Fundamentals of Vehicle

Design
Dr. Shirish P Patil &
Dr. Kamarul Tawi

Course Objectives
Understand vehicle manufacturing organization
Understand vehicle development process
Understand vehicle systems and attributes (properties)
Learn to set performance specifications for a new
vehicle
Understand system/component contribution towards
vehicle performance
Learn to set specifications for system/component design
Learn to design components to meet specifications

Course Outline
1.
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12.

Overview of vehicle design process

Vehicle performance specifications
Vehicle acceleration & powertrain design specification
Vehicle deceleration & brake design specification
Vehicle ride & chassis design specification
Vehicle roll-over & chassis design specification
Vehicle handling & chassis design specification
Vehicle durability & chassis design specification
Vehicle crash safety & body design specification
Design of the suspension system
Design of the steering system
Design of the body/door system

Course Schedule
Every Tuesday: classroom instruction (2 hours)
Every Thursday: group project discussion (3 hours)
Study time: approximately 4 hours/week

Evaluation Criteria
Final written project report including
weekly log of activities (40%)
Final project presentation (15%)
Mid-term project presentation (5%)
Team participation & contribution (40%)

Team Participation & Contribution Evaluation

No.

Performance
Criteria

Level 1

Level 2

Level 3

Level 4

Level 5

1.

Contributions

Does not
provide ideas
when
participating in
the group
discussion.

Rarely provides
ideas when
participating in the
group discussion.

Sometimes provides
ideas when
participating in the
group discussion. A
satisfactory group
member who does
what is required.

Usually provides
useful ideas when
participating in the
group discussion.
A strong group
member who tries
hard.

Routinely provides
useful ideas when
participating in the
group discussion. A
leader who
contributes a lot of
effort.

2.

Effort in Problemsolving

Does not try to

solve problems
or help others
solve problems.
Lets others do
the work.

Rarely tries to
solve problems or
help others solve
problems.

Does not suggest or

refine solutions, but
is wiling to try out
solutions suggested
by others.

Refines solutions
suggested by
others

Actively looks for

and suggests
solutions to
problems.

3.

Attitude

Always publicly
critical of the
project or the
work of other
members of the
group. Has
negative attitude
about the
task(s).

Is often publicly
critical of the
project or the work
of other members
of the group. Is
often negative
about the task(s).

Is occasionally
publicly critical of the
project or the work
of other members of
the group. Usually
has a positive
attitude about the
task(s).

Is rarely publicly
critical of the
project or the work
of others. Often
has a positive
attitude about the
task(s).

Is never publicly
critical of the project
or the work of
others. Always has a
positive attitude
about the task(s)

4.

Participation and
Working with
Others

Does not
participate,
listen to, shares
with, and
supports the
efforts of others.
Is not a good
team player.

Rarely participate,
listens to, shares
with, and supports
the efforts of
others. Often is not
a good team
player.

Often participate,
listens to, shares
with, and supports
the efforts of others,
but sometimes is not
a good team
member.

Usually participate,
listens to, shares,
with, and supports
the efforts of
others. Does not
cause ripples in
the group.

Almost always
participate, listens
to, shares with, and
supports the efforts
of others. Tries to
keep people working
well together.

Project Description
Each team (5 students) will choose a
passenger vehicle to be engineered
Team will decide the performance
specifications for the vehicle
Team will design the specifications for the
powertrain/brake/suspension/body system
so that vehicle specifications are satisfied

Requirements for the Report

List of specifications for cost, weight, acceleration,
braking, ride, handling, roll-over, crash safety and
durability. Method of setting each specification
Design of powertrain system properties to meet
acceleration specification
Design of brake system properties to meet braking
specification
Design of suspension & steering system properties to
meet ride, handling, roll-over and durability specification
Design of body system properties to meet crash-safety
specification
Design of door system properties to meet door closing
effort specification

Vehicle Classification
Vehicle
Type

Body Style

Power Train

Suspension

Passenger Car

2D/3D/4D/5D UniBody

Engine: 1.0-3.0L
Trans: 5spd/Auto
Driveline: FWD

Front: McPherson
Rear: Multi-link

MPV

4D/5D UniBody

Engine: > 2.0L

Trans: Auto
Driveline: FWD

Front: McPherson
Rear: Multi-link

SUV

5D Unibody or Body on
Frame

Engine: 1.8-5.0 L
Trans: Auto
Driveline:
FWD/RWD/AWD

Front: McPherson/SLA
Rear: Multi-link/Solid Axle

Luxury Car

4D Unibody or Body on
Frame

Engine: >2.5 L
Trans: Auto
Driveline: FWD/RWD

Front: SLA
Rear: Multi-link

Sports Car

2D/3D Unibody

Engine: >3.5 L
Trans: 5Spd
Driveline: RWD

Front: McPherson
Rear: Multi-link

Pickup Truck

2D/4D Body on Frame

Engine: >2.5 L
Trans: Auto
Driveline: RWD/AWD

Front: SLA
Rear: Solid Axle

Commercial
Truck

2D Body on Frame

Engine: >5 L
Trans: Auto

Front: SLA
Rear: Solid Axle

How to prepare vehicle

specifications?
Understand what your customer desires
Understand what your competition offers
Understand government regulation

Team Exercise
Pick a vehicle you plan to design
Write vehicle specifications by studying 2
or more competition vehicles (study dealer
specs., do internet search, etc.)

Cost Specification
What is the intended selling price of the
car?
How many units do you plan to sell?
Will you make any profit?

Weight Specification
What is intended gross vehicle weight
(GVW)?
How many passengers?
What is the luggage capacity?
Weight distribution?

Geometry Specification

Wheelbase?
Tread?
Ground clearance?
Tire size?

Acceleration Specification
0 to 100 km/h in how many seconds?
Engine torque/power?
Transmission speed? Auto or Manual?