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NoTES Op
AUTOMOBILE ENGINTERING

Author
Rqhul Potil
Asst. Prof.

ERING

i.0

Chossis. Frome

Vorious loods octing on the frome Stote the differenl bodies used in outomobiles Exploin the requirements of bodies for vcrious types of vehicles viz. privote, commerciol etc. 2.0 Steering Sytem 2.1 Requirement of the Vehicle steering 2.2 Types of Steering eors, systems ond power sfeering 2.3 Steering linkoges mechonism under steering, over steering 2.4 Turning rodius 2.5 Wheel olignment of Ackermon's & Devis Sieering geor, Mechonism 2.6 Steering geometry - coster, comber, King pin inclinotion, toe in ond toe out 2.7 Steering defects - wheelwoubble ond shimmy 2.8 List our the type of steering system used in vorious vehicles 3.0 Broking system 3.1 Exploin Functions of brokes 3.2 Requirements of outomobile brokes 3.3 Exploin stopping time ond stopping distonce 3.4 Type of Broking systems - Disc ond Drum broking system 3.5 Construction ond working of Mechonicol, hydroulic, ond oir brokes 3.6 List out the iypes of brckes used in vorious vehicles 4.0 Suspension Sysiem 4.1 Requirement of o outomobile suspension system 4.2 Types of suspension system conventionol ond

1.1 1.2 1.3 1.4 1.5 1.6 1.1

ond BodY lntroduction of Chossis frome Loyout of the Chossis ond its moin components Functions of the Chossis frome
Types of Chossis fromes

4.3 4.4 4.5 4.6

lndependent Types of springs

spring

Lominoted spring, coil spring, helicol

Need of Shock obsorber - construction ond working of differeni types of shock obsorbers Stobilizer bor ond torsion bor l-ist out the type of suspension system used in vcrious
vehicles

Chapter

Chassis Frame And body

CHAPTER

CHASSIS FRAME AND BODY

introduction of Chcssis Frome: Chossis is o French term ond wqs iniiiolly used to denote the frome ports or Bosic Structure of the vehicle. lt is the bock bone of the vehicle. A vehicie with out body is colled Chossis. The components of the vehicle like Power plont, Tronsmission System, Axles, Wheels ond Tyres, Suspension, Controlling Systems like Broking, Steering etc., ond olso electricol sysiem ports ore mounted on the Chossis frome. lt is the moin mounting for oll the components including the body. So it is olso colled os Corrying Unit.
Loyoui of Chossis ond its moin Cornponents:

SIDEI
MEMEERS HORIZONTAL
MFMRFFI

The following moin components of the Chossis ore 1 Frome: it is mode up of long iwo members colled side members

2. 3.
4.

riveted together with the help of number of cross members. Engine or Power plont: li provides the source of power Clutch: lt connects ond disconnects the power from the engine fly wheel to the tronsmission system. Geor Box

Automobile Chassis And Body Engineering.doc

5. U Joint 6. Propeller Shoft 7. Differentiol

Chapter I

FUNCTIONS OF THE CHASSIS FRAME: 1. To corry lood of the possengers or goods 2. To support the lood of the body, engine,

corried in the body' geor box etc., 3. To withstond the forces coused due to the sudden broking or occelerotion 4. To withstond the stresses coused due to the bcd rood condilion. 5, To withstond centrifugol force while cornering 4, To beah I wl p<-auirrt s7s tcr-rr lrzocl (LL -il.t ('avrci{- -sl.cc'pTn| F 7+& YCN 7, - 7'o pmwicJ'e
OF CHASSIS FRAMES: There ore three iYPes of fromes

TYPES

2. lntegrol frome 3. Semi-integrol frome

1.

1. Convenlionol frome

Conventionol frome: lt hos two long side members ond 5 to 6 c rOSS members joined together with the help of rivets ond bolts. The fro me f,4:-:-\ sections ore used generollY.
o. Chonnel Section - Good resistonce to bending b. Tobulor Section - Good resistonce to Torsion c. Box Section - Good resistonce to both bending cnd
Torsion
2. lntegrol Frome: This frome is used now
-u t -"---"J

tr
l'4

o doys in most of the cors. There is no frome ond oll the ossembly units ore oitoched to the body. All the functions of the frome corried out by ihe body itself. Due to eliminoiion of long frome it is cheoper ond due io less weight most economicol olso. 6ii'-'".;. ' P'rb Only disodvontoge is repoiring is difficult.
3. Semi -

lntegrol Frome: ln some vehicles holf frome is fixed in the front end on which engine geor box ond front suspension is mounted. ll hos the odvontoge when the vehicle is mel with occident the froni frome con be token eosily io reploce the dcmoged chossis frome. This type of frome is used in FIAT cors ond some of the Europeon ond Americon cors.
VARIOUS LOADS ACTING ON TFIE FRAME:

Vorious loods ociing on the frome ore 1. Short durotion Lood - While crossing o broken potch.

