Introduction to Automotive Engineering Scrivener Publishing 100 Cummings Center, Suite 541J Beverly, MA 01915-6106 Publishers at Scrivener Martin Scrivener (martin@scrivenerpublishing.com) Phillip Carmical (pcarmical@scrivenerpublishing.com) Introduction to Automotive Engineering R. Kaisan and Youssef Alammari This edition first published 2019 by John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA and Scrivener Publishing LLC, 100 Cummings Center, Suite 541J, Beverly, MA 01915, USA © 2019 Scrivener Publishing LLC For more information about Scrivener publications please visit www. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, except as permitted by law.
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Neither the publisher nor authors shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. Further, readers should be aware that websites listed in this work may have changed or disappeared between when this work was written and when it is read. Library of Congress Cataloging-in-Publication Data ISBN 978-1-119-47980-2 Cover image: Traimak Ivan | Bubushonok | Dreamstime.com Cover design by Kris Hackerott Set in size of 15 pt and Minion Pro by Exeter Premedia Services Private Ltd., Chennai, India Printed in the USA 10 9 8 7 6 5 4 3 2 1 Contents 1 Introduction 1 1.1 Classification of Motor Vehicle 1 1.1 Based on Type of Roads 1 1.3 Classifications by ISO 6 1.2 Functions of Subunits 7 1.3 Characteristics of Ground Vehicle 8 2 Transmission System 9 2.3 Synchromesh Gear Box 14 2.4 Differential Gear Box 15 2.5 Planetary Gear Systems 16 2.6 Manual Transmission System 17 2.7 Automatic Transmission System 17 2.8 Propeller Shaft and Drive Shaft 18 2.1 Role of Propeller Shaft 19 2.2 Functions of the Drive Shaft 19 3 Tires 21 3.2 Construction of Tire 22 3.1 Tire Tread Designs 22 3.2 Cross-Ply Tires 22 3.3 Radial Ply Tires 23 3.1 Steady State Tire Forces and Torques 24 3.2 Simple Dynamic Extension 25 References 26 v vi Contents 4 Suspension System 27 4.2 Types of Suspension System 27 4.1 Working Principle of Hydraulic Suspension System 30 4.2 Major Parts of Hydraulic Suspension System 30 4.3 Design Analysis of Suspension System 33 4.1 Dimension and Force Analysis of the Pedal 34 4.2 Design of Piston and Piston Head 45 4.3 Piston Head Design 50 4.4 Design of Main Cylinder 52 4.5 Design of Reservoir Cylinder 57 4.6 Design of the Pumping Cylinder 59 4.8 Design of Pipe 65 4.9 Design of Spring 66 4.10 Design of Release Valve 71 4.11 Design of Pin 72 4.12 Design of Ball 74 4.13 Design of Pedal 75 4.16 Testing for Rolling 84 4.1 The Longitudinal Location of CG 84 Reference 88 5 Braking System 89 5.2 Background of Brake System 90 5.3 Classifications of Brake System 91 5.4 Air or Pneumatic Brake System 91 5.1 Components of the Typical Air Brake System 92 5.2 Common Problems in Pneumatic Brake System 97 5.3 Cause of the Problem 97 5.4 Air Brake System Troubleshooting 98 5.5 Leakage in Pneumatic Brake System 98 Contents vii 5.5 Hydraulic Brake System 99 5.1 Components of Hydraulic Brake System 101 5.6 Brake Drum Design 101 5.1 Materials for Brake Lining 101 5.7 Result and Conclusion 109 References 109 6 Steering System 111 6.2 Parts of Steering System 112 6.3 Ackerman’s Steering Mechanism 112 6.4 Davis Steering Mechanism 120 6.1 Hydraulic Power Assisted Steering – HPAS System 123 6.1 Static Characteristic of the Hydraulic Power Steering System 123 6.2 Components of Hydraulic Power Steering 126 6.3 General Design of Hydraulic Power Steering Systems 128 6.4 Hydraulic Power Steering Gear Design 136 6.2 Electric Power Steering 143 6.1 Working of EPS 144 6.2 Essential Components of an EPS System 145 References 152 7 Hybrid Cars 155 7.4 Production of Hybrid Electric Vehicles 157 7.5 Types of Vehicles 158 7.2 Automobiles and Light Trucks 158 7.5 Trucks 159 viii Contents 7.7 Locomotives 159 Reference 160 8 Autonomous Cars 161 8.2 Implementable Ethics for Autonomous Vehicles 163 8.3 Mobility and Autonomous Driving 165 8.4 Safety Concept for Autonomous Vehicles 167 8.5 Conclusions 169 Index 171 Introduction to Automotive Engineering. Kaisan and Youssef Alammari.
© 2019 Scrivener Publishing LLC. Published 2019 by John Wiley & Sons, Inc.1 Classification of Motor Vehicle Motor Vehicles are used for transporting goods or pas- sengers or fulfilling specific functions on land. Motor vehicles can move on the ground, as compared to air- craft and marine craft that operate in air or water.1 Based on Type of Roads 1. Guided and Non-guided vehicles Guided Motor vehicles move along a fixed guide way; that includes railway vehicles.
Non-guided motor vehicles move in any direction. The non-guided motor vehicles are the subject of this book. 1 2 Introduction to Automotive Engineering 2. Classification according to Running gear – Single Track motor vehicles and Multi- Track motor vehicles Single Track motor vehicles are motor vehicles with two wheels with or without a sidecar.
