AT 2352 AUTOMOTIVE CHASSIS COMPONENTS DESIGN

UNIVERSITY TWO MARK QUESTIONS

May/June 2012
1. Discuss the various loads acting on a chassis frame
2. What is an energy-absorbing frame
3. A steering gearbox has a gear ratio of 16:1 and an efficiency of 85%. Assume the driver to
exert a force of 60 N at the rim of the steering wheel 0.4m diameter, determine the torque at
the drop arm shaft.
4. What are the functions of front axle?
5. Why is cone clutch more effective that plate clutch
6. What are the types of clutch operating mechanisms used in automobile?
7. What are the possible arrangements to achieve 12 speeds from a gear box?
8. What are the difference between a constant mesh gear box and sliding mesh gear box?
9. State the formula used to compute critical speed of a propeller shaft. Why it is so important?
10. What are the types of stress experienced by semi-floating axle?
Nov/Dec 2012
1. What are the loading situations the chassis generally experiences?
2. What are the factors considered while designing a torsion bar?
3. What type of sections are provided at the middle and at the ends of the front axle?
4. What are the causes of steering geometry errors with up and down wheel movement?
5. When is the torque capacity of the clutch greatest?
6. List out the various components of a clutch.
7. Why is geometric progression in gear ratios?
8. When is maximum vehicle speed attained?
9. Why is the propeller shaft critical speed important/
10. What are the types of stresses experienced by semi-floating axle shafts?
May/June 2013
1. Differentiate between horizontal lozenging and lateral bending in a ladder chassis.
2. Mention the different configurations of laminated leaf spring suspensions.
3. Classify the various axle-hubs employed in automobiles.
4. What is the difference between hydrostatic and hydrodynamic lubrication? Also mention the
kind of lubrication employed in dead axles.
5. What are the factors to be considered while designing an automotive friction clutch?
6. With an example give any two material properties for designing a friction clutch.
7. Mention the merits and limitations of gear drives.
8. What is meant by dynamic and static tooth loading in gear drives? How it is calculated?
9. Give the expression for calculating speed of propeller shaft.
10. A hatch back vehicle engine develops 30kW at 1450 rpm and its bottom gear ratio is 3:1. If a
propeller shaft of 38 mm outside diameter is to be used, determine the inside diameter of
mild steel tube to be used, assuming a safe shear stress of 56 x 10
3
kPa for the mild steel.


Nov/Dec 2011
1. Name the stresses that act on frame member.
2. Compare leaf spring with torsion bar.
3. The wheel base of a vehicle is 2m and the distance between the points of front axles is 1.3 m.
while taking a turn, the outside lock makes an angle of 20
o
. Determine the inside lock angle
for correct steering.
4. With neat diagram show the various stresses acting on front axle.
5. In a single plate dry clutch, the ratio of mean radius to the face width is 4 and the mean radius
of the friction lining is 110 mm. determine face width of the friction lining.
6. Axial force on each friction surface is 1400 N, mean radius of friction lining is 90 mm, the co-
efficient of friction is 0.3 and the number of pairs of friction surface is 4. Determine the torque
transmitted through this clutch.
7. What is the purpose of transmission system in an automobile/
8. Compare spur gear and helical gear transmission in automobile.
9. Sketch and name the parts of a propeller shaft in heavy load trucks.
10. Write down the types of rear axle housing.
April/May 2011
1. What are the loads and stresses the frame has to withstand?
2. Why are shackles used along with leaf springs?
3. What are the types of stresses encountered by front axle?
4. Why do the front wheels have toe out on turns?
5. What are the major limiting the clutch capacity?
6. Why is the multi-plate clutch of smaller diameter preferred for high performance cars?
7. How are intermediate gears decided?
8. At what condition the vehicle attains maximum speed?
9. What are the limits of maximum and minimum diameter of the propeller shaft?
10. How is fully floating axle is different from other two constructions?

Answers
May/June 2013
1. Differentiate between horizontal lozenging and lateral bending in a ladder chassis.
Horizontal lozenging - the conditions like pot-holes, road joints, surface bumps and curbs
cause the chassis frame to distort to a parallelogram shape.
Lateral Bending the chassis is exposed to lateral side force that may be due to the camber
of the road, side wind, centrifugal force while turning a corner, or collision with some object.

