Automobile Engineering Elective subject 1

An Automobile is a self propelled vehicle which contains the power source for its propulsion and is used for carrying passengers and goods on the ground, such as car, bus, trucks, etc.
Types of Automobile:
The automobiles are classified by the following ways,
1. On the Basis of Load:
 Heavy transport vehicle (HTV) or heavy motor vehicle (HMV),
 Light transport vehicle (LTV), Light motor vehicle (LMV),
2. On the Basis of Wheels :
 Two wheeler vehicle, for example : Scooter, motorcycle, scooty, etc.
 Three wheeler vehicle, for example : Autorickshaw,
 Three wheeler scooter for handicaps and tempo, etc.
 Four wheeler vehicle, for example : Car, jeep, trucks, buses, etc.
 Six wheeler vehicle, for example : Big trucks with two gear axles.
3. On the basis of Fuel Used:
 Petrol vehicle, e.g. motorcycle, scooter, cars, etc.
 Diesel vehicle, e.g. trucks, buses, etc.
 Electric vehicle which use battery to drive.
 Steam vehicle, e.g. an engine which uses steam engine.
 Gas vehicle, e.g. LPG and CNG vehicles, where LPG is liquefied
4. On the basis of body style:
 Sedan Hatchback car.
 Coupe car Station wagon Convertible.
 Van Special purpose vehicle, e.g. ambulance, milk van, etc.
5. On the basis of 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.
6. On the basis of Drive:
 Left hand drive
 Right hand drive
7. On the basis of Driving Axle
 Front wheel drive
 Rear wheel drive
 All wheel drive
8. Position of Engine:
 Engine in Front - Most of the vehicles have engine in the front. Example : most of the cars,
 Engine in the Rear Side Very few vehicles have engine located in the rear. Example : Nano car.

1. ELECTIVE AUTOMOBILE ENGINEERING Prepared By Prof. L. M. Jugulkar B. E. (Automobile), M.E (Mechanical- Production), PhD (Mechanical)

2. Vision of the Mechanical Department: “To transform the department into center of excellence by synergizing teaching, learning and research to produce globally competent, innovative and entrepreneurial Mechanical Engineers .”   Mission of the Mechanical Department: To develop state of the art facilities to stimulate faculty, staff and students to create, analyze, apply and disseminate knowledge. To build the competency to transform students into globally competent mechanical engineers by imparting quality education. To collaborate with research organizations, reputed educational institutions, industries and alumni for excellence in teaching, research and consultancy practices.

3. Program Educational Objectives (PEOs) Graduates will contribute to social reformation through their devotion in science and technology leading to uplifted standard of living. Graduates will provide solutions to global technological challenges being entrepreneurs, consultants and researchers following ethical practices. Graduates will update themselves through lifelong learning such as higher studies, cutting edge research, skill enhancement and other professional activities . Program Specific Outcomes (PSOs) Use Company standards, national and international standards like IS BS, SAE, ISO, ASTM etc for designing and manufacturing of mechanical components and systems. Engage professionally in industries or as an entrepreneur by applying manufacturing, design, thermal and management practices.

4. 1 CO No Student shall be able to understand and define     CO1 : Explain anatomy of an a automotive vehicle and location of different parts and systems. CO2 : Expand various configurations of transmission systems and auxiliary components. CO3 : Compute different performance parameters of an automobile.   CO4 : Differentiate between various types of braking system with its specific features. CO5 : Explain various steering and suspension system. CO6 : Elucidate working of automotive electronic components and electrical systems. ME4352: ELECTIVE – VI: AUTOMOBILE ENGINEERING (Theory) Course Outcome

5. What is an ‘Automobile’?? • A vehicle producing power within itself for its propulsion is known as a Self propelled vehicle. • Eg . Moped, Scooter, motorcycle, Car, jeep, truck, tractor, ships, aircrafts, rocket etc. • A self propelled vehicle used for transportation of goods & passengers on the ground is called an Automobile. • Different from Aeronautical vehicles (planes, helicopters, rockets) & marine vehicles (ships, boats, submarines)

6. Definition of Automobile • Automobi l e is a “ Self P r opelled vehi c l e ” gener a lly driven by IC Eng i ne and it is used for transportation of passengers Crouse . • Exa m ples : & goods on g r ound – W . H. Ca r , Bus, T ruck, Scooter et c .

