Introduction to Automotive Engineering

The automotive industry is one of the largest and most important industries in the world.  Cars, buses, and other engine-based vehicles abound in every country on the planet, and it is continually evolving, with electric cars, hybrids, self-driving vehicles, and so on. Technologies that were once thought to be decades away are now on our roads right now.  Engineers, technicians, and managers are constantly needed in the industry, and, often, they come from other areas of engineering, such as electrical engineering, process engineering, or chemical engineering.  Introductory books like this one are very useful for engineers who are new to the industry and need a tutorial. 

Also valuable as a textbook for students, this introductory volume not only covers the basics of automotive engineering, but also the latest trends, such as self-driving vehicles, hybrids, and electric cars.  Not only useful as an introduction to the science or a textbook, it can also serve as a valuable reference for technicians and engineers alike.  The volume also goes into other subjects, such as maintenance and performance.  Data has always been used in every company irrespective of its domain to improve the operational efficiency and performance of engines.  This work deals with details of various automotive systems with focus on designing various components of these system to suit the working conditions on roads.

R. Sakthivel is an assistant professor in the Department of Mechanical Engineering at the Amrita School of Engineering in Tamil Nadu, India.

Faisal O. Mahroogi is Director General of the Center of Leadership and Talent Development at Qassim University in Saudi Arabia.

S. Narayan is an assistant professor in the Department of Mechanical Engineering at Qassim University in Saudi Arabia.

S. Abubakar is an assistant professor in the Department of Mechanical Engineering at Ahmadu Bello University in Nigeria.

M. U. Kaisan is a member of the Department of Mechanical Engineering at Ahmadu Bello University in Nigeria.

Youssef Alammari is a member of the Department of Mechanical Engineering at Qassim University in Saudi Arabia.

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

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

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

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

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