K vector automotive participants training

1. MOHAMAD A. ALI
Automotive session

2. SESSION CONTENT
1. Introduction to suspension
2. What is suspension and why it is
mandatory
3. Components of suspension system
4. Types of frames
5. Chassis classification (Engine position)
6. Introduction to brakes
7. Brakes principal of work
8. Components of braking system
9. Types of brakes

3. INTRO. TO SUSPENSION SYSTEM
• HOW WAS THE SUFFERING BEFORE THE SUSPENSION OF THE CAR?

4. WHAT IS SUSPENSION AND WHY IT IS
MANDATORY
Suspension is system connects between wheels and car frame. This system is responsible for many
functions as follows:
• Eliminate forces or vibrations transmitted to car from road roughness.
• Give permeant full traction with road.
• Minimize body roll while steering.
• Increase the stability at all.
• Maximize the passengers comfort.

5. COMPONENTS OF SUSPENSION SYSTEM
• VEHICLE FRAME
• SHOCK ABSORBER
• SPRINGS
• STABILIZER BAR / TORSION BAR

6. COMPONENTS OF SUSPENSION SYSTEM
• VEHICLE FRAME
THE MAIN BONES OF ANY VEHICLE. SUSPENSION COMPONENTS WILL BE FIXED TO THE FRAME
AND OTHER VEHICLE COMPONENTS ARE MOUNTED ON THE FRAME.
THE FRAME HAS MANY TYPES AND SHAPES ACCORDING TO ITS USES AND
LOADS IT WILL CARRY. (SEDAN-OFF ROAD-TRUCK-BUS-FORMULA-ETC…)

7. COMPONENTS OF SUSPENSION SYSTEM
• SPRINGS
THE MAIN PART IN SHOCK DAMPING SYSTEM. IT HAS THE ABILITY TO ABSORB A GREAT
AMOUNT OF POTENTIAL ENERGY AND RELEASE IT GRADUALLY.
ALSO, THE SPRING ACTS AS SYSTEM POSITION RESET WHEN THE SYSTEM COMPRESSED OR
RELEASED DUE TO ROAD DEFECTS OR BODY ROLL THE SPRINGS WILL ADJUST THE SYSTEM TO
GIVE STABILITY AND FULL ROAD TRACTION.

8. COMPONENTS OF SUSPENSION SYSTEM
• SPRINGS
SPRINGS IN CARS HAS 2 MAIN TYPES:
1. COIL SPRING: THIS TYPE IS COMMONLY USED IN LIGHT WEIGHT CARS AS SEDAN OR EVEN
CROSS OVER CARS. IT IS MADE OF A SPECIAL WIRE WOUNDED TO THE SHAPE OF SPIRAL COIL.
IT DOESN’T NEED TO GET WIDE SPACE TO BE MOUNTED AND ITS STIFFNESS CAN BE DESIGNED AT
ANY VALUE DESIRED BUT IT CANNOT BE USED FOR HEAVY LOADS.

9. COMPONENTS OF SUSPENSION SYSTEM
• SPRINGS
ADV.: IT HAS LOWER STIFFNESS AND SMOOTH RESPONSE.
ITS SIZE IS NOT LARGE THEN, IT CAN BE MOUNTED IN SMALL FRAMES.
DIS ADV.: IT CANNOT CARRY HEAVY LOADS.
ITS STABILITY IS LESS THAN OTHER TYPE.
IT HAS LESS LIFETIME THAN THE OTHER PART

10. COMPONENTS OF SUSPENSION SYSTEM
• SPRINGS
2. LEAF SPRING: USUALLY USED AT HEAVY VEHICLES AS TRUCKS.
IT CONSISTS OF FLAT STEEL LEAVES ISOLATED WITH RUBBER AND ALL FIXED TOGETHER TO GIVE THE
REQUIRED STIFFNESS.
ITS GREAT ADVANTAGE IS IT CAN DEAL WITH HEAVY LOADS AND HAS HIGH STIFFNESS.
ADV.: IT HAS ABILITY TO ABSORB HIGH LOADS WITHOUT ANY DAMAGE.
IT HAS HIGH STIFFNESS THEN, GIVES HIGH STABILITY TO THE VEHICLE.
IT HAS LONGER LIFETIME THAN COIL SPRING.