7. History of Automobiles Captain Nicholas Joseph Cugnot – French Army – built the first self propelled vehicle in 1768-70

8. First Automobile Cugnot Steam Trolley, Steam Engine powered, 1768

9. Karl Benz Inventor of the first gasoline powered automobile, 1886

10. History Invention of Wheel is major milestone in human history after fire

11. Horse Carts

12. History – 1 8 69 Ca p ta i n Nic h o l as Cug n ot ( Frenc h ) bu i ld fi r st Automob i le 2 . 5 m ph ( 4 . 2 Kmp h ) in 15 minut e s – 3 Whe e l e r Ste a m Pi s ton ' s 1769 Cugnot Ste a m er in H D . m p4 Front W he e l Re a r W he e l / Axle S t e am Gen e ra t or Ste e ring

13. e is e 180 1 – Ri c h a rd Car r i a ge th r e v it h ri c k – Firs Ste a m TR E VITHIC K ' S P U F F ING DEVIL ON TR E VITHICK D A Y 2017 . m p4 T rev i thick was born i n 1771 i n a m in i ng Englan d . v i lla g e He in was Cornwall, te r rib l e a studen t –his teachers t h ought he was a “dis o b e die n t, slo w , obs t in a te, [a n d] spoil e d boy” who anything, bas i c a lly would nev e r a m ount to and in f a ct h e was i ll i terat t o t i nk e r h en t ir l ife – b ut he lo v ed with too l s and m ach i ne s 6 . Pu f fing DEVIL Whee l s S t e am Gen e ra t or Chi m ney

14. 188 5 – Benz M otors in G e rm a ny de v e l oped fi r st V ehi c le pro p el l ed with IC Engi n e 7

15. … Contd • 1897 – M r . Fos t er f r om Cromp t on greaves, bo r row e d first motor ca r i n india • 1901 - INDI A N M r . Jamsh e d Ji T A T A was the f i rst to own a m o tor car . Sir Ja m shed Ji T A T A

16. Class i ficati o n • P u r p ose • Pas s enger Carr i ers – Ca r , Bus • G oods Carr i ers - T rucks • Fuel Used • Pe t rol • D i esel G as • Elec t r i c • S t eam – not i n use • C a paci t y • HMV – T r u ck s , Buses • LMV – T e m po, Jeeps of Automobiles • Co n structi o n • S i ng l e un i t • A r t i cu l a t ed – E g. T ra i l er s , T rac t ors D r ive • Left hand • Right H and N u m ber of W heels • T w o Whee l er • Three Whee l er • Four Wh e e l er Bo d y • ha t chback • Sedan • Conver ti b l es • S t a ti on W agons - V ans • • • • Spe ci al Pu r po s e V eh i c l es

17. Engine SI – Spark Igni t ion CI – Co m pr e ss i on T wo St r oke Ign i t i on Four St r oke

18. Chassis & Other important Parts V eh i c l e B O DY

19. Chass i s Main S u p p o r t ing St r uctu r e of vehicle consist of almost all major parts except automobile body

20. Key co m ponent of Chass i s F r ame Have 3 di f fe r ent t y pes is Frame 1. 2. 3. Conven t ion a l fr a m e Int e gr a l Fra m e S e m i Integr a l F ra m e Fu n ct i ons of F ra m e • T o suppo r t chas s is co m ponents & body • W i t hst a nd the sta t ic & dyn a m ic load of d i f ferent co m ponents of c has s is • T o w i t hstand load of the body • T o ca r ry load • T o with s tand st r ess e s caus e d due to uneven ro a d condi t ions. • T o with s tand force caus e d due to turn i ng of t he vehi c les & sudden braking or acc e lera t i on.

21. 15 REAR F R O N T

22. 17

23. Frame Cross Sections Channel Secti o n – G o od Resist a n c e to Bendi n g Box Section – Go o d Resistan c e to both be n ding a n d torsion T u b ular Secti o n – Go o d Resista n ce t o torsio n .

24. T ypes of C h ass i s • Ac c o r d i ng to lay o ut • Convent i onal • Forward • Se m i forward • Ac c o r d i ng to m o u n t i n g of eng i ne and tran s m is s i o n • Engine at f ront • Engine fitt e d in front but cr o sswi s e • Engine fitt e d at the cen t er of t he chas s is • Engine fitt e d at the back

25. Ac c ording to m ounting of Component of Chassis • F r o n t Eng i ne R e ar Wheel Drive • Fr o nt Eng i ne Fr o nt Whe e l Drive • R e ar Eng i ne R e ar Wheel Drive • All Wheel Drive

26. Co n ventional Ch a ssis A f fe c ts visib i l i ty of driver Engine is f i t ted in front of the dr i ver cab i n or d r iver seat such as i n ca r s. Chass i s po r t i on c a n not be uti l i z e d for c a r r y i ng pa s se n ge r s and goods Heavy Engine can be fitt e d, which can used to give m ore power

