An Introduction to Automotive Engineering

179 Pages·2019·3.683 MB·English

by  Abudbaker, S., Alammari, Youssef, Gupta, Aman, Kaisan, M. U., Mahroogi, Faisal O., Narayan, S., Sakthivel, R., Sharma, Shubham

Introduction to
Automotive Engineering
Scrivener Publishing
100 Cummings Center, Suite 541J
Beverly, MA 01915-6106
Publishers at Scrivener
Martin Scrivener ([email protected])
Phillip Carmical ([email protected])
Introduction
to Automotive
Engineering
R. Sakthivel, Faisal O. Mahroogi,
S. Narayan, S. Abubakar,
M. U. 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.scrivenerpublishing.com.
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. Advice on how to obtain permission to reuse material from
this title is available at http://www.wiley.com/go/permissions.
Wiley Global Headquarters
111 River Street, Hoboken, NJ 07030, USA
For details of our global editorial offices, customer services, and more information about Wiley
products visit us at www.wiley.com.
Limit of Liability/Disclaimer of Warranty
While the publisher and authors have used their best efforts in preparing this work, they make no
representations or warranties with respect to the accuracy or completeness of the contents of this
work and specifically disclaim all warranties, including without limitation any implied warranties
of merchantability or fitness for a particular purpose. No warranty may be created or extended by
sales representatives, written sales materials, or promotional statements for this work. The fact that
an organization, website, or product is referred to in this work as a citation and/or potential source
of further information does not mean that the publisher and authors endorse the information or
services the organization, website, or product may provide or recommendations it may make. This
work is sold with the understanding that the publisher is not engaged in rendering professional ser-
vices. The advice and strategies contained herein may not be suitable for your situation. You should
consult with a specialist where appropriate. 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
1.1.1 Based on Type of Roads 1
1.1.2 Buses 3
1.1.3 Classifications by ISO 6
1.2 Functions of Subunits 7
1.3 Characteristics of Ground Vehicle 8
2 Transmission System 9
2.1 Introduction 9
2.2 Clutch 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
2.8.1 Role of Propeller Shaft 19
2.8.2 Functions of the Drive Shaft 19
3 Tires 21
3.1 Introduction 21
3.2 Construction of Tire 22
3.2.1 Tire Tread Designs 22
3.2.2 Cross-Ply Tires 22
3.2.3 Radial Ply Tires 23
3.3 Tire Dynamics 24
3.3.1 Steady State Tire Forces and Torques 24
3.3.2 Simple Dynamic Extension 25
References 26
v
vi Contents
4 Suspension System 27
4.1 Introduction 27
4.2 Types of Suspension System 27
4.2.1 Mechanical System 28
4.2.2 Pneumatic System 28
4.2.3 Hydraulic System 29
4.2.3.1 Working Principle of Hydraulic
Suspension System 30
4.2.3.2 Major Parts of Hydraulic Suspension
System 30
4.3 Design Analysis of Suspension System 33
4.3.1 Dimension and Force Analysis of the Pedal 34
4.3.2 Design of Piston and Piston Head 45
4.3.3 Piston Head Design 50
4.3.4 Design of Main Cylinder 52
4.3.5 Design of Reservoir Cylinder 57
4.3.6 Design of the Pumping Cylinder 59
4.3.7 Plunger Design 61
4.3.8 Design of Pipe 65
4.3.9 Design of Spring 66
4.3.10 Design of Release Valve 71
4.3.11 Design of Pin 72
4.3.12 Design of Ball 74
4.3.13 Design of Pedal 75
4.3.14 Link Design 78
4.3.15 Seal Design 81
4.3.16 Testing for Rolling 84
4.3.16.1 The Longitudinal Location of CG 84
Reference 88
5 Braking System 89
5.1 Introduction 89
5.2 Background of Brake System 90
5.3 Classifications of Brake System 91
5.4 Air or Pneumatic Brake System 91
5.4.1 Components of the Typical Air Brake System 92
5.4.2 Common Problems in Pneumatic Brake System 97
5.4.3 Cause of the Problem 97
5.4.4 Air Brake System Troubleshooting 98
5.4.5 Leakage in Pneumatic Brake System 98
Contents vii
5.5 Hydraulic Brake System 99
5.5.1 Components of Hydraulic Brake System 101
5.6 Brake Drum Design 101
5.6.1 Materials for Brake Lining 101
5.6.2 Specification 102
5.7 Result and Conclusion 109
References 109
6 Steering System 111
6.1 Introduction 111
6.2 Parts of Steering System 112
6.3 Ackerman’s Steering Mechanism 112
6.4 Davis Steering Mechanism 120
6.5 Power Steering 123
6.5.1 Hydraulic Power Assisted Steering –
HPAS System 123
6.5.1.1 Static Characteristic of the
Hydraulic Power Steering System 123
6.5.1.2 Components of Hydraulic
Power Steering 126
6.5.1.3 General Design of Hydraulic Power
Steering Systems 128
6.5.1.4 Hydraulic Power Steering Gear Design 136
6.5.2 Electric Power Steering 143
6.5.2.1 Working of EPS 144
6.5.2.2 Essential Components of an
EPS System 145
References 152
7 Hybrid Cars 155
7.1 Introduction 155
7.2 History 155
7.3 Background 156
7.4 Production of Hybrid Electric Vehicles 157
7.5 Types of Vehicles 158
7.5.1 Motorcycles 158
7.5.2 Automobiles and Light Trucks 158
7.5.3 Taxis 158
7.5.4 Buses 159
7.5.5 Trucks 159
viii Contents
7.5.6 Military Vehicles 159
7.5.7 Locomotives 159
Reference 160
8 Autonomous Cars 161
8.1 Introduction 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.R. Sakthivel, Faisal O. Mahroogi,
S. Narayan, S. Abubakar, M. U. Kaisan and Youssef Alammari.
© 2019 Scrivener Publishing LLC. Published 2019 by John Wiley & Sons, Inc.
1
Introduction
1.1 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.
1.1.1 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