Chapter

Chassis Frame And body

2. Momeniory durction Lood - While toking o curve. 3. lmpcci Loqds - Due to the collision of the vehicle. 4. inertic icod - While opplying brokes.. 5. Siotic Loods - Loods due to chossis ports. 6. Ovei'i-cods - Beyond Design copocity.
STATE THE DIFFERENT BODIES USED IN AUTOMOBTLES:
l

The Automobile bodies ore divided in two groups

Body

Possenger Body

Commerciol body

(g

E,

1.

v*fJ-h.st^rtql l-,enrL)n-e { t./,\t T-o wf*t" s,jo.-d -:::Ar,:::-

1-<> p>-vi cix- coz-"t-a1p sn,,tti 2 -To

),1

,* <:li#l c-a*tFO '

rwiss I ort s/=fu-,-r-t t"Vqtte , b l, e-a'ft &Cce Le rc: vy1 , -l-t,s-z-<*tt & hr,,+,.rt"fffu-qw-<

tf*r*

k-:l::#

Fe*-*-:'

Automobile Chassis And Body Engineering.doc

Chapter

truck 2. Truck Puniab bor:iy or S'uaighl

3. Truck hall body

4, Truclr Piat{orrn tYP6

5. Traotor

6, Tractor with artis'rlatad lrailer'

7, Tarlker

8. DumPer

tuc*

9. DelivarY Van

'10.

Sfiion Yialon

According to Chossis design the body con divided into l. Conventionol Type 2. lntegrol Type 3. Semi- lntegrcl Type According to other usoge: '1. Lighi vehicle Bodies - cors, jeeps 2. Heovy vehicle Bodies - Busses, Lorries 3. Medium vehicle Bodies - Vons, Metodoors

Chapter I

Chassis Frame And bodY

OF VECHILE: REQUIREMENTS OF BODIES FOR VARIOUS TYPES The body of the most vehicle should fulfill the following requirements:

2. lt should hove minimum number of components. 3. lt should provide sufficient spoce for possengers ond luggoge'
4.lt.shouldwithsiondvibrotionswNleinmotion. 5. lt should offer minimum resisionce to oir' 6.ltshouldbecheopondeosyinmonufocturing. 7. li should be ottroctive in shope ond colour' B. lt should hove uniformly disiributed lood'

1. The bodY should be light'

9.

li should hove long fotigue life l0.lt should provide good vision ond ventilotion.

&"svru

f,'ss
:'"-F+>-:*'+

e#

6w" birs'
tr'::

Automobile Chassis And Body

Engineering.doc

Chapter

Shori Answer Questions:

1. List out the vcrious components of chossis? 2. Whof ore the functions of Chossis frome?

3. Lisi out the types of Chossis frome? 4. Whot ore ihe frome sections used in Automobiles? 5. Whot ore the requirements of Bodies for vorious types of vehicles?
Essoy Type Questions:

Drow the loyout of conventionol Chossis with o neot diogrom ond exploin crboui vorious porls on it? 2. Whot ore the different clossificotion of bodies used in Automobiles ond exPloin?

l.

Chapter 2

Steering System

CHAPTER 2

STEERING SYSTEM
lntroduclion: This system provides the directionoi chonge in the movement of on Automobile ond mointcin in o posiiion os per the driver's decision wlthout rnuch siroin on him.
REQUIREMENTS OF STEERING SYSTEM:

o. li must keep ihe wheel of oll times in to rolling motion with

out rubbing on the rood. b. This sysiem should ossociote to controt the speed. c. lt must lighi ond stoble. d. lt should olso obsorb ihe rood shocks. e. li musi eosily be operoted with less moinienonce. f. lt should hove self-centering oction to some extent.

Automobile Chassis And Body Engineering.doc

Chapter 2

STEERING KNUCKLE PrvoT (KjNG PtN) STEERING KNUCKLE STEARING WHEEL STEERING COLUMN

SPRING SEAT

STEERIT.IG KNUCKLE ARM

Fig,28.1 8. Corventional steering linkage STEERING ARM

TRACK ROD

il
il

+
Functions of Steering System:

'l-STEERING BOX

STEEFING
COLUMN

ht. WHEEL t. It helps in swinging%eels to ihe 15 2. li helps in turning the vehicle of the will of the driver. 3. It provides directionol stobility. 4. It is used to minimize the tyre weor ond teor. 5. It helps in ochieving self-centering efforis. 6. It obsorbs mojor port of the rood shocks.

STEERING

Moin Components of Steering System:

Chapter 2

Steering System

KTNGPIN (WHEEL PIVOT POINT)

ut.to'**
KNUCKLE
TIE ROOS

PITMAN ARM

STEEFING GEAR
STEERING WHEEL

The following ore the moin components of steering system ore

Steering Wheel 2. Sleering column or shoft 3. Sieering Geor 4. Drop Arm or Pitmon Arm 5. Drog Link 6. Steering Arm 7. Trock-Arms B. Trock Rod or Tie-Rod 9. Adjusting Screws

l.

Types of Steering Geor Boxes:

l. Worm ond Wheel Steering Geor. 2. Worm ond Roller Steering Geor. J. Re-circuloting Boll iype Steering Geor. 4. Rock ond Pinion type Steering Geor. tr J. Com ond Roller Geor type Sieering Geor. 6. Com ond Peg Steering Geor. 7. Com ond Double lever Steering Geor. B. Worm ond Secior Type Steering Geor.
Functions of Steering Geor Box:

10

Automobile Chassis And Body Engineering.doc

Chapter 2

1. lt converts the Rotory movemeni of the steering wheel in to

2.

the ongulor turning of the front wheels. lt olso multiplies drivers efforts ond give MEHANICAL ADVANTAGE.

l.Worm ond Wheel Type: This type of steering geor hos o squore cut screw threods of the end of the steering column; which forms o worm, of the end of it o worm wheel is fitied ond works rigidly with it. Generolly covered shofl is used for the worm wheel. The worm wheel con be turned to o new position the drop orm con be reodjusted to the correct working position'
2. Re-circuloting Bcll Type: ln this type of

gecr box the endless chcrin of bolls ore provided between the worm ond nut members. The nut form o rin$ of rock hoving on oxiol movemeni. So thot the sector on the rocker shofi rocks, the bolls roll continuously between the worm ond nut. Being provided with return chombers ct the ends of the worm. This meihod reduces friciion between worm ond nut members. This type of steering geor is used for heovy
vehicles.

