Chassis: Automotive chassis is a skeletal frame on which various mechanical parts like engine, tires, axle assemblies, brakes,

steering etc. are bolted. The chassis is considered to be the most significant component of an automobile. It is the most crucial element that gives strength and stability to the vehicle under different conditions. Automobile frames provide strength and flexibility to the automobile. The backbone of any automobile, it is the supporting frame to which the body of an engine, axle assemblies are affixed. Tie bars, that are essential parts of automotive frames, are fasteners that bind different auto parts together Automotive frames: Automotive frames are basically manufactured from steel. Aluminum is another raw material that has increasingly become popular for manufacturing these auto frames. In an automobile, front the front

frame is a set of metal parts that forms the framework which also supports

wheels. It provides strength needed for supporting vehicular components and payload placed upon it.

Bonnet: Bonnet, an important part of automotive frame can be defined as a protective covering made up of a hinged metal part used for covering an engine of a vehicle. Usually automobile bonnets are made of steel, aluminum, fiberglass, and carbon fiber reinforced plastic

Hood: Hood refers to a cover placed over the engine and passenger compartment of an automobile. Hoods form an important type of automotive frames. These auto frame parts are usually made of steel, aluminum, fiberglass, carbon fibre or dry carbon. A typical hood comprises of several different parts such as hood ornament, hood scope, power bulge, and wiper jets. Automotive chassis is considered to be one of the significant structures of an automobile. It is usually made of a steel frame, which holds the body and motor of an automotive vehicle. More precisely, automotive chassis or automobile chassis is a skeletal frame on which various mechanical parts like engine, tires, axle assemblies, brakes, steering etc are bolted. At the time of manufacturing, the body of a vehicle is flexibly molded according to the structure of chassis. Automobile chassis is usually made of light sheet metal or composite plastics. It provides strength needed for supporting vehicular components and payload placed upon it. Automotive chassis or automobile chassis helps keep an automobile rigid, stiff and unbending. Auto chassis ensures low levels of noise, vibrations and harshness throughout the automobile. The different types of automobile chassis include: Ladder Chassis: Ladder chassis is considered to be one of the oldest forms of automotive chassis orautomobile chassis that is still used by most of the SUVs till today. As its name connotes, ladder chassis resembles a shape of a ladder having two longitudinal rails inter linked by several lateral and cross braces. Backbone Chassis: Backbone chassis has a rectangular tube like backbone, usually made up of glass fibre that is used for joining front and rear axle together. This type of automotive chassis or automobile chassis is strong and powerful enough to provide support smaller sports car. Backbone chassis is easy to make and cost effective. Monocoque Chassis: Monocoque Chassis is a one-piece structure that prescribes the overall shape of a vehicle. This type of automotive chassis is manufactured by welding floor

pan and other pieces together. Since monocoque chassis is cost effective and suitable for

robotised production, most of the vehicles today make use of steel plated monocoque chassis Types of automobile chassis: Motor cycle chassis An important type of automotive chassis, motorcycle chassis comprise of different auto parts and components like auto frame, wheels, two wheeler brakes and suspension. Its basically the frame for motorbikes that holds these components together. A motorbike chassis can be manufactured from different materials. But the commonly used materials are steel, aluminum, or magnesium. Motorcycle Easy Ride Frame Motorcycle Headlight Trim Kit

Motorcycle Frame Cover Motorcycle Frames and Chassis

Motorcycle Light Visors Motorcycle Rigid Frame

Car chassis The main structure of a car is known as chassis. Car chassis functions as a support for the different car parts. Automotive engine, suspension & steering chassis.

partslike

mechanism, braking system, auto wheels, axle assemblies and transmission are mounted on the car

Bus chassis is the design and quality of bus chassis depends on the capacity of bus. It can be tailor made according to the needs and can be availed with features like transverse mounted engine, air suspension as well as anti-roll bars. A well manufactured bus chassis offers various benefits like high torque from low revs, superior brake performance and more. Bus chassis designed for urban routes differs from the one manufactured for suburban routes.

Truck chassis, the backbone of any truck is designed to provide a comfortable and dependable ride. New invention in automotive sector has influenced the automobile chassis manufacturers to adopt latest trends and come up with new designs. In the present world, a truck chassis comes with enhanced geometry, power steering, disc brakes and other truck

parts.

Different chassis parts together comprise of automobile chassis. The different types of automobile chassis parts comprise of control arm, pitman arm, ball joint, stabilizer link, tie rod end, rack end and many other auto parts. On the basis of their functions, the automotive chassis parts are sub divided into: Chassis Brackets Chassis Crossmember
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Chassis Fixings: Chassis fixings function as automotive fasteners used for connecting automobile chassis. These fixings hold together the varied parts of the vehicle chassis. High strength stainless steel is the most commonly used material for manufacturing chassis fixings. Besides being rust and corrosion resistance, stainless steel chassis fixings also offer desired durability.