11. COMPONENTS OF SUSPENSION SYSTEM
• SPRINGS
MAY IT HAVE ALSO SOME DISADVANTAGES AND LIMITATIONS:
• IT NEEDS A WIDE SPACE TO BE MOUNTED IN.
• IT CANNOT DEAL WITH LIGHT LOADS AS ITS STIFFNESS IS GREATER THAN COIL SPRING THEN,
THE SUSPENSION SYSTEM IN TRUCKS, FOR EXAMPLE, HAS NO EFFECT WHEN THE VEHICLE IS
EMPTY.

12. COMPONENTS OF SUSPENSION SYSTEM
• SHOCK ABSORBER
BECAUSE THE SPRINGS HAS A RAPID RESPONSE AND LOW DAMPING CAPACITY, ANOTHER
COMPONENT IS USED TO MINIMIZE THOSE PROBLEMS WHICH IS SHOCK ABSORBERS.
ITS FUNCTION: DAMPERS ACTS AS KINETIC ENERGY ABSORBER AND DISSIPATE AS HEAT.
ITS INTERNAL COMPOSITION: IT MAINLY CONSISTS OF PISTON, CYLINDER AND OIL.

13. COMPONENTS OF SUSPENSION SYSTEM
• SHOCK ABSORBER

14. COMPONENTS OF SUSPENSION SYSTEM
SHOCK ABSORBER AND THE COIL SPRING ARE ASSEMBLED TOGETHER TO FORM ONE DEVICE
CALLED STRUT. THIS DEVICE THAT DETERMINE THE MAIN SUSPENSION STIFFNESS AND HAS MAIN
ROLE IN DAMPING MECHANISM.

15. COMPONENTS OF SUSPENSION SYSTEM
• STABILIZER BAR / TORSION BAR
THE ANI-SWAY AND TORSION BAR BOTH ARE USED TO INCREASE STABILITY WHILE DRIVING.
THE MAIN IDEA IS THAT THE BAR IS MADE OF A HIGH TOUGHNESS MATERIAL AGAINST
TORSION.
THEY REDUCE BODY ROLL AND TRACTION LOSS BUT THE MAIN DIS-ADV. FOR BOTH TYPES OF
TORSION BEAMS THAT THEY INCREASE THE SUSP. STIFFNESS AND THE ROAD DEFECTS FEELING.

16. COMPONENTS OF SUSPENSION SYSTEM

17. TYPES OF VEHICLE FRAMES
THE FRAME IS THE MAIN PART OF ANY VEHICLE AS ANY OTHER PART IS BUILD ACCORDING TO
ITS DESIGN AND FIXED ON IT. MANY TYPES OF FRAMES ARE DESIGNED ACCORDING TO ITS
USES AND APPLICATIONS.
Vehicle
Frame
Conventional
Ladder
frame
Integral
Monocoque
Semi
Integral

18. TYPES OF VEHICLE FRAMES
• CONVENTIONAL FRAME:
IT HAS TWO LONG SIDE MEMBERS AND 5 TO 6 CROSS MEMBERS JOINED TOGETHER WITH THE HELP
OF RIVETS AND BOLTS. SUCH AS: LADDER FRAME.
• INTEGRAL FRAME:
ALL THE FUNCTIONS OF THE FRAME CARRIED OUT BY THE BODY ITSELF. DUE TO ELIMINATION OF
LONG FRAME IT IS CHEAPER AND DUE TO LESS WEIGHT MOST ECONOMICAL ALSO. ONLY
DISADVANTAGE IS REPAIRING IS DIFFICULT. SUCH AS: MONOCOQUE FRAME.
• SEMI-INTEGRAL FRAME:
IN SOME VEHICLES HALF FRAME IS FIXED IN THE FRONT END ON WHICH (ENGINE GEAR BOX AND
FRONT SUSPENSION ARE MOUNTED). IT CAN BE REPAIRED EASILY AND HAS MORE ADV. THAN ABOVE
TYPES.