A,DJUSTING SCREW

TRANSFER TUBE

LOCATING

FOLLER

IRANSFER TUBE

3. Rock ond Pinion Type: This is common monuol type of steering geor box is used in mosi of the vehicles. ln this iype of steering o pinion is provided the bottom end of the sieering column. The teeth of the pinion wheel in mesh

wiih corresponding teeth provided on the rock, the end of which clre

Chapter

Steering System

t1 lt

connected io the stub oxle through the rod. The rototing moiion of the pinion operotes ihe rock in FORE ond AFT direction which in turn operoies the siub oxle.
PINION

SPRING LOADED PAD

4.

Com ond Lever Type: The com ond lever steering uses one or two lever studs fitted in toper roller beoring. When the worm in the form of helicol groove rototes the stub <rxle ond it olso rototes olcng with it. This imports o turning motion to the drop orm shoft.

5. Worm ond Sector Type: ln this type the worm on the end of the steering shofi meshes with o secior mounied on o sector shoft. When the worm is rototed by rotoiion of the steering wheel, the sector olso iurn rotcting the sector shoft. lts motion is tronsmitied to ihe wheel through the linkoge. The seclor shofi is ottoched io the drop orm or pitmen orm.

power Steering: Power steering reduces much stroin on the port of the driver while negotioting shorp curves. li mokes eosy to turn shorp corners. lt is usuolly

STEERING WORM

t2

Automobile Chassis And Body

Engineering.doc

Clrapter

orronged io be operotive when the effori of steering wheel exceeds o pre-determined volue. lt is fitted on heovy commerciol vehicles cind medium cCIrs.
Steering Linkoges: Steering Linkoge is o connection of vorious links between the steering geor box ond the front wheels. The motion of the pitmon orm ond steering geor box is tronsferred so the steering knuckles of the front wheels through the steering linkoges. The swinging movement of the piimon orm from one side to the other side gives ongulor movemeni io the front wheei througl-r the steering linkoges.

Types of steering Linkoges:

Conventionol steering Linkoge. 2. Direci cross type sieering linkcge 3. Three piece steering linkcge 4. cenier orm steering linkoge 5. Reloy type steering linkoge.
Slip Angle: The ongle between direction of the motion of the vehicle ond the center plone of the tyre is known cs Slip Angle. lt ronges from Bo to l0o.

l.

Under steer: When the froni slip ongle is greoter thon thot of reor, the vehicle tends to steer in the direction of side force. Then it is known os under sieer. This provides greoter driving stobility, especiolly when there is o side wind. Over Steer: When the reor slip ongle is greoier thon thot of front slip ongle, the vehicle tends io mover owoy from the direction of center poth. This is known os over stecr. This is odvontogeous when lhe vehicle moving on the rood hoving mony bends curves.

Sieering Geqr Rqtio or Reduction Rqtio: lt hcs been defined os lhe " number of turns on the sieering wheel required to produce on turn of steering geor cross shofi to which ihe pitmon orm is cttoched. Generolly it vories between I 4'.I ond 24' .1 .
Turning Rodius: lt is the rodius of the circle on which ihe outside front wheels moves when the fronl wheels ore turned to their extreme outer position. This rodius is 5 to 7.5 m for buses ond trucks.

Chapter 2

Steering System

'Ia

_tJ

Wheel Alignmenh it returns tc the positicning of the front wheels ond steering mechonisrn thct gives the vehicle directioncl stobility, reduce the tyre weor io o minimum.
Foctors effects the wheel olignment:

Foctors pertoining to

wheel:- o. Bolonce of wheels(Stotic ond Dynomic)

b. lnflotion of tyre. c. Broke odjustments.

2. Steering Llnkoges. 3. Suspension System 4. Steering Geometry

-o. coster b. comber c. king pin inclinotion d. toe-in

ond toe-out etc.,

Steering Geometry: lt refers to the ongulor relotionship between the froni wheels ond ports ottoched to it ond cor frcme.
The sieering Geometry includes
I

2. Comber ongle 3. King-pininclinotion 4. toe-in 5. toe-out etc.,

Coster Angle: This is the ongle between bockword or forword tilting of the king pin from ihe verticcl oxis of ihe top. This is obout 2o to 4o. The bqckword tilt is colled os positive coster. The forword tilt is colled negotive coster.

. Cosier ongle

Comber: The ongle between wheel oxis lo the verticol line of the top colled comber ongle. lt is opproximotely 1/zo to 2o.

is

King-pin inclinotion: lt is the ongle between verticcl line to the king pin oxis. The inclinotion tends to keep wheels stroight oheod ond moke lhe wheels

to get return to the siroight

inclinotion is normolly kept
7o to

position ofter completion

Bo.

of o turn. The

14

Automobile Chassis And Body Engineering.doc

rYRr cENr Rr

Chapter

l---

LINE

CAMBER ANGLE

TOTAL INCLINA-IION VERTICAL LINE KINGPIN INCLINATION

KINGPIN CENTER LINE

ROAD SURFACE

POINTS OF INTERSECTION

Toe-in: lt is the omount in minimum of the front port of the wheel points inwqrds opproximotely 3 to 5 mm, lt prevents side slipping excessive tyre weor, proper rolling of front wheels ond steering stobilify.

