ACD CH.

CH.1

FUNDAMENTALS OF
AUTOMOBILE COMPONENT
DESIGN

12 Marks

Contents of Chapter
1. Component design - Concept.
2. Modes of failure of different automotive components.
3. Basic requirements of automobile components.
4. Basic automobile component design procedure.
5. Use of standards in component design
6. Preferred numbers.
7. Ergonomic considerations in component design.
8. Aesthetic considerations in component design.

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Design considerations in machine design:

1. Types of loads and stresses caused by the load.

2. Motion of parts and kinetics of machine.

3. Material selection criteria based on cost, properties etc.

4. Shape and size of parts.

5. Frictional resistance and lubrication.

6. Use of standard parts.

7. Safety operations.

8. Work shop facilities available.

9. Manufacturing cost.

10. Convenient of assembly and transportation.

Classification of design.

Depending Upon the method used design may be classified as

i) Industrial Design

ii) Rational Design

iii) Empirical Design

iv) Optimum design

v) System design

vi) Elemental design

vii) Computer aided design

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general procedure to solve a design problem

1. Recognition of need. First of all, make a complete statement of the problem,indicating the
need, aim or purpose for which the machine is to be designed.

2. Synthesis (Mechanisms). Select the possible mechanism or group of mechanisms which will
give the desired motion.

3. Analysis of forces. Find the forces acting on each member of the machine and the energy
transmitted by each member.

4. Material selection. Select the material best suited for each member of the machine.

5. Design of elements (Size and Stresses). Find the size of each member of the machine by
considering the force acting on the member and the permissible stresses for the material
used. It should be kept in mind that each member should not deflect or deform than the
permissible limit.

6. Modification. Modify the size of the member to agree with the past experience and
judgment to facilitate manufacture. The modification may also be necessary by
consideration of manufacturing to reduce overall cost.

7. Detailed drawing. Draw the detailed drawing of each component and the assembly of the
machine with complete specification for the manufacturing processes suggested.

8. Production. The component, as per the drawing, is manufactured in the workshop.

Selection Criteria of materials for ACD

1. Availability:

 readily available in the market, in large enough quantities to meet the requirements

2. Material Cost:

 there is a limiting cost beyond which designer can’t afford if this exceeds consider other alternative
material.

3. Mechanical properties:

● technical factor governing the selection of material eg strength under fluctuating, static load, elasticity,
stiffness, toughness, hardness.

● Depending upon the working conditions & requirements, the properties are considered and material is
selected.

Eg. Material for connecting rod should be capable to withstand fluctuating stress induced so here
endurance limit becomes the selection criteria.

4. Manufacturing considerations:

 Machinability of material ,casting property, The manufacturing processes such as forging, casting,
rolling, machining, extrusion etc. governs the selection of material.

5. Manufacturing Cost:

 It includes cost of processing the material into finished goods.

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Types of failure:
1. Force-and /or 8. Wear
temperature induced
9. Impact
elastic deformation
10. Fretting
2. Yielding
11. Creep
3. Brinnelling
12. Buckling
4. Ductile rupture
13. Combined creep and
5. Brittle fracture fatigue
6. Fatigue 14. Radiation damage
7. Corrosion

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Types of failure:
1. Force-and /or temperature by the imposed operational
induced elastic deformation: loads or motions, becomes
Failure occurs when the elastic great enough to interfere with
deformation in a machine the ability of the machine to
member, brought about by the satisfactorily perform its
imposed operational loads or intended function.
temperatures, becomes great
enough to interfere with the
ability of the machine to
satisfactorily perform its
intended function.
2. Yielding: Failure occurs when
the plastic deformation in a
ductile material brought about

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3. Brinnelling: Failure occurs when the static forces between

two curved surfaces in contact result in local yielding of one
or both mating members to produce a permanent surface
discontinuity of significant size.
4. Ductile rupture: Failure occurs when the plastic deformation
in machine part that exhibits ductile behavior is carried out
the extreme so that the member separates into two pieces.

4. Ductile rupture: Failure occurs when the plastic deformation in machine

part that exhibits ductile behavior is carried out the extreme so that the
member separates into two pieces.
5. Brittle fracture: Failure occurs when the elastic deformation, in a machine
part that exhibits brittle behavior, is carried to the extreme so that the
primary inter atomic bonds are broken and the member separates into
two or more pieces.
6. Fatigue: Fatigue failure is a general term given to the sudden and
catastrophic separation of a machine part into two or more pieces as a
result of the application of fluctuating loads or deformations over a
period of time. Failure takes place by the imitation and propagation of a
crack until it becomes unstable and propagates suddenly to failure. The
loads and deformations that are cause failure by fatigue are typically far
below the static failure levels.

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7. Corrosion: Failure implies that a machine part is rendered

incapable of performing its intended function because of
the undesirable deterioration of the material as a result of
chemical or electrochemical interaction with the
environment. Corrosion often interacts with other failure
modes such as wear or fatigue.
8. Wear: It is undesired cumulative change in dimensions
brought about by the gradual removal of discrete particles
from contacting surfaces in motion, usually sliding,
predominantly as a result of mechanical action.

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9. Impact: Failures result when a machine member is subjected to monostatic

loads that produce in the part stresses or deformations of such magnitude that
the member no longer is capable of performing its function. The failure is
brought about by the interaction of stress or strain waves generated by the
dynamic or suddenly applied loads, which may induce local stresses and strains
many times greater than would be induced by static application of the same
loads.
10. Fretting: Fretting action may occur at the interface between any two solid
bodies whenever they are pressed together by a normal force and subjected to
small-amplitude cyclic relative motion with respect to each other. Fretting
usually takes place in joints that are not intended to move but, because of
vibrational loads or deformations, experience minute cyclic relative motions.

