Complete Technology Handbook on Automobile Components and Allied Products (Transmission, Clutch, Chassis, Suspension, Battery, Brake, Radiator, Chain, Drive Shaft, Piston, Pin etc)

Complete Technology Handbook on Automobile Components and Allied Products (Transmission, Clutch, Chassis, Suspension, Battery, Brake, Radiator, Chain, Drive Shaft, Piston, Pin, Piston Ring, Valve, Control Cable, Silencer, Engine Mounting, Auto Lock, Drum, Gear, Leaf Spring, Various Engine Parts, Shock Absorber, Cylinder Block, Tyre & Flaps) with Detailed Manufacturing Process and Project Profiles

Chapter 1

Introduction

Classification of Vehicles

Layout of an Automobile Chassis

Main Components of Chassis

Types of automobile chassis

Full forward chassis

Semi-forward chassis

Bus Chassis

Engine at front chassis

The engine fitted at the rear

The engine fitted in center chassis

Long wheelbase chassis

Overhang Chassis

Half-integral and Half-frame chassis

Components of the Automobile

The Chassis

The Engine

The Transmission System

Clutch

Gearbox

Differential

Axle

The Body

Steering system

Braking system

The Auxiliaries

Chapter 2

Materials used in Automobiles

Metals and Alloys

Steel

Sheet steel

High strength steels

Stainless Steel

Cast Iron

Aluminum

Copper

Magnesium

Lead

Gold

Requirements of the Materials in Automotive

Material properties

Material cost

Material availability

Material compatibility

Material innovation

Material selection tools

Safety, Crashworthiness

Crashworthiness Tests

Frontal Offset Crash Test Detail

Side Impact Crash Testing/Ratings Criterian

Side Barrier Crash Test Scenario

Static Stability Factor

Recycling and Life Cycle Considerations

Current materials in use and their future

Metals

Steel

New grades of steel and alloys

Duplex austenitic-ferritic stainless steel

Austenitic stainless steel

Advances in manufacturing and joining technique

Aluminium

Aluminium alloys for body-in-white applications

Aluminium alloys for brazing sheet applications

Magnesium

Mechanical properties of Mg alloys

Technical problems and solutions for use of magnesium alloys in automotive industry

Plastics and composites

Fabrication

Cost

Manufacturability

Design data/test methodologies

Joining and inspection

Renewable materials, barriers and incentives in use of biocomposites

Thermoplastic/thermoset polymers

Composite processing

Chapter 3

Materials and Technologies for Automotive Use

Introduction

Advanced High Strength Steel (AHSS)

Aluminum Alloys

Carbon Fiber Reinforced Polymer (CFRP)

Light Plastics and Composites

Sustainable Materials

Steel Sheets

High Strength Steel Sheets

New precipitation-hardened high strength hot rolled steel sheet “NANO-Hiten”

New high strength hot rolled steel sheet for strain aging use “BHT”

High strength galvannealed steel sheets

SFG Hiten

Low Carbon Equivalent Type Hiten

High formability ultra-high strength cold rolled steel sheets

High carbon steel sheets with high formability . Coated Steel Sheets

Coated steel sheets with high lubrication for automotive use

Development of Inorganic Type High Lubrication Galvannealed Steel Sheets

Organic Solid Lubricant Technology

Summary

Hot dip galvanized steel sheet with excellent surface appearance

Improvement of Surface Appearance

Surface Roughness Transfer Technologies and Frictional Properties

Summary

Evaluation and Application Technologies for Automotive Steel Materials

Tailor welded blanks

Application technologies of hydroforming

Application technologies for high strength steel sheets in press forming

Application of CAD-CAE systems

High Frequency Electrical Materials for Cars of the Future “Super-Core”

Features of JFE Steel’s Super-Core

JNEX

JNHF

Automotive Applications

Stationary equipment

Rotating machinery

Other electrical applications

Summary

Ferritic Stainless Steels for Automobile Exhaust System Parts

Steels for Mufflers

Steels for Exhaust Manifolds

Steels for Catalytic Converter Substrate

Steel Tubes

HISTORY Tube

High Formability ERW Tubes for Automotive Use

Stainless Steel Tubes for High Temperature Service in Automotive Exhaust Systems

Bar Products for Automotive Use

Bearing Steels “NKJ”, “KUJ7”