27. Semi Forwa r d Chassis • Half port i on of t he engine is in the dr i ver cab i n half is out s ide the cabin such as in T ata t r ucks / & and re m ain i ng T e m pos • In t his ar r ange m ent a pa r t of t he chas s is is u t i l iz e d for ca r ry i ng ext r a pas s enge r s

28. Forwa r d Chassis • C o m plete engine i s m o u nted ins i d e t h e dr i v er ca bin, Driver seat i s just above the front whee l . • Mo r e Boot Space A vai l able as full ut i l i z at i on of chas s is

29. Engine Con v en t ionally at fro n t • t he eng i nes are fi t ted a t f r o n t & d r i v e is g i ven to “ r e a r ” t he wheels f r om t h e • • Ad v a n t a ges Eno u gh spa c e i s a v ailable f o r l u g g age beh i nd t h e rear seat The w e ig h t o f ve h ic l es is w e ll balance • • I n cre a sed e f ficiency of cooli n g sy s tem 24

30. Engine fitted in front but crosswise • T h is f r ont en g i ne l a yout re q uires v e ry s m all space to fi t the e n gine . H en c e, m ost co m pact c ars use th i s l a yout w h i c h has ve r y s m a l l space to a c co mm o d a t e the en g in e . Des i gn i s mo r e c o m pli c ated • as compar e d to the longitudin a l l y plac e d e n gi n e. T h is i s b e c a use i t d oes not l e ave e nou g h sp a ce f o r a c c e s s orie s .

31. Engine is mounted at center • Mi d -eng i n e , r ea r -whe e l dri v e f o r m a t can b e consi de r ed the ori g in a l l a y o ut o f a u t o mobi l es. Drive is gi v en to the re a r . Eq u al Distrib u ti o n o f weig ht . • • • La r gest d ra wback o f mi d -en g i n e cars is spac e ; res t r icted re a r passen g er • Co n s e q u ent l y m ost m i d -engi n e ve h icles are tw o -seat ve h icle s . T h e en g i n e in e f fect p u shes t h e passen g er co m p a r t m e nt f o rward t o wards t h e fr o nt axle (if en g i n e is be h i n d d r i v er ) . •

32. Engine Fitted at b ack • Flat floor i s avail a b l e si n ce l o ng p r opeller s h af t s are eli m i n ated • W ith p r o p e l ler eli m i n ation of c e n t er giving s h aft t he of g r avi t y lowered stab l e d r i v i n g B e tter adhesion • o n r o ad cli m b i ng s p e c ia l ly hi l l when

33. Other i mportant chass i s types • T abu l ar Space F r a m e • Mon o coque Fra m e • B a ckb o ne Fra m e 28

34. r r h • Fo highe y s t re T ubular F r ame • • I t i s 3 - di m ensional design T ubular s p a c e fr am e chas s is e m plo y s doz e ns o f c i r c ular s e c t ion t u be, po s i t i on s in di f fe r e nt dire c t i o n s to provide m e c h a nical s t reng t h against force from an y w h e r e. • Th e se tub e s a r e w e lded & for m s a ve r y co m plex s t ructur e . ngt re q uir e d b s p ort s c a r s , tu b ular spa c e fr am e chas s is usually inco r pora t e a s t ro n g s t ructu r e u n der b o th d o ors.

35. Advantages & Dis advantages • V ery st r o n g in any • V ery complex , c o st l y an d time con s umi n g to b u il t . I t engag e s a l o t of s p a c es ri s e t h e doo r s e al and result in di f ficult to a c c e ss t o t h e c a b i n . d i rect i on with lad d e r Mo n ocoque (compared chassis and chassis of • t h e sa m e weigh t ) • I m p o s s ib l e f o r r o b o tized p r o d ucti o n .

