PEMP

AME2510

Loads, Design and Structure

Session delivered by:
Dr. Vinod K. Banthia

 M.S. Ramaiah School of Advanced Studies, Bengaluru 1

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AME2510

• Session Objectives
– At the end of this session the delegate would
have understood the

• Role/Importance of automotive body structure

• Types of operational loads and load cases
• Design Analysis of the structure
• Different aspects of design of the structure.

 M.S. Ramaiah School of Advanced Studies, Bengaluru 2

 PEMP
AME2510

Session Topics
1. Operational conditions and loads for automotive
body structure
2. Design considerations for automotive body
structures
3. Types of construction for automotive body
structures

 M.S. Ramaiah School of Advanced Studies, Bengaluru 3

 PEMP
AME2510

Automotive
Body Structures

 M.S. Ramaiah School of Advanced Studies, Bengaluru 4

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AME2510

Structure:
• arranged in a definite pattern of organization
• arrangement of particles/parts in a body
• methods or format for storing the data
• arrangement of elements for carrying loads

Building
Towers

Aircraft

Skeleton
Video Clip

Automotive
http://www.m-w.com/cgi-bin/dictionary
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AME2510

Loads on Vehicle Structure

Running Loads
Operational environment: (not crash loads)

Road
Type
Condition
Terrain
Environment (corrosion)

Nature of loads:
Repeated dynamic of low magnitudes (Fatigue failure)
Transient dynamic loading of high magnitude (Overload failure)
Weight of the vehicle/passenger/luggage
 M.S. Ramaiah School of Advanced Studies, Bengaluru 6
 PEMP
AME2510

Loads on Vehicle Structure

Repeated dynamic of low magnitudes:
Uneven road, cobblestones, Belgian pave, medium sized pot-
holes, twists and turns, transport, Intermittent operation
Crack initiation and propagation
(Monitor/maintain/Repair/Replace)

Transient dynamic loading of high magnitude:

Large pot holes, kerb bump, obstacles, large bumps, panic
braking, sharp cornering, tie-down loads (transportation)
Limited/localised permanent deformation
(Maintain/Repair/Replace)
Static loads:
Service Loads (jacking, towing, hoisting, retrieval from ditch etc.)
(designated locations) Local
(Maintain/Repair/Replace)
 M.S. Ramaiah School of Advanced Studies, Bengaluru 7
 PEMP
AME2510

Loads on Vehicle Structure

Difficult to get the magnitude (instrumentation)
Magnitudes of loads:
? Changing conditions
Complex nature

Use approximate loads for the first cut design

Historical data
Experience based
Performance criteria based
Final assessment:
Laboratory Tests
Simulation
Accelerated tests
Road tests
Proving ground
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 PEMP
AME2510

 M.S. Ramaiah School of Advanced Studies, Bengaluru 9

 PEMP
AME2510

Loads on Vehicle Structure

Lack of standardisation, unlike aircrafts and ships
Different OEMs follow their own methodology and databas (based on
their historic data, their focus on different performance parameters)

Basic global load cases:

Vertical symmetrical (bending about y-y axis)
Vertical asymmetric (torsion about x-x axis and bending about y-y axis)
Fore and aft loads
Lateral loads
Local load cases
Crash loads

Dynamic loads = Static loads x dynamic load factor

J.C.Brown and S.T.Serpento, “ Motor Vehicle Structures: Concepts and Fundamentals”, SAE International

 M.S. Ramaiah School of Advanced Studies, Bengaluru 10

 PEMP
AME2510

Loads on Vehicle Structure

Bending Loading:

Rrr
Rrl
Rfr
mg
Rfl

 M.S. Ramaiah School of Advanced Studies, Bengaluru 11

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AME2510

Loads on Vehicle Structure

Bending loading:

J.C.Brown and S.T.Serpento, “ Motor

Vehicle Structures: Concepts and
Fundamentals”, SAE International

 M.S. Ramaiah School of Advanced Studies, Bengaluru 12

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AME2510

Loads on Vehicle Structure

Pure Torsion Loading:

Rr/2 tr
Rr/2
Rf/2
tf
Rf/2 Rf Rr
t f  tr
2 2
 M.S. Ramaiah School of Advanced Studies, Bengaluru 13
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AME2510

Loads on Vehicle Structure

Combined Loading:

Rr/2
Rr/2
0
mg
Rf

 M.S. Ramaiah School of Advanced Studies, Bengaluru 14

 PEMP
AME2510

Loads on Vehicle Structure

Lateral loading:

y
mv2/r
b mgt/2h
a Yr
mg
Yf
Other source of lateral load are kerb bump, asymmetrical loading during turn.
 M.S. Ramaiah School of Advanced Studies, Bengaluru 15
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AME2510

Loads on Vehicle Structure

Longitudinal loading:

z
maa
x

y
(a)
mab (b)

(a)
(b) mg

(Forces shown on only left side wheels for clarity)

 M.S. Ramaiah School of Advanced Studies, Bengaluru 16

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AME2510

Loads on Vehicle Structure

Asymmetrical loading: Bumps, pot holes

q PV
PH
h

PH = KDyn*PV/tanq

J.C.Brown and S.T.Serpento, “ Motor Vehicle Structures: Concepts and Fundamentals”, SAE International

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AME2510

Design Considerations for Vehicle Structure

Stress consideration
Instant overload Elastic instability Fatigue
Stress due to static load * Dynamic factor < (2/3) * yield stress
Generally, satisfactory for fatigue also for most locations. For locations with stress
concentration, more detailed analysis needs to be carried out.

Stiffness consideration
Bending Torsion
Important consideration from performance, handling and comfort
Ride/Handling Vibration and noise
Apertures Attachment points
“Feeling” of security Crash characteristics

Vibration consideration
Natural frequencies
 M.S. Ramaiah School of Advanced Studies, Bengaluru 18
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AME2510

Design Considerations for Vehicle Structure

• Type of structure for the purpose
• Proper layout for satisfactory load paths
• Proper Sizing of panels

• Material of construction
• Product form

• Stress levels – overload and fatigue

• Stiffness – global and local
• Vibration characteristics

 M.S. Ramaiah School of Advanced Studies, Bengaluru 19

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AME2510

Design Considerations for Vehicle Structure

• Styling
• Regulations and Standards
Safety requirements
Overall size and weight
Environmental requirements
• Ergonomic requirements
Seating
Placement of and access to controls
Visibility

• Aerodynamics/Flow requirements

• Comfort
• Layout

 M.S. Ramaiah School of Advanced Studies, Bengaluru 20

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AME2510

Forms for Vehicle Structure

The purpose of the vehicle structure is to

“link up the mounting points for the vehicle’s rear suspension and final
drive, front suspension and steering, engine and gearbox, tank for fuel and
seats for occupants”
Rigid, Light and Durable

• Body on chassis – legacy of horse drawn carriage

Separate load bearing chassis and flexible “coach”
• Integral body • Spaceframe

 M.S. Ramaiah School of Advanced Studies, Bengaluru 21

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AME2510

Types of Vehicle Structure

Ladder Frame

High bending stiffness

Adaptability to different shapes and sizes of bodies

Low torsional stiffness (open section)

Box section
High torsional stiffness
Tube joint strength
Joint detail
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Types of Vehicle Structure

Cruciform Frame

Good torsional stiffness

Torsion being resisted by

bending of cruciform members
of open cross-section

Combine with ladder frame

(good bending stiffness)

Also assists in carrying

lateral loads
J.C.Brown and S.T.Serpento, “ Motor Vehicle Structures: Concepts and Fundamentals”, SAE International

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AME2510

Types of Vehicle Structure

Torque tube Frame

J.C.Brown and S.T.Serpento, “ Motor Vehicle Structures: Concepts and Fundamentals”, SAE International

Space Frame

J.C.Brown and S.T.Serpento, “ Motor Vehicle Structures: Concepts and Fundamentals”, SAE International

 M.S. Ramaiah School of Advanced Studies, Bengaluru 24

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AME2510

Types of Vehicle Structure

Integral/Unitary Frame (monocoque):
Most widely used construction for passenger cars

Outer skin as a body surface as well as structure

Formed sheet metal parts spot welded together
Lighter – Stiffer (3.6x) – Quiter – Less expensive
Structure with considerable redundancy
(difficult for stress analysis)
J.C.Brown and S.T.Serpento, “ Motor Vehicle Structures: Concepts and Fundamentals”, SAE International

 M.S. Ramaiah School of Advanced Studies, Bengaluru 25

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AME2510

Summary
• Operational conditions, and resulting loads, for automotive
structures have been explained
• Design considerations for automotive body structures have
been discussed
• Types of automotive body structures and their pros and cons
have been discussed

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