Graphite Steel “HFC1 Steel”

BN Free Cutting Steel “CCBN Steel”

High Surface Durable Carburized Dual-phase Steel

High Toughness Microalloyed Steel for Hot Forging

Warm Compaction Method with Die Wall

Lightweight Composite Material for Automotive Headliner “KP Sheet”

Chapter 4

Use of Aluminium in Automobiles

Introduction

Aluminium in Automobile

Advantages of Using Aluminum

Disadvantages of Using Aluminum

Space Frame Technology

Sand Casting

Al-Si Alloys

Grain Refinement

Modification

Extrusion

Al-Si-Mg Alloys

Moment of Inertia

Heat Treatment

Solutionizing

Aging

Annealing

Exposed Loads on Chassis

Static Loads

Dynamic Loads

Fatigue

Welding

Stress Corrosion Cracking

Sand Casting

Spiral Fluidity Test

Mechanical Properties of A356.0 and Silafont-36

Mechanical Properties Change with Heat Treatment

Chapter 5

Use of Plastics in Automobiles: Technology Activities and Priorities

Reducing weight

Energy management technologies

Cost modeling

Polypropylene

Polyurethane

Polyvinyl Chloride

Acrylonitrile Butadiene Styrene

Nylon 6/6

Polystyrene

Polyethylene

Polyoxymethylene

Chapter 6

Manufacturing of Engine Parts

Introduction

Market Potential

Basis and Presumptions

Implementation Schedule

Technical Aspects

Process of Manufacture

Quality Control and Standards

Production Capacity

Pollution Control

Manufacturing Technoloy of Piston Ring

Introduction

Market Potential

Basis and Presumptions

Implementation Schedule

Technical Aspects

Material

Manufacturing Process

Piston Ring Coatings

Production Capacity

Quality Control

Pollution Control

Power Consumption

Manufacturing Technology of Lead Storage Battery

Introduction

Market Potential:

Basis & Presumptions

Implementation Schedule

Technical Aspects

Process of Manufacture

Process Flow Chart Quality Control & Standard

Production Capacity (Per Annum)

Motive Power Required

Pollution Control Requirements:

Energy Conservation

Lighting

Additional Information

Manufacturing Technology of Valve and Valve Seat

Introduction

Introducing Engine Valves

Valve Mechanism and Operation

Intake Stroke

Compression and Power Strokes

Exhaust Stroke

Valve Timing and Overlapping

Engine valve material

Valves sizes

Manufacturing Technology of Automobile Silencer

Introduction

Market Potential

Basis and presumptions 

Implementation Schedule

Technical Aspects

Process of Manufacture

Quality Control and Standards

Pollution Control

Energy Conservation

Production Technology of Automobile Chain

Introduction

Market Potential

Basis and presumptions

Implementation Schedule

Technical Aspects

Process of Manufacture

Quality Control and Standards

Pollution Control

Energy Conservation

Manufacturing process of Cylinder Block

Introduction

Functional requirements of an engine block

Material used in engine block casting

Grey cast iron alloys

Aluminum alloys

Compacted graphite cast iron

Tooling required for casting engine block

Manufacturing process of engine block

Theory behind casting

Quality consideration during the production

Possible defects during the production

Production Technology of Cylinder Linear

Introduction

Functions of Cylinder Liners

Formation of Sliding Surface

Reduction of Wear

Heat Transfer

Sealing

Withstanding Combustion

Market & Demand Aspects:

Raw Materials

Manufacturing process & Source of Technology

Basis of Project preperation and Technical aspects

Presumption

Quality Control & Standards

Pollution Control

Advantages of Cylinder Liners

Disadvantages of Cylinder Liners

Production Technology of Automobile Control Cable

Introduction

Market Potential

Basis and Presumptions

Technical Aspects

Process of Manufacture

Implementation Schedule

Process Flow Chart

Quality Control and Standards

Production Capacity

Motive Power

Pollution Control

Production Technology of Engine Mounting PAD

Introduction

Market Potential

Basis and Presumptions

Implementation Schedule

Technical Aspects

Process of Manufacture

Manufacturing Technology of Auto Locks

Introduction

Market

Basis & Presumptions

Implementation Schedule

Technical Aspects:

Process Outline

Quality Control and Standard

Production Capacity

Pollution Control

Manufacturing Technology of Radiator

Introduction

Uses & Market Potential:

Product

Raw Material

Manufacturing Process:

Power Requirement

Assembly Fixtures

Chapter 7

Manufacturing of Automobile Chassis

Manufacturing of automobile Body

Car Manufacturing Process

Body-In-White Concepts

Structural Components

BIW Manufacturing Processes

Blanking and Stamping Processes

Subassembly Processes and Major subassemblies of a BIW

Engine Sub-assembly

Transmission Sub-assembly

Suspension Sub-assembly

Electrical Sub-assembly

Dashboard Sub-assembly

Understanding Sub Assembly In Automotive Manufacturing

Improved Efficiency

Enhanced Quality Control

Streamlined Logistics

Flexibility in Production

Vehicle Sub-assembly

Truck Sub-assembly

The Process of Automotive Sub Assembly

Component Preparation

Sub-Assembly Design

Quality Control and Testing

Sub-Assembly Integration

Documentation and Traceability

Benefits of Sub Assembly in Automotive Production

Streamlined Assembly Process

Enhanced Quality Control

Improved Ergonomics and Worker Efficiency

Supply Chain Management

Cost Savings

Body Framing Process

Door Manufacturing Processes

Rolling and Blanking Processes

Door Fitting

Market Potential

Basis and Presumptions

Implementation Schedule

Technical Aspects

Process of Manufacture

Pollution Control

Energy Conservation

Manufacturing of brake disc

Introduction

The Materials used for the manufacturing process

Equipment/tools used for manufacturing

The Manufacturing Details of Ceramic Composite Brake discs

Quality considerations and defects that would occur in production

Production Technology of Brake Drum

Introduction

Market Potential

Basis and Presumptions

Implementation Schedule

Technical Aspects

Process of Manufacture

Quality Control and Standards

Production Capacity (per annum)

Pollution Control

Manufacturing Technology of Gear Blank

Introduction

Raw Materials

Manufacturing Process

The Process of Flow Chart

Basis of Project Selection:

Presumptions:

Production Capacity

Utilities

Production of Gear Technology

Introduction

Types of Gears and Their Applications

Spur Gears

Helical Gears

Bevel Gears

Worm Gears

Materials Suitable for Making Gears

Mechanical properties

Friction

Manufacturability

Different Gear Manufacturing Processes

Die Casting

Forging

Extrusion and Cold-drawing

Powder Metallurgy

Gear Machining Process

Gear Hobbing

Gear Shaping

Gear Broaching

Gear Milling

How to Choose the Right Gear Manufacturing Process

Gear Manufacturing Post Processing Options

Grinding

Lapping

Honing

Shaving

Gear Shaping

Working of Gear Shaping

Types of Gear Shaping

Applications of Gear Shaping

Advantages and Disadvantages of Gear Shaping

Difference between Gear Shaping and Hobbing

Gear Shaper machine

Pinion cutter gear shaping process

Setup

Working

Gear Shaping by Rack Shaped Cutter

Gear Cutting by Milling

Advantages

Disadvantages

Bevel Gears

Gear manufacture by casting method

Methods of forming gears

Roll forming

Stamping

Powder metallurgy

Extrusion

Gear Generating Process

Gear Hobbing

Typing of hobbing

Arial hobbing

Radial hobbing

Tangential hobbing

Gear shaping (The Fellows process)