19. TYPES OF VEHICLE FRAMES
AT THE FOLLOWING PART, THE FRAME TYPES WILL BE MENTIONED WITHOUT ANY
CLASSIFICATION.
• LADDER FRAME
• MONOCOQUE
• BACKBONE FRAME
• SPACE FRAME
• PLATFORM

20. TYPES OF VEHICLE FRAMES
• LADDER FRAME
ADV.:
USED TO CARRY HIGH LOADS
EXCELLENT TO RESIST BENDING MOMENT
DIS ADV.:
HAS HEAVY WEIGHT
BAD IN TORSIONAL STIFFNESS

21. TYPES OF VEHICLE FRAMES
• MONOCOQUE
ADV:
THE FRAME AND BODY ARE MERGED TO BE MONOCOQUE FRAME
IT HAVE LOWER PRODUCTION COST
HAS LIGHT WEIGHT
COMMONLY USED IN PASSENGER CARS
DIS ADV.:
IT IS HARD TO BE FIXED IF ANY DEFORMATION HAPPENS

22. TYPES OF VEHICLE FRAMES
• BACKBONE FRAME
ADV:
IT CAN CARRY RELATIVELY HIGH LOADS
IT HAS HIGH BENDING MOMENT RESISTANCE
DIS ADV.:
ITS BODY IS NOT SAFE IN CASE OF SIDE ACCIDENTS.

23. TYPES OF VEHICLE FRAMES
• SPACE FRAME
CONSISTS OF METAL TUBES OR BARS ARE ASSEMBLED BY WELDING OR OTHER METHODS. IT IS USED
MAINLY IN RACING CARS AS FORMULA CAR.
ADV.:
IT HAS RELATIVELY LOW WEIGHT
CAN CARRY HIGH LOADS ACCORDING TO ITS DESIGN
DIS ADV.:
ITS DESIGN CANNOT GET FANTASTIC DESIGN SHAPES
IT HAS GREAT RESISTANCE AT SOME TYPES OF STRESSES AND MIN. FOR ANOTHER TYPES

24. TYPES OF VEHICLE FRAMES
• PLATFORM
IT WAS USED IN OLD CARS LIKE VOLKSWAGEN BEETLE CAR. IT CONSISTS OF A PLATFORM THAT
THE BODY IS MOUNTED ON IT. ITS MANUFACTURING WAS STOPPED BECAUSE IT HAS GREAT
LIMITATIONS AS HEAVY WEIGHT.

25. INTRO. TO BRAKING SYSTEM
THE CAR ENGINE OPERATION IS TO CONVERTS THE HEAT ENERGY INTO KINETIC
ENERGY IN ORDER TO ACCELERATE THE CAR OR TO KEEP ON CONST SPEED
OPPOSES FRICTION. SO WE NEED A SYSTEM THAT OPPOSES THE ENGINE
EFFECT CONVERTING THE KINETIC ENERGY INTO HEAT TO STOP THE CAR OR
DEC. ITS SPEED.

26. PRINCIPAL OF WORK
THE HIGH KINETIC ENERGY NEEDS HIGH FORCE TO OPPOSE IT THEN, PASCAL’S PRINCIPAL IS
USED TO DUPLICATE THE FORCE MANY TIMES.