Toe-out: lt is the difference in ongles belween two front wheels ond vehicle frome during turning. lt is used to prevent drogging of tyre during turn. Reversible steering: When the defleciion of rood wheels is tronsmitted ihrough the steering wheel to rood surfoce, the system is colled Reversible. lf every imperfection of rood surfoce couses the sieering to rotote, ii couses much stroin on the pori of the driver to control the vehicle. ll couses much stroin on ihe port of the driver to control the vehicle. There fore such of ihe reversibility is not desired. But, some degree of reversibility desired, so thot the wheel becomes stroight after toking o curve. lrreversible sieering: lf the front rood wheels does not tronsfer ony deflection io the steering which is colled irreversible steering. After negotioting o curve ond ihe steering wheel not returned eosily, there couses the production of

Chapter 2

Steering SYstern

i5

some degree of un due siresses on the steering mechanism, therefore irreversible clso ciesired "

geor mechonisms Steering Mechonism: There ore two types of steering

].DovisSteeringgeor2.AckermCInnsteeringgeor]
poir, it hos more Dovis steering Geor: The Dovis steering geor hos sliding Geor weor oui fric.tion thon the turning poir, there fore the Dovis steering eorlier ond become inoccurCIte <rfier certoin time' This type is rnothe moticollY Accurote.

l.

porollel to The Dovis geor mechonism consists of cross link KL sliding onother link AB onC Ir connected to the stub oxle of the iwo front wheel by link KL slides in levers ACK ond DBK pivoted of A ond B respectively. The cross pivoted the beoring ond .roit pins of its ends K cnd L. The slide blocks ore steering on ihese pins ond move with the turning of bell cronk levers os the geor is soid to be wheel is operoted. when the vehicle is running stroight the ongle 90 t o to in iis mid-position. The short orms AK ond BL ore inclined on upon lheir stub oxles Ac ond BD respectively. The correct steering depends ihe suitoble selection of cross orm ongle o, ond is given by
Ton o = y>l2lWhere b= AB = distonce

between ihe pivots of front oxle.

l=wheel bose
2.

Ackermqnn Steering System: lt hos only turning poir' li is not mothemoticolly occurote except in three positions. The trock orms ore mode inclined so thot if the oxles ore extended they will meet on the longitudinol oxis of the cor neor reor oxle. This system is colled ockermonn steering.
STEERING DEFECTS AND THEIR CAUSES AND REMEDIES:

L
o. b.

Wheel wobble: The oscillotion of the froni wheels of low speeds

is

colled wheel wobble.

Couses
tn Correci DYnomic Boloncing

o.

Remedies Correct the wheel bolonce

of wheels. Uneven TYre Pressure

b.

Check the tYre Pressure

Adjust suitoblY.

c'The comber moy be incorrect or c.

uneven

cL ftre Ooll ioinis moY be worn out'

d.

Reoloce with o new one

l6

Automobile Chassis And Body

Engineering.doc

Chapter

e. Excessive

coster

e.
o.

Adjust

f. Steering geor or wheel beoring

moy be loosen. o. Tvre moy worn unevenlY

f. Adjust or Reploce

Reploce

2.

High Speed shimmy: The oscillotion of the front wheels of high speed colled high sPeed shimmY.

is

- stroighten or reploce c. wheei Rim mcy be buckled b. Front wheel beoring moy loose or worn out - Tighten or Reploce - RePloce c. Foulty shock Absorber - Adjust d. lncorreci toe-in
3. Excessive bocklosh in steering:

-Tighten c. Steering geor bose moy be loose - Reploce b. Drop orm moy be loose on splines c. Front wheel stub oxle beoring loose or worn out-Tighten or Reploce - Tighten Properly d. Loose steering Linkoges is known

4. Steering Wonder: The moving of Vehicle slightly in one side

os wondering

o. Tyre pressure in two sides is not equol - Check ond correct -Adjust b. Steering knuckle beoring tight - RePloce c. Bodly worn Tyre - Correcl it. d. lncorrect Toe-in
5. Hord Steering: When ihe effort required for steering is more it is colled hord steering.

o. Low Tyre pressure b. Excessive coster c. Steering geor too iight

d. lncorrect wheel

Alignment

- Correci pressure - Adjust - Adjust - Adjusi

Chapter 2

Steering System

17

CCNAPARATIVE STEERING DATA OF SCME INDIAN AUTOMOBILES

Comber

Hinduston Ambossodor Mork l! Fiot I 100

Rock
& Pinion

B114"

Worm
& Roller

(0 to 30)

{2

1to9
UN

degrees
+

degre
es 10 mts

degre
es

l-

2O'

loden
7

+/- l0
mts 30
SECS

loden

Jeep CJ3B

Com
&

1112

7112

.l.2 2.4

io

degrees

degre
ES

degre
ES

Lever

t8

Automobile Chassis And Body

Engineering.doc

Chapter

Shori Answer Quesiions:

Whot ore ihe Requirements of Steering systems? 2. Exploin the functions of steering systems? 3. Lisi out the moin components of steering system? 4. Whot ore the functions of steering Linkoges used the Auiomobiles? 5. Whot ore the types of steering linkoges used the Automobiles? 6. Whot is meont bY wheel wobbling? 7. Whot ore the couses for high Speed Shimmy?
Long Answer Quesiions:

l.

l. 2. 3.
4.

Whot ore ihe types of sleering geor boxes used ond exploin ony one of them? Whot is meont by Steering Geomeiry ond exploin with neot sketches? Exploin obout different Steering mechcnisms i.e. Don's ond Ackermcn steering with neot diogroms? Exploin the following in brief: o. SliP Angle b. Under Steer ond Over Steer c. Reversible Sieering ond lrreversible steering

d.

