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Chassis

Chassis design

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47 views26 pages

Chassis

Chassis design

Uploaded by

shirishc123
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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CHASSIS DESIGN

INTRODUCTION
Chassis is a French term and was initially used to
denote the frame or main structure of a vehicle.
It is now extensively used to denote the complete
vehicle except the body for the heavy vehicle
having a separate body.
The chassis contain all the major units necessary
to propel the vehicle, direct its motion, stop it, and
allow it to run smoothly over uneven surfaces.
It is the main mounting for all the components
including the body.
It is also known as carrying unit.
Provides safety
The chassis include following
Frame,
Front suspension,
Steering mechanism,
Radiator,
Engine, clutch, gearbox,
Propeller shaft,
Rear spring,
Road wheels,
Differential, half shaft, universal joints,
Brakes end braking system,
Storage battery,
Silencer,
Shock absorbers, fuel tank, petrol and hydraulics
pipe cables and some means of mounting these
Building a Chassis
Design Tradeoffs
Stable vs. Maneuverable

Accessible vs. Compact

Strong & Rigid vs. Light

Safety vs Luxury

Manufacturability & Affordable vs. Everything


2007 FIRST Rookie
Workshop
Types of Chassis
Ladder Frame Chassis
Space Frame Chassis
Monocoque Frame Chassis
Ulsab Monocoque
Backbone Frame Chassis
Aluminium Space Frame
Carbon Fibre Monocoque
Ladder Frame Chassis
Indicated by its name, looks like a ladder - two longitudinal rails
interconnected by several lateral and cross braces. The longitude
members are the main stress member. They deal with the load
and also the longitudinal forces caused by acceleration and
braking. The lateral and cross members provide resistance to
lateral forces and further increase torsional rigidity.
Advantage
It doesnt have much advantage these days. It is easy and
cheap for hand build, that's all.

Disadvantage
Since it is a 2 dimensional structure, torsional rigidity is
very much lower than other chassis, especially when
dealing with vertical load or bumps.

Most SUVs, classic cars, Lincoln Town Car, Ford Crown


Victoria etc.
Monocoque Frame Chassis
Monocoque is a one-piece structure which defines the overall shape
of the car. While other chassis types provides only the stress
members and need to build the body around them, monocoque
chassis is already incorporated with the body in a single piece .
Advantage
Cheap for mass production.
Inherently good crash protection.
Space efficient.

Disadvantage
Heavy.
Impossible for small-volume production.

Used by nearly all mass production cars, all Porsche.


Ulsab Monocoque
Basically ULSAB (Ultra Light Steel Auto Body) has the
same structure as a conventional monocoque. What it
differs from its donor is in minor details - the use of
"Hydroform" parts, sandwich steel and laser beam welding.
It is used in Opel Astra, BMW 3-series.

Advantage
Stronger and lighter then conventional monocoque
without increasing production cost.

Disadvantage
Still not strong or light enough for the best sports cars.
Hydroforming
Backbone Frame Chassis
Backbone chassis is very simple: a strong tubular
backbone (usually in triangular section) connects the
front and rear axle and provides nearly all the
mechanical strength.
Advantage
Strong enough for smaller sports cars.
Easy to be made by hand thus cheap for low-volume production.
Simple structure benefit cost.
The most space-saving other than monocoque chassis.

Disadvantage
Not strong enough for high-end sports cars.
The backbone does not provide protection against side impact or off-
set crash.
Therefore it need other compensation means in the body.
Cost ineffective for mass production.

Used by Lotus Esprit, lan Mk II, TVR, Marcos.


Space Frame

A nodal triangulated truss networks that attempts to distribute all


loads in axial direction so that no part of force is subjected to
harsher bending force.
Used in FSAE competition

Advantages
Impact protection
Good weight holding capability
Provide torsional rigidity
Disadvantages
Used for compact design
Complex, costly and time consuming
Still expensive for mass production
Aluminum Space Frame

ASF consists of extruded aluminum sections, vacuum die cast


components and aluminum sheets of different thicknesses.
They all are made of high-strength aluminum alloy. At the
highly stressed corners and joints, extruded sections are
connected by complex aluminum die casting (nodes).
Advantage
Lighter than space frame

Audi claimed A8's ASF is 40% lighter yet 40% stiffer than
contemporary steel monocoque. This enable the 4WD-equipped
A8 to be lighter than BMW 740i.
Used in Lamborghini Countach and Audi
Carbon Fibre Monocoque

Carbon Fiber is the most sophisticated material used in aircrafts,


spaceships and racing cars because of its superior rigidity-to-
weight ratio.

Advantage
The lightest and stiffest chassis.
Provides great safety at high speed

Disadvantage:
By far the most expensive
Complex in production
Factors Affecting Cracking

Incorrect welding procedures (i.e. undercutting, no


preheat, slag inclusions, transverse welding of flanges
etc.).
Accident damage.
Overloading of chassis
Insufficient reinforcement.
Over length wheelbase.
Design fault
Basic Terminology

Front Strut Bar


Rear Strut Bar
Side Fender Bars
Anti-roll Bar
Front Strut Bar
The Front Strut Bar is installed to minimize the weight
transfer of the vehicle body, therefore the vehicle will
not loose traction easily during cornering.
Below is the Multi-Point Strut Bar -
Rear Strut Bar
The Rear Strut Bar is particularly useful for a front engine
front wheel drive vehicle. The Understeer behavior can be
corrected by stiffening the rear chassis by installing a Rear Bar.
Fender Bar
Most of the vehicles front chassis over hanging is designated
to carry the vertical loads from the front suspensions, it is
vital that this part of the chassis is strong enough to take the
bounce and rebound force of the suspension.
Anti-roll Bar
Anti-roll bars tie the lower suspension components
together across the front or back, and affect a car's over
steer and under steer. Sway bars will keep your car flat in
turns instead of leaning over to one side.
THANK YOU

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