Examples: Motorcycle – Any two- wheeled vehicle with or without a sidecar. Moped - Motor cycle with pedals and a petrol engine of low power. Single-Track Motor Vehicles Scooter –This is a light, small wheels automotive. Multi-Track Motor Vehicles -Motor vehicles with three or more wheels.
Salooncar (sedan) –This is a type of motor car in which the space for driver and pas- sengers is cut off from other areas. Hatchback car having a large sloping back.1 Single track motor vehicles. Introduction 3 Salooncar (sedan) Hatchback (a) (b) Figure 1.2 Multi-track motors. Pick-up (also pickup) – it is a small truck commonly used by operators.
Van - covered vehicle, with no side win- dows, for transporting goods or people. Truck (UK Lorry) - large strong motor vehicle for transporting goods, soldiers, etc. Tractor fitted with an endless belt passing round the wheels of a tractor enabling it to travel over rough ground. Car - Motor vehicle intended for carrying a maximum of 9 passengers with luggage.2 Buses Buses are used to transport people.
The capacity of buses is more than 9 passengers and luggage. Buses fall into one of the following categories, depending upon the intended use. Microbus: The capacity of microbuses is approximately 25 passengers. 4 Introduction to Automotive Engineering (a) Open convertible (d) Van body K-shape (b) Pontoon body (e) Headlights and all wheels in body; clad floor (c) Headlights, rear wheels, spare wheel in body, no bumpers Figure 1.3 Multi-track cars.
City buses (Urban buses): are designed and equipped for driving regularly scheduled in-city and suburban routes. Due to short intervals between stops in local traffic, facili- tation of rapid passenger turnover by means of low steps, wide doors and as low a vehicle floor as possible, is particularly important. Tour buses (Long-distance coach): are designed to provide a comfortable ride over long distances. Tour buses have large luggage compartments from front to rear below the floor.
Transport Vehicles: Transport vehicles are further classified as follows: According to the type of body: 1. General-purpose cargo trucks: with an open drop-sided body used for carrying bulk and packaged goods. Special-purpose trucks: with bodies adapted for a certain kind of work, e., dump trucks with tiltable bodies used to carry viscous and bulk materials, or with bodies specially adapted for transporting peat, cement, mixed fodder, grain, cotton, cattle, gasoline, milk, etc. According to the load capacity: 1.
Extra-light-duty trucks: up to 0.75 Ton, built on the chassis of passenger cars and used for deliveries of light loads in the communication and communal services and in trade. Light-duty vehicles: from 0.5 Ton, that work in trade, at industrial enter- prises and in agriculture, hauling light loads. They also serve as cargo taxis. According to the load capacity: 1.
Medium-duty trucks: from 2.0 Ton, mostly carrying loads for organizations and enterprises with moderate cargo traffic. Heavy-duty trucks: from 5.0 Ton, used on hard surface roads for carrying building materials, fuel, and products man- ufactured by large industrial enterprises. Extra-heavy-duty vehicles: above 10.0 Ton, for work in ore and coal mines and at big construction projects with a large amount of steady cargo traffic. As a rule, these vehi- cles are diverted from public highways.
6 Introduction to Automotive Engineering 1.3 Classifications by ISO ISO3833 classifies ground vehicles in 7 groups: 1. Cars for travelers 3. Pick-up Buses 4. Semi-trailers Classifications according to their drives as: 1.
Rear-wheel Front engine drive Figure 1.4 Cross-wheel drive.5 Front engine front-wheel drive.6 Front-wheel rear engine drive. Front-wheel Front engine drive 4. Engine behind transmission 6. Engine in front of transmission 7.
Rear-wheel Rear engine drive 8.2 Functions of Subunits Mechanical energy is converted into Motion. Any Automobile consists of Power-train and Non- Power-train components. Power-Train components parts involved in the process of generating power to converting it to motion. Non-Power-Train compo- nents parts includes Body, Frame and Steering.
Parts of Automobile Systems 1. Clutch, gear box, shaft and differential 5. Ignition, starting lighting and battery 8 Introduction to Automotive Engineering Engine Rear wheel Transmission Drive shaft Clutch U-joint Differential Figure 1. Wheels and tires 8.
Braking system Drive train indicates the power flow of motor vehicle from engine to driving wheels. The main components of the drive train are: Engine-Clutch-Transmission-Driveshaft- Differential-Wheels.3 Characteristics of Ground Vehicle The main aim of studying the mechanics of vehicles is to gain the ability to establish rules for the develop- ment, design, and selection of vehicles. Performance means the ability of the vehicle to accelerate, over- come obstacles and to stop. Handling is concerned with the driver’s response to the vehicle.
Ride is related to the vibrations from ground due to motion. Introduction to Automotive Engineering. Kaisan and Youssef Alammari. © 2019 Scrivener Publishing LLC.
Published 2019 by John Wiley & Sons, Inc.1 Introduction The transmission helps to transmit power from the engine to the wheels. It consists of gears, shafts, and other electrical connections. It is composed of sys- tems shown in Figure 2.2 Clutch This part is used to engage and disengage the engine from drive. It allows the driver to control the power flow between the engine and transmission or trans- axle operating by the friction principle.
9 10 Introduction to Automotive Engineering Engine Transmission Rear axle drive Clutch Drive shaft with differential Figure 2.1 Arrangement of components. Engine Transmission Rear axle drive Clutch Drive shaft with differential Transmission Engine Transfer case Front axle drive Rear axle drive Figure 2. Clutch Driving shaft Driven shaft Figure 2.3 Principle of clutch.