Turning Rodius

{Jhapter 3

BRAKING SYSTEM
CHAPTER

10

-III

BRAKING SYSTEM:

INTRODUCTION:

the mechonism in the motor vehicle which is used shortest possible io slowing Cown ond stJpping the vehicle to rest in the dislonce. principle of Broking system: while operoting the broking system the KINETIC in to HEAT ENERGY' ENERGY of moving vehicte is converted Functions of Brokes: Brokes hove the following functions' l.lt is used to stoP the vehicle' when required. 2.lt is used to control the speed where ond olong the slope' 3.lt is used to control the vehicle while descending position wiihoui the presence 4.To pork the vehicle ond held it in stctionory
Broking
is

of Driver. Requirements of Automobile Brokes: quolity' l.lt should work efficiently inespective of rood condition ond opplicotion. 2.The retordolion must be uniform throughout its of the driver' 3.The pedol effort must be within the convenieni.co.poc,ity woter ond dust. 4.lt must be relioble ond should not be effected by heoi 5.lt should be in minimum weighi' 6.lt should hove long life. /.lt should be eosy to mointoin ond odjust' B.Noise ond vibrotions ore to be minimum' g.There should be provision for secondory broke or porking broke' Stopping distqnce ond Broking efficiency: the minimum For prcrcticol mecrsure for broking efficiency ihot of opplied. distonce in which it con be broughi in to rest ofter the broke is
The stopping distonce depends upon
1

.Grip between the tyre ond rood surfoce' 2.Iyr e treod condition' 3.Tyre inflotion' 4.Noture of rood surfoce.
The stopping distonce is colculoted by D=kv2

Where d=stopping distonce in kilometers' K=Conston-t depending upon the rood ond tyre inflotion' V=velocity of the vehicle per hour'

20

Automobile Chassis And Body

Engineering.doc

Chapter

The volue of k is 1125 for 4 wheel broking system. 1l12for 2 wheel broking system. The broking efficiency is colculoted by ihe equotion:

q:v2i3D where v=velocity of the vehicle d=stoPPing distonce.

Condition of

Broke

Broking efficiency in %
g0%
77% 70% 60% 50% 37%

l.Perfect 2.Excellenl 3.Good 4.Foir S.Poor 6.Bod /.Very bod

Below Foir is very donger.

30%

Clossificqlion of Brokes:The following ore the clossificotions of Brokes: 1.By method of power o) Mechonicol brokes b) Hydroulic brokes c) Vocuum brokes d) Air brokes e) Electricol brokes f) Mognetic brokes g) Air ossisted hydroulic brokes
2.By method of opplicotion: o) Service or foot brokes b)Porking or hond brokes 3.By method of operotion:

c) Monuol
b) Servo c) Power operotion

4.By melhod of Broking contsct

o. lnternol Exponding Brokes

Ciiapter

-l

BR.AKING SYSTE,M

11 L'

5.By Method of Applying Broke force: c. Single Acting Brokes'

b. Exiernol Controcling Brokes'

b. Double Acting

Brokes'

Types of

Mechonicol Brokes:

c.
b.
Drum Brokes:

Drum Brokes {lnternol Exponding or Externol Conirocting) Disc Brokes (single or Two coliper)

Construction: The moin components of drum brokes ore I . Broke drum 2. Bcck Plote

3. Broke shoes 4. Broke Liners 5. Retcining SPrings 6. Com 7. Broke Linkoges

ln this system the wheel is

conioct ihe rototing drum for broking operotion. The shoes provide lining on oiher lheir outer surfoce. The com is used to lift the broke shoes of one end' come end is connected by some meihod so os to moke os the broke sleeve into contoct in the broke drum. The retoining spring is provided for bringing pedol. ihe broke shoes bock to its originol position, ofier releosing the broke broke drum. This All these ports ore fitted in the bock plote ond enclosed with
sysiem
.

otioched to drum. There ore broke shoes used to

Working:When the pedol is pressed the com moves the shoes ouiwords drum' ihrough linkoges, there by coming in frictionol contoct with ihe rototing help the broke As soon os the broke pedol is releosed the retoining springs shoes to brought bock ond releose the brokes' 2. Disc brokes: There ore two types of disc brokes:

l.

SPot TYPe o. Swinging ColiPer TYPe b. Sliding coliPer tYPe

2. Clutch TYPe
pressure in Construction:The discs ore mqde of grcy cost lron' The broke cose of disc brokes hove to be much lighter thcn the drum brokes.

22

Automobile Chassis And Body Engineering.doc

Chapter

It consists of rototing disc ond two friction pods which ore octuoted by the four hydroulic wheel pistons contoin in two holves of on cssembly is colled o coliper. The coliper ossembly is secured to the steering knuckle in o front wheel brokes. The rood wheel is foshioned to the outer surfoce of the disc. The friction pods rides freely on eoch side of the discs. They ore in position being the hydroulic systems.

Working: When the brokes is opplied hydroulic pressure is supply to the fluid inlet tube, due to which the wheel cylinder piston force the friction poCs cgoinst the rototing disc. ln the relecrsed piston, the spring hold the piston pcds so thot they mcintcin contoct with disc surfoce.

Construction cnd Working of Hydroulic systems: Hydrculic brckes moke used of hydroulic pressure to force broke shoes out words ogoinst the broke drum boseC on PASCAL'S LAW.