2. Mention the different configurations of laminated leaf spring suspensions.
Fully elliptic, three-quarter elliptic, half or semi elliptic, quarter elliptic, transverse mounted
semi elliptic and cantilever mounted semi elliptic.

3. Classify the various axle-hubs employed in automobiles.
Elliot type, reverse Elliot type, Lemoine type and reverse lemoine type



4. What is the difference between hydrostatic and hydrodynamic lubrication? Also mention
the kind of lubrication employed in dead axles.
Hydrodynamic lubrication is said to exist when the moving surfaces are separated by the
pressure of a continuous unbroken film or layer of lubrication. Hydrostatic lubrication is
essentially a form of hydrodynamic lubrication in which the metal surfaces are separated by a
complete film of oil, but instead of being self-generated, the separating pressure is supplied
by an external oil pump.

5. What are the factors to be considered while designing an automotive friction clutch?
a. Selection of proper type of clutch that is suitable for given application.
b. Selection of suitable material at the contacting surfaces.
c. Designing the clutch for sufficient torque capacity.
d. Engagement and disengagement should be without shock or jerk.
e. Provision for carrying away the heat generated at the rubbing surfaces

6. With an example give any two material properties for designing a friction clutch.
a. The two materials in contact must have a high coefficient of friction.
b. The materials in contact must resist wear effects, such as scoring, galling, and ablation
c. The materials should possess good thermal properties, high heat capacity, good thermal
conductivity, withstand high temperatures
7. Mention the merits and limitations of gear drives.
Merits:
No chain or belt to break
High power transmission within compact space
Disadvantages:
Noisy
Cannot transmit power to longer distance.

8. What is meant by dynamic and static tooth loading in gear drives? How it is calculated?
Static gear loads are generated by statically loading the input shaft at the specified input torque, without
any motion being imparted to the gears. Dynamic load occurs when a pair of teeth is just coming into
mesh.

9. Give the expression for calculating critical speed of propeller shaft.
Critical speed Nc =
1890000

2
* (
0
2
+

2


10. A hatch back vehicle engine develops 30kW at 1450 rpm and its bottom gear ratio is 3:1. If a
propeller shaft of 38 mm outside diameter is to be used, determine the inside diameter of
mild steel tube to be used, assuming a safe shear stress of 56 x 10
3
kPa for the mild steel.
Hint: Use formulas: P =
2
60000
, kW
and
T
J
=
f
s
R



May/June 2012
1. Discuss the various loads acting on a chassis frame
Vertical bending
Longitudinal torsion
Lateral bending
Horizontal lozenging

2. What is an energy-absorbing frame
The modern vechile frames are made by constructing the front- and rear-end of the frame in
a manner so that it crumbles in a concertina manner during collision and absorb the main
shock of the impact.

3. A steering gearbox has a gear ratio of 16:1 and an efficiency of 85%. Assume the driver to
exert a force of 60 N at the rim of the steering wheel 0.4m diameter, determine the torque
at the drop arm shaft.
Refer notes on front axle and steering

4. What are the functions of front axle?
The front axle carries the weight of the front part of the automobile as well as facilitates
steering and absorbs shocks due to road surface variations.

5. Why is cone clutch more effective that plate clutch
Simple in construction
More area of frictional contact

6. What are the types of clutch operating mechanisms used in automobile?
Mechanical - Movement at the pedal pad is transferred through an operating mechanism, to the clutch
assembly on the rear of the flywheel.
Hydraulic - The pedal acts on a master cylinder, connected by a hydraulic pipe and flexible hose, to a
slave cylinder, mounted on the clutch housing.

7. What are the possible arrangements to achieve 12 speeds from a gear box?
Quick change gear box

8. What are the difference between a constant mesh gear box and sliding mesh gear box?
In sliding mesh gear box, the individual gear ratio is chosen by sliding the selected gearwheel
axially along the splined main output shaft, but in constant mesh gear box, the gears on the
lay shaft and the main shaft are always in a constant mesh, the gear ratio is selected by engage
the dog clutch.

9. State the formula used to compute critical speed of a propeller shaft. Why it is so important?
Critical speed Nc =
1890000

2
* (
0
2
+

2

It is important to calculate the critical speed because, whirling may occur at certain critical
speed leading to failure of the material. So, the speed of operation of the propeller shaft should
be always lower than the critical speed.