36. Monocoque Mono c oque i s a on e - piece s t ructure w hich def i n e s o v e ra l l shape o f t h e ca r . w hile l a d d er, t a b u l a r & ba c kbone p r o v i de o n ly s t re s s m e m bers. T o d a y 99 % ca r p r odu c ed in this planet a r e m ade of s t e e l Mo n oc o que chas s i s . C h a s s i s are m ade by weldi n g of Several pieces. (Spot Welding ) Mo n oc o que i s m ade o f s t e e l 31

37. Advantages & Disadvantages • S p a c e - e f ficie n c y . • Mon o co q ue • chassis • It is very heav y . I m p o ss i ble f o r s m all v o l u m e p r o du cti o n . In c ase of a c cidents benef i t cr a sh p r oduc t i o n bec a u s e i t u s es m eta l . a l o t of • wh o le str u cture o b so l et e . beco m e • Che a p p r o d ucti o n for m ass

38. Back • Similar desi g n . Bone F rame t o t h e body f r a m e • I t con s ist backb o ne o f a st r o n g t u bular ( Usu a lly r e c t a n g ul a r i n C/ s ) . • A bod y i s p l a c ed o n t he st r uct u r e . • This t y pe o f chassis has been used in n u m erous sp o rts c a r s .

39. Advantages & D i sadvantages • Th e v ulne r a b le pa r ts o f the drive shaft are co v e r ed b y a thi c k tub e . The whole sys t em i s e xtre m e l y re l i a ble. How e ve r , if a problem oc c urs, r e pai r s a r e m ore co m pli c a t e d . • The m o d u l ar sys t em e n a bles c o nfigur a t i o n s o f 2 - , 3 - , 4 - , 5 - , 6- , o r 8 - a xle v e hicl e s with various w h e e l base s . 34 Manufacturing the backbone chassis is more complicated and more costly. However, the more axles with all-wheel drive are needed, the cost benefit turns in favor of backbone chassis . The backbone chassis is heavier for a given torsional stiffness than a uni -body . The chassis gives no protection against side impacts

40. T ypes of V ehicle Layout Or Chassis Layout 35

41. Front Engine Rear Wheel Drive Eng i ne T rans m is s ion Drive Shaft C lu tc h F in a l D rive

42. Front Engine Rear Wheel Drive • Mo s t co m m on t y pe o f lay o u t . • Engi n e Loc a ted a t f r o n t and driving p o w e r is gi v en t o rear wheel s . • Dri v i n g P o wer fl o w s f r o m e n g i ne t o rear wheel t h r o u g h vari o us m e c han i c a l li n kage s .

43. atio n , m aki n g t h e rear lt a n eous a c c e leration e s . Advantages & Disadvantages • B e t t er h a n d li n g : - Ac c eler a ti n g force i s app l ied to t h e rear w heels, o n which t h e d o wn du e t o l o a d tran s fer i n a c c e ler f o rce i n cre a ses, ti r es be t ter a b le t o t a k e simu and curving th a n the f r o n t tir ON D R Y RO A D O N L Y

44. Even weight distribution • The d i v i sion o f wei g ht betwe e n t h e f r o n t and rear wheels has a sign i fi c ant i m pact o n a c a r's han d ling, and it is m uch easier to get a 50 / 50 weight d i st r i b u t ion i n a rear wheel d r i v e ca r . Steering radius • A s n o complicated d r i v e s h aft j o ints are req u ired at t h e f r o n t wheels, i t i s p o ssible t o t u rn t h em f u rt h er t h an wo u l d be p o s s i b le using f r o n t wheel d r i v e, res u lti n g i n a sma l ler steeri n g r a d i u s .

45. Less load at f ront axle • The d ri v i n g f o rce is g i ven at re a r axle hence there is no need to p r o v i d e co m p l ex desi g n on fr o nt axle. E f fe c t i ve Cool i ng of the eng i ne due to exposure of coo l ing s y stem to flowing a i r

46. Disadvantages Decreased interior space – This isn't an issue in a vehicle with a ladder frame like a pickup truck, where the space used by the drive line is unusable for passengers or cargo. But in a passenger car, rear wheel drive means: Less front leg room (the transmission tunnel takes up a lot of space between the driver and front passenger), less leg room for center rear passengers (due to the tunnel needed for the drive shaft), and sometimes less trunk space (since there is also more hardware that must be placed underneath the trunk).

47. Less Inn e r spa c e

48. Increased weight • The dri v e s h a f t, w h ich con n e c ts th e e n g i ne a t the f r o n t t o t he dri v e a x le i n t h e b a ck, a d d s w eig h t . There i s extra s h e e t metal t o form t h e tran s mission tu n ne l . A rear wheel d r i v e c ar will wei g h sligh tl y m o r e t h an a co m pa r able f r o n t wheel d r ive c a r , but less t h an f o ur wheel d r i v e.