Consiruction:The moin components of the system I . Moster Cylinder 2. Wheel Cylinder

is

The figure shows the moster cylinder is connected by tubing to the wheel cylinder, of eoch of the four wheels. The system is filled with the liquid under light pressure when the broke is not in operotion. The broke fluid generclly c mixture of glycerin ond clcohcl cr coster oil, denofured

olcohol ond some odditives. The brokes shoes which ore mounted on the inner side of the broke drum ond do not rotote. The broke liners ore fitted on the outer surfoce of the
i

Chapter

BRAKING SYSTEM

23

bicrke shoes. The broke pedol is connected to ihe moster cylinder piston by rneons of o piston rod.

working: When the broke pedcrl is pressed the piston is forced in io ihe rnoster cylinder, ihe hydroulic pressure is opplied equolly to oll wheel cylinders. The pisions in the wheel cylinders pushed outwords ogoinst the broke drum. When the driver releose the broke pedol, ihe piston in the mosier cylinder returns bock to its originol position due io the return spring pressure. Thus the pisions in the wheel cylinder come bock in its originol inword position. Thus the brokes ore releosed
Construction qnd working of Moster Cylinder
FILLER CAP

PISTON STOP

ReiAtNeR sPRtl'tG

-.

RELIEF OB BYPASS PORT

-,

ililililil
VALV:
SEAT

PISTON
SECONDARY CU
P

PRIMARY CUP

RETURN SPBING

CHECK VALVE

Moster Cylinder: The Moster Cylinder is the heort of the hydroulic broke system. lt consists of iwo moin chombers. The fluid reservoir which contoins ihe fluid to supply to the broke system, ond the compression chomber in which the piston operotes. The reservoir supplies fluid to the broke system through two ports. The lorger port is colled the filler or intoke port ond is connected to the hollow portion of the pision between the primory ond secondory cups which oct os piston'seols. The smollor port is colled the relief, byposs or compensoting port which connects the reservoir directly with ihe .yiind"r ond lines when the piston is in the releosed position. When the brcke pedol is depressed, ihe moster cylinder piston moves forword lo force the liquid under pressure inio the system. The relief port is seoled out of the system.Ihe liquid pressure is conducted to the wheel cylinders, where it forces the wheel cylinder pistons out words. These pistons force the broke shoes out ogoinst the broke drums.

24

Automobile Chassis And Body Engineering.doc

Chapter

When broke pedol is releosed, the return spring quickly forces the mosier cylinder piston bock ogoinst the piston stop. Becouse ihe fluid in the lines returns rother slowly, o vocuum iends to form in the cylinder in froni of the piston. This couses the primory cup to collopse to ollow the liquid to flow from the reservoir through the filter port post the piston to fill the vocuum'

Construction ond working of Wheel Cylinder

WHEEL CYLINDER:

Wheel cylinder is the second importont hydroulic broke sysiem. lt consists of two pistons which con move in opposite directions by the fluid pressure. lt is rigidly mounted on the broke shield or bocking plcte. The boois protect ihe cylinders from foreign substonces. p1qyided in thg.cy|inder !9g9-r-J!il.9ir_gn*liquiq to.jb*e,pumped out of the' system during of the bleeding operotion . piston cup fits tightly in the cylinder ogoinst eoch piston ond seol the mechonism ogoinst leokoge of the broke fluid. A Spring serves io hold the cups ogoinst the piston when the pressure is decreosed. When the brokes ore opplied the broke fluid enters the cylinder from o broke line connection inlei between ihe two pistons. lt couses to force oul the tr,rro pistons in opposite directions. This motion is tronsmitted to the broke shoe. Directly or through links force them ogoinst ihe broke drum, thus cpplying the broke.
Construction qnd lvorking of Tqndem moster Cylinder ln lhis mosier cylinder there ore two pistons in the ond hydroulic pressure developed in iwo chombers one for the front left, ond reor right brokes ond cther foi'the front right cnd recr left brokes" ln tondem moster cylinder one cylinder operotes the front brokes while the other cylinder operotes ihe reor brokes"

Chapter

BRAKING SYSTEM

Ccnstruclion ond working of Air Brcke System:

Theoirbrokesystemconsistsofiwo-stogeoir-compressordrivenbythe compresses it ond cronkshofi or georbox shoft. lt tokes oir from oimosphere, volve" Where the pressure of the delivers to the oir reservoir through un-looder looder volve opens to the reservoir reoches the moximum degree, ihe unin to the otmosphere otmosphere. Then the compressed oir is directed
directly.
consists of o Eoch of ihe four wheels fitted with broke chombers pushes it' This force diophrogm, ond which ihe oir pressure is opplied ond broke' Eoch of the broke operoies the com octuoting lever ond opplies the is olso fitted between chomber is connecied io the broke pedor, ond oir firter the broke volve ond reservoir' volve opens ond working. When ihe broke pedol is pushed the broke The broke volve consists compressed oir is ollowed in to the broke chomber. of ihree POSSOgeS l. Air intoke 2. Exhoust 3' Broke chomber be closed when the broke pedol is pressed the exhoust possoge wili goes bock to the ond Air intoke possCIge open ond compressed oir opens while intoke closes chomber. ouring iui'itn siroke the exhoust possoge fiited with on emergency ond used oir goLs to the otmosphere. This system foils the oir broke mechonicol broke, which con be used when oir supply li c bro ki n q systeln' ,f , t r. whte:i js c-qlle d,q[ !$i519 d hyd ro u "

S6CK ADJUSTR
8RA(E
CTIAT.IBER

st6P LGtlTSwffCtt

Advontoges:

l.

