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Monocoque chassis
- 1. Monocoque Chassis Presented By- MANU P. SOMAN ROLL NO 24
- 2. Contents • What is a Chassis? • Different Types of Chassis • Ladder frame chassis • Tubular space frame chassis • Aluminum space frame • ULSAB Monocoque chassis • Back bone frame chassis • Introduction to Monocoque Design • What is Monocoque construction? • Where is this used? • Origin of Monocoque design • History of Monocoque Frame
- 3. What is a Chassis? • A ‘vehicle frame’, also known as its chassis, is the main supporting structure of a motor vehicle, to which all other components are attached, comparable to the skeleton of an organism.
- 4. Different Types of Chassis • Ladder frame chassis • Tubular space frame chassis • Monocoque frame chassis • ULSAB Monocoque chassis • Back bone frame chassis • Aluminium space frame • Carbon fibre Monocoque
- 5. Ladder frame chassis • The ladder frame is one of the simplest and oldest of all designs. • It consists of two symmetrical beams, rails, or channels running the length of the vehicle, and several transverse cross-members connecting them.
- 6. • Originally seen on almost all vehicles, the ladder frame was gradually phased out on cars in favor of perimeter frames and unitized body construction. • This chassis is heavier at the same time than a single body. • The chassis does not provide any protection against any side impacts. • The vehicles like Mahindra bolero and Tata sumo are build on these chassis. • It is also seen on trucks.
- 7. Tubular space frame chassis • As ladder chassis is not strong enough, motor racing engineers developed a 3 dimensional design - Tubular space frame. • One of the earliest examples was the post-war Maserati Tipo 61 "Birdcage" racing car.
- 8. • Tubular space frame chassis employs dozens of circular- section tubes, position in different directions to provide mechanical strength against forces from anywhere. • These tubes are welded together and forms a very complex structure. • For higher strength required by high performance sports cars, tubular space frame chassis usually incorporates a strong structure under both doors, hence result in unusually high door sill and difficult access to the cabin.
- 9. • In the early 50s, Mercedes- Benz created a racing car 300SLR using tubular space frame. • This also brought the world the first tubular space frame road car, 300SL Gullwing. • Since the sill dramatically reduced the accessibility of cabin, Mercedes had to extend the doors to the roof so that created the "Gullwings".
- 10. • Since the mid 60s, many high-end sports cars also adopted tubular space frame to enhance the rigidity / weight ratio. • Some of them used space frames for the front and rear structure and made the cabin out of monocoque to cut cost.
- 11. Aluminium space frame • Audi A8 was the first mass production car featuring Aluminium Space Frame (ASF) chassis.
- 12. ULSAB Monocoque chassis • Traditional steel monocoque became heavier. • As a result, car makers turned to alternative materials to replace steel, with aluminum. • Porsche Engineering Services developed a new kind of steel monocoque technology calls Ultra Light Steel Auto Body (ULSAB).
- 13. • Compared with conventional monocoque, Porsche Engineering claimed it is 36% lighter yet over 50% stiffer. • Although ULSAB was just announced in early 1998, the Opel Astra and BMW 3-Series have already used it in some parts.
- 14. Back bone frame chassis • Backbone tube chassis is a type of automobile construction chassis that is similar to the body-on-frame design. • Instead of a two-dimensional ladder-type structure, it consists of a strong tubular backbone (usually rectangular in cross section) that connects the front and rear suspension attachment areas.
- 15. • The backbone chassis was extensively developed by Hans Ledwinka who used it in greater numbers on the Tatra 11 and subsequent vehicles.
- 16. Introduction to Monocoque Design • Monocoque, meaning 'single shell' in French, is a construction technique that utilizes the external skin to support some or most of the load. • Monocoque construction techniques were first used as early as 1912. Today, a modified type of monococque construction called “unit body” or unibody is very popular.
- 17. • A Monocoque chassis is a structure which integrates body and chassis together to form a composite structure which has better stiffness as well as weight advantage. • In a Monocoque chassis the stress generated by the vehicle during motion is being distributed among the structure and does not form localised stress which may have higher value of deformation.