Rack-type cutter generating process

Pinion type cutter generating process

Advantages

Disadvantages

Gear cutting by milling

Disc type cutter

End mill cutter

Advantage

Uses

Bevel Gear Generating

Straight Bevel-gear generator

Spiral bevel-gear Generator

Gleason Method

Templet Gear cutting process

Gear finishing process

Gear shaving

Gear grindings

Disadvantage

Gear lopping

Shot blasting

Phosphate coating

Gear planning

The Sunderland process

The maag process

Principal of gear planning

Production of Gear Box Housing

Parts of a car gearbox

Different types of gearboxes in cars

Manual gearbox

Automatic gearbox

Automated Manual Transmission (AMT)

Torque Converter Gearbox

Continuously Variable Transmission (CVT)

Dual Clutch Transmission (DCT)

Functions of the car gearbox

How does a car gearbox work?

Advantages and disadvantages of manual gearbox

Advantages

Disadvantages

Advantages and disadvantages of automatic gearbox

Advantages

Disadvantages

Interesting facts about car gearboxes

Car Gearbox Prototyping and Manufacturing Process

CNC machining

3D Printing

Initial validation and testing

Synchromesh Gearbox

Constant Mesh Gearbox

Preselector Transmission

Production Process of Leaf Spring

Introduction

Parts of Leaf Spring

Metal Plates or Leaves

Master Leaf

Centre Bolt

U-bolt

Rebound Clip

Spring Eye

Shackle

Rubber Bush

Types of Leaf Spring Suspension

Multi-leaf Spring

Mono Leaf Spring

Semi-elliptical Leaf Spring

Quarter-Elliptical Leaf Spring

Three-Quarter Elliptical Leaf Spring

Full Elliptical Leaf Spring

Transverse Leaf Spring

Advantages

Disadvantages

Manufacturing Process

Process Flow Chart

Standard size of Leaf Spring

Material used for Leaf Spring

Pollution Control Measures:

Energy Conservation:

Production Technology of Shock Absorbers

Introduction

Components of a Shock Absorber

Mount

Bushing

Coil Spring

Piston and Piston Rod

Cylinder

Bolts

Additional Small Parts of Shock Absorber

Working Principle of Shock Absorber

Types of Shock Absorbers

Conventional Telescopic Shock Absorbers:

Strut-Type Shock Absorbers

Spring Seat Shock Absorbers

Functions of Shock Absorbers

Symptoms of Bad and Failing Shock Absorber

Advantages of Shock Absorber

Disadvantages of Shock Absorber

Applications of Shock Absorbers

Manufacturing process of shock absorber

Production Technology of Automobiles Tyres

Introduction

Innovations and Advancements in Tyre Manufacturing Technology

Tyre Production Process

Rubber & Compound

Fabric & Steel

The Belt & Ply

The Bead

The Tread

The Sidewall

The Inner Liner

Putting it all together – building the tyre

Curing

Inspection

Environmental Concerns and Sustainability in Tyre Production

Natural Rubber (NR)

Environmental Effects

Mechanical Effects

Oils and Solvents

Synthetic Rubbers

Styrene Butadiene Rubber (SBR)

Butadiene Rubber (BR)

Chloroprene Rubber (CR)

(Acrylo) Nitrile Butadiene Rubber (NBR)

Iso Butylene Isoprene (Butyl) Rubber (IIR)

Ethylene Propylene Rubber (EPDM or EPR)

Silicone Rubber

Chloroprene Rubber

Tread Design

Tread Design Types

Symmetric Tread

Asymmetric Tread

Unidirectional Tread

Tread Elements

Sipes

Blocks

Ribs

Shoulder

Void Ratio

Grooves

Tread Design and Wet Road Conditions

Types of Tyres Used in Cars

All-Season Tyres

Summer Tyres

Winter Tyres

Performance Tyres

Run-Flat Tyres

All-Terrain Tyres

Mud-Terrain Tyres

Emergency Spare Tyres

Space-Saver Tyres

Choosing the Right Tyre for Your Car

Tyre Size

Tyre Tread

Tyre Construction

Driving Conditions

Tyre Profile and Aspect Ratio

Speed Marking of Tyres

How to read a tyre width and the aspect ratio?