This sysiem used in

heovy vehicles becouse they ore more powerful thon hydroulic or mechonicol brokes'

26

Automobile Chassis And Body Engineering.doc

Chapter

2.
3.

lt simplifies the chossis design The compressed oir is used for purposes like tyre infloiion; for horn,

windscreen wiper etc. Disodvontoge: lf there is ony leokoge in possoge ihe entire system will be foil. Therefore seoling of oir is very difficult'

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I . 9!'. I r ll, l,: $. l-:,.r--Ir' 1 l'' tlr'L"

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Chapter

BR.AKLN,IG SYSTEI\4

27

Short Answer Questions:

1. Exploin ihe funciion of brokes? 2. Whot ore the requirements of Automobile brokes? 3. Whot ore the clossificotions of brokes? 4. Whot does stopping distonce meon?

5.

Exploin obout broking efficiency?

Long Answer Questions:

Whct ore the types of mechonicol brokes exploin ony one of thern? 2. Exploin the construction ond working of Hydroulic brokes? 3. Exploin the Construction ond working of Air brokes?

l.

*> -f*
d:r#?
l.
L,

PPv''rk'n*

28

Automobile Chassis And Body Engineering.doc

Chapter 4

CHAPTER.IV

SUSPENSION SYSTEM:

lnlroduction: The outomobile frome ond body ore mounted on the front ond reor oxle not directly but through the springs ond shock obsorbers' The ossernbly of ports, which perform the isolotion of ports from the rood shocks, moy be in the forms of bounce, pitch ond roll is colled suspension system. Functions of susPension sYsiem: l. lt prevents the vehicle body ond frome from rood shocks. 2. lt gives stcbility of the vehicle. 3. li sofeguords the possengers onC goods from rood shocks' 4. lt givei the good rood holding while driving, cornering ond broking' 5. it gives cushioning effect. 6. lt provides comfort. Requirements of suspension system: 1. There should be minimum deflection' 2. lt should be of low initiol cost. 3. lt should be of minimum weight. 4. lt should hove low mointenonce ond low opercrting cosi. 5. lt should hove minimum tyre weor. Components of Suspension system: Coil springs. Leof springs, shock obsorbers, Spring shockles, stobilizer , lndeperrce.ll_sL,spension sysleln: The independent suspension system meons rood wheels to the frome in:ryhigluql5gAl ony orrongemffis foll of the wheel hos no direct effect on the other wheel. ll eliminotes wheel wobbling.

Advontoges:

1. lt proviCes sofier suspension.

2. lt reduces wheelwobbling 3. li reduces the tendency of fitting of the wheel on one side due to rood vibrotion 4. lt provides more spoce for engine occommodolion. 5. lt promotes under steer which results low un sprung weight. 6. The movement of the spring on one wheel is not ironsmiited to the other wheel.
Sprung Weight: lt is weight of oll the poris supported by the spring including weight of the sPring.

Chapter 4

SUSPENSION SYSTEM

2q

weight: li is the weight of oll the poris between lhe spring ond rod cnd the portion of spring weight it self.
Un sprung

Bosic suspension movements:

l. ,:\2
3.

Bouncing' ,i-f verticol movement of the compleie body. Pitching: The roicting movement of oll ihe poris between the spring ond rood ond the portion of spring weight itself. Rolling: The movement obout longitudinol oxis produced by the centrifugcl force during cornering.

Types of front

lndependent suspension system: There ore three types:

bone Type .*2. Veriicol guide type

qiwirh

Q' lna"L Pt't;:I'Jrl1

rlzzt'd-

Troiling Link Type Wish bone Type of Front lndependent suspension system: ln this type of suspension system coil springs ore mostly used beiween the two suspension orms cnd ore controlled with frome ond of the open ends of the upper ond lower wishbones which ore connected to the chossis frome. The upper orm is shorier thon lower one. This keeps the wheel trock constont. The closed ends of the both orms ore connecied with steering knuckle, supporied by meons of kingpin. A coil spring is ploced in between the lower suspension orm ond frome. Types of suspension springs:

5l

l.

Steel Springs

Leof Springs b. Coil Springs c. Torsion bor Springs

q.

2. Rubber Springs: o. Compression Springs b. Progressive Springs 3. Plostic Srings

4.Air Springs:
5.

o. Bellow Type b. Pestoon Type

Hydrculic Type

Construction ond working of Leof Springs:

30

Automobile Chassis And Bodl' Engineering'doc

Chapter 4

Leof springs ore formed by bending. They ore mode of long strips of steel. Eoch strip is nomed os Leof. The long leof is colled Moster Leof, ond ii consists of eyes at its both ends. One end is fixed to the chossis frome, the other end is fixed to the shockle spring. The spring will get eiongoted during exponsion ond shortened during compression. This chonge in length of spring is compensoted by the shockle. The U-bolt ond clomps ore locoted ot the intermediote position of the spring. The bronze or rubber bushes ore provided on both eyes on the moster leof .
Types of Leof Springs: There ore five types of leof springs

Full - elliPtic iYPe 2. Semi - elliPtic tYPe 3. Three Quorter - elliPiic iYPe 4. Tronsverse SPring tYPe 5. HelPer SPring tYPe

l.

l.