27. COMPONENTS OF BRAKING SYSTEM
THE BRAKING SYSTEM HAS MANY COMPONENTS THAT HELPS IN FORCE MAXIMIZATION NOT
ONLY THE PEDAL AND PISTON, THESE ARE THE BRAKES MAIN COMPONENTS THAT:
• PEDAL
• BOOSTER
• MASTER CYLINDER
• FLUID TANKS
• HYDRAULIC FLUID LINES
• PISTON AT THE ROTOR
• DISK AND CALIPER
• FRICTION PADS

28. COMPONENTS OF BRAKING SYSTEM
Pedal Master cylinder

29. COMPONENTS OF BRAKING SYSTEM
BOOSTER DISK AND CALIPER

30. TYPES OF BRAKES
THERE ARE TWO DIFFERENT TYPES OF BRAKES. THIS DIFFERENCE IS
FOUND IN THE FINAL PART OF BRAKES WHICH ARE:
• DISK BRAKES .
• DRUM BRAKES.

31. TYPES OF BRAKES
DISK BRAKES
MOST COMMON IN THE MODERN CARS. CONSISTS OF DISK SAND CALIPER. ITS
IDEA OF OPERATION IS WHEN THE PEDAL IS PRESSED AND THE PISTON PUSHED
UP, THE BREAKING PADS AND CALIPER WILL START HIGH FRICTION WITH THE
DISK CONVERTING THE KINETIC ENERGY TO HEAT ENERGY DECREASING THE
WHEEL SPEED.

32. TYPES OF BRAKES
• THIS TYPE HAS MANY ADVANTAGES AS:
• IT HAS GOOD VENTILATION FOR HEAT LOSS.
• ITS EFFICIENCY IS HIGH.
• EASY TO BE MAINTAINED.
• IT HAS ABILITY TO EXPEL THE ASBESTOS WHICH THE PADS MATERIAL AND IT IS POISONING.
ALSO, THIS TYPE HAS SOME DIS-ADVANTAGES AS THE HIGH COST FOR MANUFACTURING THEN
HIGH MARKET PRICE.

33. TYPES OF BRAKES
DRUM BRAKES
THIS TYPE WAS FIXED IN OLD CARS AND SOME REAR WHEELS IN MODERN
CARS. ITS IDEA OF OPERATION IS EASY ALSO BUT SOME COMPLEX PARTS ARE
ADDED TO MAKE THE MECHANISM WORKS EFFECTIVELY. THE MAIN IDEA IS THAT
THE PISTON WILL EXPANDS THEN THE BRAKING PADS STARTS FRICTION WITH
THE WALLS OF THE DRUM, THEN HEAT GENERATED THEN THE SPEED DECREASES.

34. TYPES OF BRAKES
THIS TYPE HAS SOME ADVANTAGES BUT NOT AS THE DISK BRAKES: MAINLY ITS PRICE IS LOWER
THAN DISK BRAKES.
THE DIS-ADVANTAGES ARE MORE SO ITS USAGE IS DECREASING:
• NOT EASY TO BE MAINTAINED.
• COMPONENTS ARE LITTLE BIT COMPLICATED.
• VENTILATION IS NOT GOOD SO:
• LOWER EFFICIENCY.
• NO ASBESTOS EXPELLING WHICH IS POISONING.

35. OTHER TYPES OF BRAKES
BRAKES MAY HAVE OTHER MANY TYPES AS:
• PNEUMATIC BRAKES
THIS TYPE IS USED AS HELPING SYSTEM FOR THE HYDRAULIC ONE AND RARELY TO BE USED
ALONE. THIS TYPE USED IN HEAVY VEHICLES AS TRUCKS AND BUSES. THE RESPONSE OF AIR IS
SLOWER THAN HYDRAULIC SYSTEM AS THE AIR IS COMPRESSIBLE FLUID BUT IT STILL EFFECTIVE
AND COMMONLY USED.
• PARKING BRAKES
THE WIRE SYSTEM WAS MOSTLY USED IN RELATIVELY OLD CARS AND SOME MODERN CARS
TOO. THIS SYSTEM DEPENDS ON A WIRE WHICH IS CONNECTED TO A HANDLE, WHEN THE
HANDLE IS PULLED IT APPLY TENSION ON THE WIRE THAT WILL APPLY THE BRAKING PADS ON
AS IF THE PISTON IS PUSHED UP.

36. THAT’S ALL THE
STORY ☺