiency than external combustion engine.
FOUR STROKE PETROL ENGINE
LECTURER HOUR – 7
FOUR STROKE DIESEL ENGINE
TWO STROKE ENGINE
1.7 IC Engines
ENGINE
1.8 Components of IC Engines
o This is the main block of the engine.
o This contains the cylinder and provides housing for the
crank, crank shaft and other engine parts.
o This is the basic frame for the engine and the parts fitted
on it.
o Material: Hard Grade cast iron or Aluminium alloys
This is the top most part of the engine which covers
the cylinder.
It is bolted with the engine block at the top.
Provides combustion chamber, and mounting areas for
spark plugs and valve parts
Material: Hard Grade cast iron or Aluminium alloys
Gasket are used so that a gas tight joint is
formed.
These joints will withstand high pressure and
heat developed in the combustion chambers.
This is usually cast as a single piece.
Material: Soft copper and asbestos sheet
Used to guide and seal piston and to mount
cylinder assembly to head.
It contains gas under pressure during
combustion
2. OIL RINGS -
prev
ents lubricant entering into the combustion
chamber.
Too much oil film and the engine will use excessive
oil and too little oil causes heat and insufficient
lubrication
The link between the crankshaft and the piston