49. Higher purchase price • Due t o the a d ded c o s t o f m a terials, r e ar whe e l d r ive is typically s l i g h t ly more expen s ive to p u rch a se v e hicle. . th a n a comp a rable f r o n t whe e l d r ive

50. Fro n t Engine Fro n t Wh e el Drive Eng i ne T ra n s m ission F in a l D rive

51. Front Engine Front W heel Drive • I n this type the e n gine is m o u nt e d o n the fr o nt s i de of the v e hic l e a n d the driving p o wer i s gi v e n to the front w h e e ls o n l y . The pow e r flows from engine t o f r o n t axl e . T h is ty p e o f ar r a n g e m ent • • h a ve a d dition a l sub t ype c ross i.e . front m o u nt e d engine.

52. Advantages • I n terior s p ace : • Si n ce the p o w e rt r ain eng i ne c o m par t m ent is a si n gle u n it co n t a ined in t he o f t h e vehicl e , t h ere i s n o need to dev o te i n terior spa c e f o r a d r i v e s haft t u n n el or f o r rear d i f fe r entia l , i n c r e a si n g t h e v o l u m e available passengers and c a r g o . I n ner S P A C E Eng i ne

53. Better handling on s l ippery surface • Sl i p p er y - surface tractio n : pl a cing t h e m ass o f t h e d r i v etra i n o v er t h e d r i v e n wheels imp r oves tr a ction o n w e t, s n ow y , o r icy s u r f ace s . Improved drive t r ain e f fic i ency • The d i rect con n e c ti o n be t w e en e n g i ne and tr a nsaxle reduce the mass and o f the d r i v e tr a in c o mp a red to m e chan i c a l inertia a rea r - w heel d r ive v e hicle with a similar eng i ne and tr a n s missio n , a l l o wing g r eater f u el e c o n om y .

54. D isadvantages • L e ss T urni n g Ra d ius • The d r ive shafts m ay li m it the a m o u nt b y which the f r o n t wheels ca n t u r n , Mo r e W eig h t o n f r o n t r esul t s i n rapid w ear of f r o n t ti r es. • F r o nt - w h eel dri v e ha s w o r s e acc e lerati o n t h an r ea r - w heel dri v e, which i s why mo s t s p o rty and race cars u s e r ea r - w heel dri v e.

55. Steering A WD FWD VS R WD VS

56. FWD VS R WD

57. Rear Engine Rear Wheel Drive

58. 54

59. Advantages • W eig h t over rear w heels, i n cre a sed traction whi l e a c c e leratin g . • Fron t axle con s tr u ction i s simplif i e d . • Absence o f p r o p el l er s h a f t r esul t s i n dec r ease of fl o or hei g h t . • Engi n e c om p o nents m o u n t ed a t re a r o f re a r axle hence m o re s p a c e i s available.

60. Disadvantages • Sep a rate coo l ing m ech a n i s m i s needed f or effective coo l ing mo u n t ed a t r ea r . of the eng i ne a s the eng i ne is • Mo r e l o ad o n rear s i d e m a y r esult i n overtu r ning (Over s t eer) o f t h e veh i cle. • Lon g er li n kages are requ i red to o p er a te clutc h , gears f r om d r i v e r .

61. All w heel Drive

62. A WD or 4WD All w h e e ls Al w a y s eng a ged. Safe and adv a nt a geous over 4 W D 4 wheels can be engaged only in difficult terrain. In normal condition power is given to rear wheels only.

63. Advantages • 4 WD imp r o v es tr a ction i n dan g erous d r iving con d i tions, s u ch as s n o w , m ake ice, r o cks, and o t h e r scenarios t h at can con t rol di f ficul t . By engaging b o th se t s o f wheels, traction a nd control i m p r o v e s . • Addi t i o n al w e ig h t cont r i b u t e s to better grip o n the r o a d . • 4 WD i s g r e a t f o r t h o s e who li k e o f f- r o adi n g .

64. Disadvantages • The m a i n disadv a ntage o f 4 W D i s a d d e d cost for p u r c h a s e , m a int e n a n c e , and fu e l . T h e extra eq u i pm e nt (di f f e r e nti a l s , t r ans f er ca s e, etc. ) adds c ompl e xity a n d weight t o t he v e hic l e, incr e a s ing initial m a rket value, tir e wea r , and the cost o f repa i rs and m a i ntenance. The a d ded power a nd wei g ht o f 4 W D and A W D sys t e m s re q uire m o re fuel, m ak i ng t h em less e f fi c i e nt than the i r 2 WD cou n t e rpa r t s . Add e d we i gh t i m pro v es tr a c t ion a n d c o n t r ol, bu t i t also inc r eases t he braki n g distance r e q u i r ed t o make a co m plete st o p . Lighter ve h i c l e s ca n av o i d coll i s i on easie r than heavi e r vehic l e s . • •