11. Creep: Failure results when the plastic deformation in a machine member
accrues over a period of time under the influence of stress and temperature
until the accumulated dimensional changes interfere with the ability of the
machine part to satisfactorily perform its intended function.
12. Buckling: Failure occurs when, because of critical combination of magnitude
and/or point of load application, together with the geometrical configuration of
a machine member, the deflection of the member suddenly increases greatly
with only a slight increase in load. This nonlinear response results in buckling
failure.

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13. Combined creep and fatigue: It is a combination failure mode in which

all of the conditions for both creep failure and fatigue failure exist
simultaneously, each process influencing the other to produce
accelerated failure.
14. Radiation damage: Failure occurs when the change in material
properties induced by exposure to a nuclear radiation field are of such a
type and magnitude that the machine part is no longer able to perform
its intended function.

● factors affecting human efficiency

1. Lighting
2. Noise
3. Temperature
4. Relative Humidity
5. Ventilation, air quality and thermal comfort
6. Vibration

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Ergonomic aspects of machine design:

o‘ergonomics’= two Greek words ergon = work and nomos =

natural laws.

oErgonomics means the natural laws of work.

o components of ergonomics –

–Anthropometry,

–Physiology

–psychology

Anthropometry: dimensions of the components are finalized for easy

•

handling by operator without fatigue and with consistence efficiency

• e.g. diameter of steering wheel, distance from chair to pedals.

Physiology: With the help of physiology components are designed to be

•

operated by hand or foot force.

•For e.g. Gear shifting, Steering wheel are designed to be operated by hand
because they require speed and accuracy which is imparted by hand and brake
pedal clutch pedal etc. are designed to be operated by foot force because they
require great amount of force is require than accuracy.

Psychology: Psychology affects mode of operation for e.g. size, colour and
•

push operation of emergency stops button of any machine.

•The size of emergency control is made large and painted in red so that they
can be easily identified and always they are push operated. All these
components make design of automobile components user friendly.

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Aesthetics:

Aesthetics is defined as it is a way of adding perceived

•

value to a product and a pleasing design appearance.

Or
 It is outward expression of quality of product.

Aesthetic consideration in
designing automobile components:
1. Shape:
The external appearance is an
important feature, which gives grace
& luster to the product. This is true for
automobile, household appliances.
The role of designer is to create the
new shapes of machines which have Morgan has suggested the meaning of
aesthetic look.
attracts the observers.
2. Colour: Selection of proper colour is an
impotent consideration in product
design. Many colors are associated
with different conditions.
colors in the following table

E.g. Aerodynamic shape of aero plane for

functional requirements to resist
minimum air resistance.
3. Surface finish:
For greater strength, bearing loads,
good fatigue life & wear qualities of
product, and the good surface finish is
required. Better surface finish always

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Standardization

It is defined as obligatory norms to which various characteristics of a

●

product should conform.

●The characteristics include materials, dimensions and shape of the

component, method of testing and method of marking, packing and storing of
the product.

Standards for design in ACD -

●

1.standards for materials

2.Standards for shapes and and dimension
3.Standards for fits, tolerances and surface finish
4.Standards for product testing
5.Standards for Engg Drawing

Standard Vs Code

Standard: Code:
Defined as a set of ● Defined as a set of
specified for parts, specifications for the
materials or processes. analysis, design,
manufacture , testing ,
Objective – reduce variety
erection of product.
Limits items to a
● Objective – Achieve a
reasonable level
specified level of safety

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Advantages of Standardization:-
●

1. Mass production is easy.

2. Rate of production increases.

3. Reduction in labor cost.

4. Limits the variety of size and shape of product.

5. Overall reduction in cost of production.

6. Improves overall performance, quality and

efficiency of product.
7. Better utilization of labour, machine and time

Preffered Sizes/Numbers:

● Preferred numbers (also called preferred values) are standard guidelines for
choosing exact product dimensions within a given set of constraints.
● The system is based on the use of geometric progressive to develop a set of
numbers.
● Preferred numbers are used to specify the specification because a company may
manufacture different models of same product.
● There are four basic series, denoted by R5, R10, R20, R40 which increases in
steps of 58%, 26%, 12%, 6% respectively.

● Each series has its own series factor given below,

● Minimize sunnecessary variation in sizes

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● Types of series:
– Basic series –
● 5 series R5,R10,R20,R40 AND R8
● Increase in steps is 58%,26%,12%,6% and 3% respectively in
above series
– Derived series –
● any series formed from the 5 basic series
● we can obtain geometric series for any range of nos

Importance of aesthetics: -
1. It gives the functional requirements and appearance of the
product, the functional requirements results in shapes which
are aesthetically pleasing.
2. It gives the cumulative effect of a number of factors like form,
color, rigidity, and tolerance, motion of individual
components, manufacturing method and noise.
3. Better surface finish always attracts the observers which
increases the customers satisfaction

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Importance of ergonomics:

1. The importance of ergonomics is to reduce

the operational difficulties present in man –
machine joint system & thereby reduce the
resulting physical and mental stresses.
2. It gives exhaustive details of the dimensions
and resisting forces of different control
elements.
3. Standardization of automobile system
controls as per the regional anthropometry.

1) Indicated power: The power developed inside the cylinder is known as indicated
power.
2) Brake power: This is the actual power delivered at the crankshaft.
3) Frictional power: Power lost in frictional losses at the working surfaces like
bearing, piston rings, valves etc. is known as frictional power.

Relation between Indicated power, Brake power and Frictional power Frictional
power = Indicated power - Brake power

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