VEHILCE BODY ENGINEERING

CLASSIFICATION OF CARS

MANUFACTURING COSTS BY VEHICLE AREAS

FOUR DOOR SALOON

SPORTS COUPE

COUPE

LIMOUSINE

ESTATE CAR

CONVERTIBLE

Good positioning of the driver Forward visibility increased by moving the driver closer to the wind screen Downward visibility which is important in military vehicle is increased by positioning the driver as high as possible to the lower edge of wind screen Vertical visibility should be such as to enable the driver to see traffic lights

Reducing the blind areas : -Horizontal visibility -should be more than 90 % visible area. - Rear visibility improved by having fast back

Eye position of average driver Horizontal 180 Vertical - 750

 P h -

Seat cushion angle Back rest angle Steering column angle Maximum force on pedal Seat cushion height

IMPORTANCE OF AERODYNAMICS SAFETY DESIGN

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FRONT AIR DAM

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Limits the Amount of Air Passing Underneath the Car Contributes to High Pressure In Front of the Car Causes Low Pressure Underneath the Car
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SIDE SKIRTS

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Side Skirts Prevent High Pressure Air Around the Car from Disturbing the Low Pressure Underneath the Car

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CANARD VORTICES

Vortices Spin Inwards, Towards the Vehicle on Each Side

Canard Vortices Work In Conjunction With Side Skirts to Limit the High Pressure Air From Mixing With the Low Pressure Air Found Underneath the Car
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VENTURI TUNNELS / REAR DIFFUSERS

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REAR DIFFUSER

Expands Air Back Down to Road Velocity

Slows the Flow and Raises the Air Pressure Acts as a Pump Drawing More Air from the Undertray

Rear Wing Drives the Diffuser Because of its Proximity to the Wing's Low Pressure Side Reduce the Overall Pressure Drag on the Vehicle by Introducing High Pressure Air into the Low Pressure Wake Region

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EFFECT ON BLUFF BODIES

With VG

Without VG

VGs Cause Drag, but Reduce Pressure Drag by Delaying Flow Separation from Occurring Reducing the Magnitude of the Separation Region Increases the Static Pressure of Separation Region

Higher Velocities Closer to Car, Resulting in a Smaller Wake Behind Vehicle

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Vibration Analysis
Dynamic analysis helps is finding the following vibration characteristics. Natural Frequencies Mode Shapes Modal strain energy Effect of Mass Amplitude and Phase angle Energy distribution

Crash testing
Crash testing is the way to analyze how best a

vehicle can save the occupant during an UNDESIRABLE crash.

Frontal Impact Test Modes

Flat frontal impact test- vehicle traveling

longitudinally forward impacting on fixed rigid barrier with 100% overlap. Offset deformable barrier test- vehicle impacting on driver side,on a deformable barrier with 40% overlap. Angular impact-vehicle impacting on a fixed rigid barrier at 30 deg front the line perpendicular to line of travel on either side of the vehicle.

Occupant protection system

Vehicle Compartment

Restraint Systems
Seat Belts Air Bags Knee Bolster Collapsible Steering

Frontal Crash Crush Zone

Engine room is normally packed

densely, leaving only limited space for front crush zone. Rail design at the crush zone is fine tuned to crush at the predefined F/D characteristics. Power train pack acts like a rigid block. Often one body design is combined with different engine configuration too.

Rear Crash Load Path

Typical Side Door Intrusion Test

CAR BODY CONSTRUCTION