Full

elliptic

The

odvonioge of this type is the eliminotion of shockle ond spring. The

lubricotion ond weor frequently which ore on of the moin drow bock of ihis type of springs.
2. Semi

- elliptic

T.{A}H LEAF

{.L^A[ilF

EVF

ff{r* fiolT - **

Er-L I pTlc This iype is more populor f or reor suspension ore used in 7 5% of cors

sgrdr

3. Three

- Quorter -

elliPtic tYPe:

type is rorely used in now-a-dcys. lt gives resisionce, but occuPies more spoce thon other tYPes.
This 4. Tronsverse Type:

type of spring is ononge tronsversely ocross the cor insteod of longitudinol direction. The trcnsverse spring for fronl oxle os shown in figure,
This

Chapter 4

SUSPENSION SYSTEM

3i

which is nolied rigidly to the frame of the center ond oitqched to the oxle by rneons of shcrckle at both ends.
5. Helper Springsi The helper springs ore used in heovy vehicles for reor suspension. When vehicle fully looded the moin sp[ring os well os helper spring to come in oction ond obsorb the rood shocks. When the"lood of the vehicle is less the helper spring will no't oct ond the moin spring only obsorb the rood shocks'

Need of Shock Absorber: lf the suspension springs ore rigid enough, they will not obsorb rood shocks efficiently, ond if they ore flexible enough, they witl continue to vibrote for longer iime even ofier the bump hos possed" Therefore, the springing device must be compromise flexibility ond stiffness o shock obsorber needed in Automobile Suspension system.
Types of Shock Absorbers: They ore moinly two types

o. Von tYPe b. Piston - i )Single Acting ii). Double Acting c. TelescoPic tYPe Construction ond Working of Single octing Telescopic hydroulic shock obsorbers:
2. Hydroulic

l. Mechonicol'

32

Automobile Chassis And Body Engineering.doc

Chapter 4

MOUNTING

l]lliil t;ilVl It
l,|!il(
rt.l

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IJI

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PREss PLArrl

ril'
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llllll ( 'll
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:ll: AL

GLAND SPRING
I

ll

lr ll ,t.ll )

I'i )lt

PISTON ROD GUIDE

I tt
AN

ll ti

DRAIN TUBE

llt ilAM ll.rtlL

BAFFLE PISTON

''l;ll,?f
I'l'i lol'l
I

."i

PISTON VALVE SPRING PISTON VALVE PLATE

tlN(

PISTONVALVE
SCREW RESERVO]H

VAlVll t'l A1[:

lil

U0IJNli

vAl

ltl tlrrtlNl)

OUTEIl

T(.JIII

vl

:ll'l

{ll.l(

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CYl,lNt.)l:ll

Irl lit.llvolll
,rrll v^l vl l'l Al
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VAt Vl

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r'r tAH

The telescopic shock absorber consisis of o cylinder to which o heod is welded to screwed to ihe outer tube" The spoce between outer ond inner tube is colled reservoir. A pressed steel cop and cxle eye by meons of which cylinder is screwed to the oxle CIre welded to the outer tube. A pision slides inside the cylinder ond screwed to the piston rod of which its upper end of chcssis eye, it is ottoched to the frome of the vehicle. The port of the pision

rod thot is outside of the cylinder is protected by o cover which is welCed to the chossis eye. A piston rod glond pocking prevent the leokoge, when the piston posses through ihe heod ond ony fluid is iropped by it is supplied to ihe reservoir through drcin hole.

Chapter 4

SUSPENSION SYS'TEM

33

Working: if ihe axle eye mcves upwords then the fluid must be disploceci frorr-t tne bottom. Top side of the bcttom side fluid through the outer ring of the piston by lifting the non reiurn volve. But since the increose in the volume of upper end of the cylinder is less thon the volume of the lower end. Fluid will oiso disploced through ihe inner ring of holes of non return'Volve of foot voive, ond the level ct the fluid will roise in the reservoir. The pressure setup will Cepend on the size of hole in the piston ond Fooi volve ond the squire of the speed of which the cylinder is moved'

downword motion of the cylinder the fluid will be disploced form ihe upper end of the piston. ln the leover end through the inner ring of hole of non return volve in the piston. The fluid will olso be drow in ihe lower end of the cylinder from ihe reservoir io the outer ring of hole of non return volve of the fooi volve. Fig of shock obsorber
For

Siqbilizer Bor: Siobilizer is necessorily used in oll independent front suspension. lt reduces tendency of the vehicle to roll on either side when toking o turn. lt is simply o bor of olloy sieel with orms of eoch end connected to the lower wish bone of the independent suspension system. lt is supported irt bush beorings fixed the frome ond is pcrollel to cross member. When both the wheels defleci up or down by the some omount, the stcrbilizer bor simple turns in the beorings. tVhen only one wheel deflects, then only one end of the stobilizer moves, ihus it octs os o spring between two sides of the independeni front susPension.
Torsion Bcrr Torsion bor suspension is used in independent suspension sysiem. ll is o rod octing in iorsion ond tcking sheor slresses only. lt is mcde up of heoi treoted olloy spring steel. This bor stores omount of energy neorly os some os coil spring.

oi one end to the fr4ome, while the other end is fixed to the end of the wheel orm ond supported in the beoring. The other end of the wheel orm connected to the wheel hub. When the wheel strikes o bump, it
The bor is fixed storts vibro.ting up ond down, thus exerling torque on the torsion bor which octs os o spring.

Au-t.-:n:obile Ctrassis Anc! Boci;'

Fngiileering'rior;

{.hartrer

Short Answer Questions

'1. Explcin ihe functions of suspension system? 2. List oul the requlren')ents of suspension sy5fspQ 3. Whct ore the types of suspension springs? 4. whot ore the bosis suspension movemenis? 5. Er.ploin obout sprung weight ond un spiLrng weight?
Long Answ,er Questions

cillcut wish bone type of front independerrt suspension? 2. lVhci cre the iypes of ieof spring used in ouiomobiles crnd explolr-i wilh neot sketches? 3. Exploin the construciion cnd working of single octing, ielescopic, hycjrculic shock obsorber wiih c nect sketch? 4. Explcin briefly obout following contents: c. sicbilizer bor

l.

W"5ct

o;e ihe types of lndependenl suspension systerrr onci exploin

b" Tcrsit:n