10. What are the types of stress experienced by semi-floating axle?
Driving torque as well as both vertical and horizontal loads. Vertical load produces shearing
force and bending moment. The horizontal force due to tilting of the vehicle, cornering
centrifugal force or side wind gives rise to both side thrust and a bending moment.
Nov/Dec 2012
1. What are the loading situations the chassis generally experiences?
Vertical bending
Longitudinal torsion
Lateral bending
Horizontal lozenging

2. What are the factors considered while designing a torsion bar?
Torsion bar should be designed under maximum dynamic load (bump road) considerations
and the corresponding allowable stress.

3. What types of sections are provided at the middle and at the ends of the front axle?
At the center I section is provided to withstand vertical bending and at the ends circular or
oval cross-section is provided to withstand torsional load.

4. What are the causes of steering geometry errors with up and down wheel movement?
Toe-in and toe-out and camber of the wheel

5. When is the torque capacity of the clutch greatest?
At minimum or zero slip, the torque capacity of the clutch is greatest.

6. List out the various components of a clutch.
Driving member pressure plate assembly and fly wheel
Driven member disc or plate assembly and the clutch shaft.

7. Why is geometric progression in gear ratios?
For heavy commercial vehicles, the gear ratios are usually arranged in geometric progression.
The basis for this is to have the engine operating within the same speed range in each gear.
This would ensure that in each gear, the operating fuel economy is similar.

8. When is maximum vehicle speed attained?
The maximum vehicle speed is attained when the gear is set in top and the throttle is held
fully open.

9. Why is the propeller shaft critical speed important?
It is the speed at which the propeller shaft rotates violently lending to failure of the propeller
shaft. This should be avoided. The length of the propeller shaft governs the critical speed of
the propeller shaft.

10. What are the types of stresses experienced by semi-floating axle shafts?
Driving torque as well as both vertical and horizontal loads. Vertical load produces shearing
force and bending moment. The horizontal force due to tilting of the vehicle, cornering
centrifugal force or side wind gives rise to both side thrust and a bending moment.


Nov/Dec 2011
1. Name the stresses that act on frame member.
Vertical bending stress
Longitudinal torsion shear stress
Lateral bending stress
Horizontal lozenging

2. Compare leaf spring with torsion bar.


3. The wheel base of a vehicle is 2m and the distance between the points of front axles is 1.3
m. while taking a turn, the outside lock makes an angle of 20
o
. Determine the inside lock
angle for correct steering.
Hint: use the formula cot cot =

4. With neat diagram show the various stresses acting on front axle.



5. Axial force on each friction surface is 1400 N, mean radius of friction lining is 90 mm, the co-
efficient of friction is 0.3 and the number of pairs of friction surface is 4. Determine the
torque transmitted through this clutch.
Hint: Use the formula T = n W R to find the torque transmitted by the clutch

6. What is the purpose of transmission system in an automobile?
Transmission is the mechanism which is used to transfer the power developed by engine to
the wheels of an automobile. The transmission system of an automobile includes clutch, gear
box, propeller shaft axle and wheels, etc. The main function of the transmission is to provide
the necessary variation to the torque applied by the engine to the wheels. This is achieved by
changing the gearing ratio between the engine and the drive shaft.
7. Compare spur gear and helical gear transmission in automobile.
In a spur gear the teeth are straight-cut and the edge of the teeth is parallel to the axis of
rotation. In a helical gear the teeth are cut at an angle and the edge of the teeth is non parallel
to the axis of rotation. Helical gears operate quietly compared to spur gears. Spur gear can be
used only in a transmission involving parallel orientation; the gears can be meshed correctly
only if they are perfectly parallel to each other. A helical gear on the other hand can be meshed
in parallel or cross orientation.

8. Sketch and name the parts of a propeller shaft in heavy load trucks.




9. Write down the types of rear axle housing.
Semi floating axle housing
Three-quarter floating axle housing
Full floating axle housing

10. In a single plate dry clutch, the ratio of mean radius to the face width is 4 and the mean
radius of the friction lining is 110 mm. determine face width of the friction lining.
Hint : use the formula R / b = 4.