- 18. Where is this used? • This form of chassis is now a days being adopted by various segments of vehicle from its inception in F1 which later was adopted to be used for sports cars and now SUV even. • The performance of the structure depends on another important factor i.e., the material used to build the structure.
- 19. • The range of material used are from carbon titanium fibre used in Pagani Huayra to Mahindra XUV 500 where aluminium is used. • It depends on the type of vehicle and the required performance specifications.
- 20. Origin of Monocoque design • Monocoque construction originated in the aerospace field. • Early airplanes utilized wood or metal frames that created the structural base for everything else to be built upon. • This caused the weight of the frame to be a huge issue which led to the development of Monocoque construction techniques.
- 21. • One of the first aircraft to adopt these new construction techniques was the Deperdussin monocoque, built in 1912. • This formed a structural shell that acted both as the aerodynamic, outer shell and the main load-bearing component, which greatly reduced the overall weight of the aircraft.
- 22. History of Monocoque Frame • In 1922, the Lancia Lambda was the first production automobile to adopt monocoque construction techniques
- 23. • An aluminum alloy monocoque chassis was first used in the 1962 Lotus 25 Formula 1 race car .
- 24. • In 1992 the McLaren F1 became the first production car with a Carbon-fiber Monocoque.
- 25. Construction of Monocoque Chassis • The one piece chassis is actually made by welding several piece together. • The floor-pan, which is the largest piece, and other piece are press- made by big stamping machines. • They are spot welded together by robot arms (some even use laser welding)in a stream production line. • The whole of the body acts as a load bearing member onto which suspension, engine and transmission is bolted. Reinforcements are provided at different sections like doors, bonnet etc.
- 26. Benefits of Monocoque Chassis • A Monocoque construction is much lighter in comparison. • The amount of material that it requires to provide significant strength to the car is much less, therefore from manufacturability point of view, it’s economical to produce. • All Monocoque cars can be made lighter with the use of better materials and iterative computer analysis. • It offers high fuel efficiency due to the low weight that it can achieve through inherent design that it has.
- 27. • The whole structure is actually an outer shell providing better space efficiency. • Monocoque chassis benefit in crash protection because it uses a lot of metals • Cheap for mass production.
- 28. Challenges of Monocoque chassis • It has very complex design. • Impossible for small volume production. • The backbone does not protect side impact or off set crash. • The setup cost for tooling is too expensive-big stamping machines and expensive moldings. • As there’s no separate structure that provides support, in case of accidental collision, chances of permanently damaging the car are quite high.
- 29. Advantages of BOF over Monocoque structure • Can tackle bad roads better. • Much better for off-roading. • Repair bills are much less when it comes to damage control after hardcore off-roading. • Accident repair is also less because of separate chassis and body.
- 30. Advantages of Monocoque structure over BOF • More light, hence fuel efficient. • More safe because of integrated chassis/body. • Better handling. • Much better in ride comfort.
- 31. Carbon fibre Monocoque • Carbon fiber Monocoque is better than traditional monocoques due to its superior rigidity-to-weight ratio. • Cars with Carbon-Fiber body panels include Ferrari 288GTO and Porsche 959.
- 32. Reference • Bicheno, J. (1998) ‘The Lean Toolbox’ Picsie Books, Buckingham. • Bramley, A. Mileham, A Newnes, L Owen, G. (1999) ‘Advances in manufacturing technology’ • Professional Engineering Publishing Ltd, Bury St Edmunds & London. • Monden, Y. (1993) ‘Toyota Production System‘ Industrial Engineering and Management Press • Institute of Industrial Engineers, Norcross, Georgia. • Nieuwenhuis, P. & Wells, P. (1997) The Death of Motoring? • Storey, J. (1994) New Wave Manufacturing Strategies, London: Paul Chapman
- 33. THANK YOU & ANY QUESTIONS?