Chassis power point:

MODULE-1 : MODULE-1 AUTOMOBILE CHASSIS AND BODY Slide 3: CHASSIS FRAMES TESTING OF CHASSIS FRONT AXLE STUB AXLE Slide 4: INTRODUCTION CONSTRUCTIONAL DETAILS CLASSIFICATION Slide 5: Main structure of the vehicle Now used to denote complete structure of vehicle Light vehicles have mono structure having body integral with frame Contains all major units necessary to propel the vehicle It is the main mounting for all units including body Also known as carrying unit Slide 6: CHASSIS IS SUB-DIVIDED INTO RUNNING GEAR includes frame ,suspension system ,brakes ,wheels and tyres POWER PLANT includes engine assembly and power transmission assembly Electrical system is a part of both chassis and body Slide 7: ACCORDING TO THE FITTING OF ENGINE FULL FORWARD CHASSIS SEMI-FORWARD CHASSIS BUS CHASSIS FRONT ENGINE CHASSIS REAR ENGINE CHASSIS CENTRE ENGINE CHASSIS Slide 8: FULL FORWARD CHASSIS Full forward chassis is that in which the engine is placed outside the driver cabin or seat like in cars and old TATA trucks. In this type of arrangement, the driver seat is far enough from the front wheels and is not able to see just infront of the vehicle SEMI-FORWARD CHASSIS In this type the half portion of the engine is in the driver cabin and the remaining half is outside the cabin like in standard, bedford pick up. It provides better visibility of road to the driver BUS CHASSIS In this type the whole engine is f itted in the drivers cabin. It provides an increased floor space in the vehicle. The drivers seat is just above the front wheel and he can see the full front road right from the front wheels. Drive is given to the rear wheels. Slide 9: FRONT ENGINE CHASSIS In most of the vehicles the is fitted infront of the chassis. The drive is given to the front wheels only like in MATADOR vehicles. REAR ENGINE CHASSIS Engine may also be fitted at rear portion of the vehicle like in VOLKSWAGON.this arrangement doesnt require long propeller shaft. Gearbox and differential are combined in one unit. CENTRE ENGINE CHASSIS The engine may also be fitted at centre of the chassis. This arrangement provides full space of chassis for use. In royal tiger world master buses of Delhi transport the engines are fitted at centre of the chassis. Slide 10: According to the number of wheels fitted and number of driving wheels the chassis are of following types.. 44 drive chassis It consists of 4 wheels and all are driving wheels 42 drive chassis It consists of 4 wheels out of which 2 are driving wheels 62 drive chassis It consists of 6 wheels out of which 2 are driving wheels 64 drive chassis It consists of 6 wheels out of which 4 are driving wheels Slide 11: FRAME Also called under body. Main part of chassis. Rigid structure which forms a skeleton. Engine is mounted at front end of frame and is connected to clutch and transmission unit to complete power assembly. At rear end rear axle housing is attached through the rear spring Slide 12: FUNCTIONS OF FRAME Frame is provided with cross members to increase the rigidity and to withstand the shocks, blows, twists, and vibrations coming during operation. A frame is required to carry the weight of the vehicle and its passengers, to withstand the engine torque, thrust stresses, accelerating and breaking torque, to resist the effect of centrifugal forces when cornering and to withstand bending and twisting stresses due to fluctuations of front and rear axles. REQUIREMENT FOR A GOOD FRAME It should be strong and stiff enough to resist the severe twisting and bending forces to which it is subjected particularly when vehicle is travelling at high speed over a rough road. Slide 13: There are mainly two types of frames. CAR FRAME TRUCK FRAME GENERAL DESIGN OF FRAME: It consists of two longitudinal or side members. In trucks the side members are frequently straight, but in cars they are narrow towards front end. The side members are braced together by a number of cross members of channel or tubular section. Several brackets are provided for supporting the running boards, other brackets if necessary, are provided to support engine, gear box, brake shaft etc.