How to read a tyre construction type and the wheel diameter?

How to read the maximum load and speed of a tyre?

How to identify the brand name and range of the tyre?

How to identify the type of tyre?

How to read tyre pressure?

How to read a tyre date code?

Manufacturing Technology of Auto Tubes and Flaps

Introduction

Market Potential

Basis and Presumptions

Implementation Schedule

Technical Aspects

Process of Manufacture

Manufacturing Technology of Axle

Importance of Axle strength

Types of Axle

Front axle

Rear axle

Stub axle

Production Process

Forming

Welding assembling

Machining

Axle unit assembly

Chapter 8

Heat Treatments of Automobiles

Introduction

Materials Used In Auto vehicles

Bake Hardening Steel Sheets

High Tensile Strength Steel Sheets

Corrosion Resistant Coated Steel Sheets

Constructional Steels

Case Hardening Steels

Heat Resistant Steels

Powder Metallurgy Products

Copper Alloys

Aluminum Alloys

Magnesium Alloys

Titanium Alloys

Composite Materials

Plastics and Rubber

Glass and Ceramics

Heat Treatment

Types of heat treatment

Processing technology in heat treatment

Carburizing and Carbonitriding

Nitro-carburizing

Induction hardening

Powder Metallurgy and Sintering

Key issue in heat treatment: atmosphere control

Carbon potential control

Gas carburizing processes

Reduced pressure carburizing (Vacuum carburizing)

High Pressure Gas Quenching

Carbonitriding

Low temperature nitrocarburizing and oxynitrocarburizing

Surface modification and hybrid heat treatment

Solid lubricant coatings

Emerging technologies in materials, heat treatment and surface engineering

Materials

Carburizing and carbonitriding

New nitriding methods for aluminum

Nitriding of stainless and maraging steels

Furnaces for heat treatment of fasteners and automobile parts

Washing machine

Hardening furnace

Quenching tank

Continuous hot blast tempering furnace

Capacity of the main furnace

Capacity of the quenching tank

Capacity of the continuous hot blast tempering furnace

Capacity of the dyeing tank

Crucible type annealing furnaces

Application

Features

Specifications of the bell type furnace

Features

Chapter 9

Forging Technology of Automobile Parts

Introduction

Definition of Forging

What is forging?

Materials suitable For Forging

properties of the forgeable materials?

Forgeability

Factors affecting on Forging

Characteristics of forged parts

Forging Process Tools

Types of Forging machine:

Types Of Forging

Open die forging:

Hand Forging

Closed Die forging:

Drop forging

Forging Operation

Operations carried out in forging process

Forging dies

Forging Process Application

Forging Process:

Casting Process

Powder Forging Process

Spanner Forging

Forging Sequence for Spanner

Crankshaft Forging

Other Application

Forging defects with their remedies

Advantages of Forging:

Disadvantages of Forging

Applications of Forging Process:

Chapter 10

Painting Technology of Automobiles

Introduction

Demand for anti-fouling paints for automotive

Increasing demand for foam control agents

Need for mar & stain resistance additives

Spray Priming System

The Beginning

Enamel Paint

Acrylic Lacquer Paint

Acrylic Enamel Paint

Water-Based Paint

Clear Coat Paint

Advancements in Car Paint Technology

Nanotechnology in Paint Formulations

High-Performance Ceramic Coatings

Waterborne Paint Systems

Pearlescent and Chameleon Paints

Digital Printing and Customization

Types of Automotive Paints, Step By Step Painting Process

Stage 1: Applying The Primer - Car Painting – Primer Application

Stage 2: Spraying The Base Coat- Car Painting – Base Coat Spray

Stage 3: Spraying The Clear Coat - Car Painting – Clear Coating

Spray priming system

Dip priming system

Electropriming system

Performance

Pretreatment

Rust removal

Alkali degrease

Metal phosphate (conversion coating)

Pretreatment as a corrosion inhibitor: mechanism

Priming

Spray priming

Dip priming

Products

Pigmentation

Prime pigments:

Extenders

Process

Electropainting

Anodic electrocoat

Resin systems

Pigmentation

Mechanism of deposition

Practical considerations

Basic plant requirements

Control methods

Deficiencies of anodic electrocoat primers

Cathodic electrocoat

Resin system

Pigmentation

Colour

Performance characteristics

Plant requirements

Dip rinsing

Ultrafiltration

Control method

Pretreatment

General appraisal and current developments

Surfacers

Background

Introduction

Product types and formulation

Resins systems

Alkyds

Epoxy esters

Polyesters

Epoxies: film modifiers

Crosslinking resins

Pigmentation

Prime pigments

Extenders

Polyurethane-modified polyester surfacer (including ‘colour keyed’ products)

Summary of basic parameters

Specific gravity (ASTM D1475)

Flash point

Film properties (stoved film)

Appearance

Anti-chip coatings

Background and resin types

Pigmentation

Inverted or reverse process

Electro powder coating (EPC)

Automotive topcoats

Alkyd or polyester finishes

Basic chemistry

‘Sagging’

‘Solvent-popping’ resistance

General properties

Thermosetting acrylic/NAD finishes

Basic chemistry

General properties

Metallic appearance

‘Sagging’

‘Solvent-popping’ resistance

Thermoplastic acrylic lacquers

Basic chemistry

General properties

Basecoat/clear technology

Solvent-borne

Basic chemistry

Application/process

Colour/pigmentation

Painting of plastic body components

Sheet moulded compound (SMC) and dough moulded compound (DMC)

Polyurethane: PU RIM and PU RRIM

Injection moulded plastics

Painting problems

Adhesion

Heat distortion

Surface texture

Solvent sensitivity

Degradation of mechanical properties

Paint processes and products

On-line

Off-line

‘Part-way’ down paint line

Spray application

Air spray

Spray losses

Automatic spray

Low-pressure hot spray

Airless spray

Electrostatic spray

Resistivity

Electrostatic application of water-borne automotive coatings

General plant design features

Paint circulating system for electrical insulation

Externally charged atomizers

Application efficiency - practical considerations and processes

Modern spraybooth design-ventilation modes

Preconditioning the air

Concentrators

Process details: typical application parameters-turbo bells

Stoving procedures

Oven technology

Design considerations of convection ovens

Oven configuration

Oven ventilation

Oven heating

Fresh air requirements

Fuel available/heating method

Fume and odour emission

Thermal incineration

Catalytic combustion

Future stoving developments

Performance/testing

Appearance

Performance

Physical properties

Chemical resistance

Test procedures

Cure (test for crosslinking products)

Sandability (surfacers)

Adhesion: crosshatch test (1.5 mm or 2.0 mm template)

Future developments

High solids technology

Solids range:

Resin types:

Types of product involved:

Higher solids surfacer technology

Application solids

High solids polyester topcoats

Higher solids basecoats

Ultra high solids coatings

Water-borne products

Solids range

Resin types

Product types

Surfacers

Basecoats

Powder coatings and aqueous slurries

Resin types: epoxy, polyester, acrylic

Aqueous powder slurries

Solid colour basecoats

Clearcoats

Pigmentation

Painting of plastics

Electrodeposition and spray application

Chapter 11

Plant Economics of Automotive Engine Valves

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 12

Plant Economics of Brake Pad and Shoe

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 13

Plant Economics of Leaf Springs for Tractor Drawn Trolleys & Four Wheeler Tempos

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 14

Plant Economics of Lithium Ferro Phosphate Battery Pack

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 15

Plant Economics of Showroom Cum Workshop and Service Centre

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 16

Plant Economics of Tubeless Valves for Cars and Trucks

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 17

Plant Economics of Tyre and Tubes Including Flaps

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 18

Addresses of Machinery and Equipment Suppliers

Chapter 19

Addresses of Raw Material Suppliers

Rubber Chemicals

Carbon Black

Process Oil

Zinc Oxide

Mineral Fillers and Synthetic Rubber

Stearic Acid