Technical University of

Mombasa
EAU 2201: Vehicle Technology I

DAE 03 (Y2S1):

Lecture Notes 1: Chassis

Sub-Topics:
• Chassis frame construction; separate unit, methods of attachments, reinforcement points and methods.
• Integral chassis frame construction; joining/attachments methods;
• Frame designs; noise reduction, reinforcements/strengthening methods;
• Heavy duty chassis frame construction;
• Tubular construction.

Prepared by:
Eng. Abdillahi Hassan Bakari (MSc. Marine
Eng. & Naval Arch, BSc. Mech. /Auto. Eng.)
Eng. Abdillahi H Bakari EAU 2201: Vehicle Technology I: Chassis Technical University of Mombasa (TUM) October 2022

Chassis
A vehicle chassis should fulfil the following functions;
• To carry all the stationary loads attached to it and loads of passenger and cargo carried
in it.
• To withstand torsional vibration caused by the movement of the vehicle.
• To withstand the centrifugal force caused by cornering of the vehicle.
• To control the vibration caused by the running of the vehicle.
• To withstand bending stresses due to rise and fall of the front and rear.

There are basically three forms of chassis;

• Conventional chassis type; This includes channel sections, tubular sections and box
section.
• Integral chassis type; Body and frame combined to form a box like structure with a high
torsional rigidity
• Semi Integral chassis; Where the front of the vehicle consists of fixed frame at the front
where the engine gear box and front suspension is mounted.

Separate Unit Chassis Construction

The usual commercial vehicle construction consists of two heavy gauge channel section
side members connected by channel or box section cross members riveted, bolted or welded in
place. The side members are usually straight and may have an increased depth of section
towards the centre where the greatest bending loads occur. The side members are usually
of channel section in commercial vehicles and box section in cars, the latter being deeper in
section between the wheels to provide greater resistance to bending load.
The forward and rear ends are upswept to allow for movement of the axles and in plan view
are made narrow at the forward end to allow a greater steering lock and therefore a smaller
vehicle turning circle.
NB: The principle is suited to low volume production, and a variety of bodies for
specialized duties can be accommodated on the same chassis.

The cross members connect the side members and are of channel, box or tubular section.
They are welded, riveted or bolted to the side members. Additional cross members are
sometimes added to provide extra resistance to engine torque.

When independent types of suspension are used the chassis has to be made much more rigid
to resist the twisting of the chassis members. The upsweep at the forward end is reduced
and the engine is arranged lower in the chassis. This improves the road holding of the
vehicle and is only possible because allowance for axle movement is now no longer
required (no beam axle)

NB: The principle is suited to low volume production, and a variety of bodies for
specialized duties can be accommodated on the same chassis.
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Eng. Abdillahi H Bakari EAU 2201: Vehicle Technology I: Chassis Technical University of Mombasa (TUM) October 2022

Figure 1: Separate unit construction

Chassis Floor
The floor is mostly a fluted mild steel sheet floor which is welded to the chassis members. The
combination of fluting and welding adds greatly to the rigidity and, therefore, lighter
gauges of sheet metal can be used for the whole assembly to reduce its weight, without
sacrificing its strength.

Figure 2: Chassis Floor

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Eng. Abdillahi H Bakari EAU 2201: Vehicle Technology I: Chassis Technical University of Mombasa (TUM) October 2022

Integral Chassis Frame Construction

The integral or unitary structure of a car can be considered to be made in the form of
three box compartments;
• The middle; this is the largest compartment. It stretches between the rear and front
road wheel axles. It provides the passenger space.
• The extended front box; this is built over and ahead of the front wheels. It encloses the
engine and transmission units, and,
• The rear box; It is located behind the back axle providing boot space for luggage.

These box compartments are constructed in the form of a framework of ties and struts
pieces made from rolled sheet steel pressed into various shapes such as rectangular,
triangular, trapezium, top hat or a combination of these sections to form a closed box thin
gauge section. These sections are designed to resist direct tensile and compressive or
bending and torsional loads, depending upon the positioning of the members within the
structure.

The integral chassis construction is the most widely used modern car structure type, spot
welded, pressed steel sheet metal body. It is well suited to mass production methods. The
body is self-supporting, so that the separate chassis is omitted, saving weight. Although
particularly light the assembly is very strong because all the loads acting on it are
spread over the whole of it.

The walls, or surfaces of the box, consist of the skin panels (such as the roof, floor, bulkheads,
etc.) where possible. Elsewhere, open bay ring frames (side frame, windshield frames, etc.)
form the surface of the box, wherever openings are required. Beam members are also
used to carry out-of-plane loads, for example in the floor.

The chassis becomes a sub-frame in this form of construction and other sub-frames
are often used for the front and rear suspension units, and sometimes for the final
drive assembly. These detachable subframes are usually attached by rubber mountings to
reduce the amount of noise and vibration transmitted to the body shell.

These body assemblies must be well protected from corrosion because of thin steel employed.
Chemical compounds and special paints have to be applied to the underside of the vehicle at
regular intervals and all the boxed sections should be sprayed internally with anti-
corrosion solutions. Water drain holes in these sections and in doors must be kept clear.
The vibration or drumming of the larger panels is a common fault and special
compounds are painted on their inner sides to reduce this. Felt may also be reduced.

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Eng. Abdillahi H Bakari EAU 2201: Vehicle Technology I: Chassis Technical University of Mombasa (TUM) October 2022

Figure 3: Structural tensile and compressive loading on an integral body car (a) Lengthwise
body loading (b) Transverse body loading (c) Integral construction

The weight of the occupants causes a sagging effect which is resisted by the floor and
roof panels. Since these two members are widely spaced, thin sheet metal can be used to
form a box-like structure that is both strong and light in weight.
Torsional stiffness of the body is achieved by strengthening the scuttle at the front and
by using crossties, or fitting a ribbed metal panel behind the rear seat squab.

Figure 4: Sagging Effect prevention and scuttle strengthening

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Eng. Abdillahi H Bakari EAU 2201: Vehicle Technology I: Chassis Technical University of Mombasa (TUM) October 2022

Alternative Frame Designs

Conventional Frame
It consists of two channel-shaped side-members, which are held apart by a series of cross
members.

Box Section Frame

Consist of independent suspension with a very rigid frame at points where the body and
components are to be attached. Have box section members welded together and suitably
reinforced in the regions of high stress.

Backbone Frame
This consists of two longitudinal, box-section members welded together at the center and
separated at the front and rear so as to accommodate the main components. A series of
outrigger frame members are welded to the spine to support the floor of the body.

Energy Absorbing Frame

Are constructed such that the front and rear ends of the frame in a manner that allows them
to absorb the main shock of the impact. Body panels in the vicinity of these crumple zones
are generally damaged beyond repair when they suffer a substantial impact, but this
is a small price to pay for occupant safety

Figure 7: Frame designs (a) Conventional (b) Box section (c) Backbone (d) Energy absorbing