Slide 14: CAR FRAMES This frame has good beam strength and is quite suitable for long body brackets This need not be as deep as the channel section for the same strength This section permits o lower floor level and ultimately lower centre of gravity Allows sufficient freedom to designers for the layout of under body assemblies and running gear Usually in this type there is an X-member for providing torsional rigidity. box section car frame X-member type car frame Slide 15: TRUCK FRAMES Truck frames are made of uniform width from end to end. The longitudinal members are made of channel sections. In this type longitudinal members have maximum section at middle and decreases towards the end. A cross member is provided at the middle of frame to act as support for central bearing of propeller shaft Frame consists of pressed steel side members and cross members secured together by cold squeezed rivets. Side members are formed in deep channel sections. Slide 16: FRAME REPAIR AND ALIGNMENT Although the frame is strong enough, it does not require any care. However , if the vehicle is carelessly driven on rough road if it is heavily loaded, some defects can occur in frame. LOOSE RIVETS: Due to rough driving and heavy loads, the chassis rivets become loose. The loose rivets can be easily rusted. The frame member also become loose and create noise. Before servicing the loose rivets must be checked and replaced. LOOSE RIVETS CRACKS Slide 17: GUIDELINES FOR REPLACING THE LOOSENED RIVETS Cut the rivet head by drill or gas torch. Dont use chisel. By cutting rivet hea d with chisel. The size of rivet hole may increase and also it is deformed. If the hole size increased, then use the over size rivet so that it can be fitted tightly in it. Before fitting new rivet, clean the hole carefully, there should be no burr in it. Properly heat the new rivet and fit it carefully by riveting hammer. Dont fit cold rivet, it doesnt make strong joint. Dont fix the loose rivet by welding but replace it. Slide 18: CRACKS: Cracks may also occur in chassis frame. Cracks can be found out if seen carefully. If not visible, then make a chalk solution in water and paste it on frame where crack is suspected. Let the solution dry and slightly hammer the frame. The crack will be seen clearly. Repair the crack so on otherwise it will increase and frame will break If you dont have arrangement for repairing crack, the n drill holes on each side of crack. The holes will check the crack for increasing it. The holes work like first aid for cracks. After that make arrangement for repairing the crack. Slide 19: GUIDELINES FOR REPAIRING CRACKS Make V-groove on crack. Chamfer the upper portion of the groove. Fill the V-groove by electric arc welding. Grind the upper surface of the welding. If the crack is long enough, then weld a strip on this welded surface. It gives more strength to the crack frame. Slide 20: If the alignment of the frame is bent due to the accident, it is adjusted by heating the bent member and straightened by jack. Slide 21: TESTING OF FRAME ALIGNMENT Frame alignment can be checked by a frame aligning fixture. This fixture is equipped with bendin g tools for straightening frame parts. If this fixture is not available, the frame alignment can be determined by X or diagonal method of checking from given points on each side rail. This is done by marking on the floor all points from which measurements should be taken. Drop a plumb-bob from each point indicated and mark the floor directly underneath the point. A A B B C C D D Slide 22: PROCEDURE FOR CHECKING FRAME ALIGNMENT Check frame width at front and rear end, using corresponding marks on floor. If width correspond to specifications, draw a centre line the full length of the vehicle, half-way between marks indicating front and rear widths. If frame width is not correct and centre line cannot be laid out from checking points at the end of frame, it can be drawn through intersections of any two pairs of equal diagonals. With the centre line properly laid out, measure the distance from it to points opposite over the entire length of chassis. If frame is in proper alignment measurement should not vary. To locate the point at which the frame is sprung, measure the diagonal marked A-B, B-C, C-D. if the diagonals in each pair are with in 3.17 mm, that part of the frame included between points of measurements may be considered as in satisfactory alignment. These diagonals should intersect at the centre line. If the measurement do not agree with the above limits, it means that correction will have to be made between those points that are not equal. Slide 23: FRONT AXLE The front axle is used to carry the eight of the front part of the vehicle as well as to facilitate steering and absorb shocks due to road surface variations. It must be right and robust in construction. It is usually a steel drop forging having 0.4% carbon steel or 1-3% nickel steel. It is made of I section in centre portion while ends are made either circular or elliptical. With this construction, it takes bending loads due to the load of vehicle and also torque due to braking of the wheels. spring seats A A B B section at AA section at BB Slide 24: TYPES OF FRONT AXLES There are two types of front axles: LIVE FRONT AXLE DEAD FRONT AXLE The front axles are usually dead axles because they do not rotate, in contrast to the live axles that they are used to transmit power to the rear wheels. A live front axle, as compared to dead front axle, has the additional function of transmitting the driving power taken from a transfer gear box to the front wheels. The dead front axle has sufficient rigidity and strength to transmit the weight of the vehicle from the springs to the front wheels. cotter pin king pin stub axle main beam steering arm end steering pin attachment

Slide 25: STUB AXLE The front wheels are mounted on stub axles, which are connected to the front axle by means of king pins. The stub axles are the forging of 3% nickel steel and alloy steels containing chromium and molybdenum. Stub axle turns on the king pin which is a light drive fit in the axle beam eye located and locked by a taper cotter pin or some similar arrangement. Phosphor bronze bushes are fitted into the forked ends of the axle to provide a bearing surface for the king pin. Vertical loads are taken by a steel washer or thrust bearing located either on the top fork of the stub axle or between the lower fork and the underside of the axle beam. Slide 26: There are four types of stub axles ELLIOT REVERSE ELLIOT LAMOINE REVERSE LAMOINE The Elliot stub axle is attached to the front axle by placing it in the end with a king pin and cotter to join the two together. In reversed Elliot type stub axle , the arrangement is reversed. thrust washer king pin cotter front axle stub axle ELLIOT TYPE REVERSE ELLIOT TYPE stub axle thrust washer cotter Slide 27: In lemoine type stub axle, instead of yoke type hinge, a L-shaped spindle is used. king pin king pin stub axle stub axle front axle front axle LEMOINE TYPE REVERSE LEMOINE TYPE Slide 28: FRONT WHEEL ASSEMBLY The wheel revolve over two ball bearings which can be adjusted by means of an adjusting nut. The front wheel bearing have to withstand: The weight of the vehicle. Side thrust and tendency of the wheel to tilt when cornering. Shock loads due to uneven road surfaces. stub axle cover oil seal brake drum bush back plate grease container adjusting nut drain hole