Historical back ground- function, constraints, objectives, free variables- material index- process selection

1. Higher Technological Institute
Chemical Engineering Department
CAR’S FRAME
Student: Abdel-Rhman Magdy Abdel-Lah Youssef
ID: 20160517
January / May 2018

2. Chapter one
Historical background

3. 1.1History of materials used to manufacture car’s frame
1.1.1: Wood:
 The first motor car bodies made between 1896 and
1910 like carriages were made almost entirely of wood.
 The joints between car body part were rein forced by
wrought iron brackets were individually fitted.
 Top of car ere made from rubberized canvas.
 About 1921 the Weymann construction was introduced,
in which the floor structure carried all the weight of the
seating, and the body shell.
1.1.2: Steel:
 1923 represented the first attempts to build all car
body from steel.
 1927 represented the real beginning to manufacture
car body from steel completely because presses
became capable of producing a greater number of
panels and in more complex shapes.
 During the 1930s most of the large companies use
steel to manufacture body shell, and motorcars
began to be produced in even greater quantities.
 Steel is there first choice because it more light-
weight, stronger, stiffer.

4. 1.1.3 Glass-Fiber:
 In 1953 The Chevrolet Corvette was the first
manufactured car with a fiberglass body.
 In 1957 Lotus Elite was manufactured as
another car with Glass-Fiber body.
1.1.4 Carbon fiber:
 In early of 80s, cars with a carbon
fiber body manufactured like;
Ferrari 288GTO.
Ferrari 288GTO

5. 1.1.5: Aluminum:
 Manufacturing of cars with body of Al started with manufacturing cars with
steel body, but at this time Sheets of Aluminum was more Expensive than
steel, also cast Aluminum brackets more expensive than steel.
 For the two previous reasons steel body of cars manufactured for the
masses and Al body of cars manufactured for rich.
 In 1994 Audi A8 represented as the fist car manufactured with completely AL
frame.
 The important advantage of cars with Al frame its light weight.
 While Al may seem like a miracle metal for car production, there is a reason
not all cars are made from Al, It costs a lot more than Steel
Audi A8

6. Chapter two
Stages of Project

7. 2.1: Function, Constraints, Objectives, Free variables
Function Car frame
Constraints
1- No thermal expansion.
2- High corrosion resistance.
3- Low thermal Conductivity.
4- High strength.
5- No deflection
6- Length is specified.
7- High stiffness
Objectives Minimizing mass.
Free
variables
Select material

8. 2.2: Material Index
M2 =
ρ
E
M1=
Ơf
ρ

9. Strength – Density Chart

10. Analysis of charts:
Strength – Density Chart
1-Steel. 2-Ni alloys. 3-GFRP.
4-Al alloys. 5-Ti alloys. 6-Wood.
7-CFRP.
Young’s modulus – Density chart
1-Steel. 2-Ni alloys. 3-GFRP.
4-Al alloys. 5-Ti alloys. 6-Wood.
7-AL2O3. 8-SiC. 9-CFRP.

11. 2.3:Process selection
Car frameFunction
1-Material: Al alloys.
2-shape: Dished sheet.
3-Mass: 211Kg.
4-Thickness: 11mm.
5-Roughness: 2µm.
6-Tolarance: 1mm.
7-Batch size: 9500.
Constraints
…………………………………………….Objectives
Select processFree variable

16. FinishingJoiningShapingChart
1-Precission machining.
2-Grinding.
3-Lapping.
4-Polishing
1-Adhesives.
2-welding metals.
3-fasteners
1-sand casting.
2-Die casting.
3-Investment casting.
4-Low pressure casting.
5-Forging.
6-Extrusion.
7-Sheet forming.
8-Powder method.
9-Electro machining.
10-Conventional machining.
First
................
...............
................
................
..............
1-Sheet forming..
2-Conventional machining.
Second
..............1-Fasteners.
2-Welding metal.
3-Adhesives.
1-Conventional machining.
2-Sheet forming.
Third
............................
1-Conventional machining
Fourth
1-Pricission machining..............
1-Conventional machining
Fifth
1-Pricission machining...............1-Conventional machiningSixth
........................1-Conventional machiningSeventh
Process charts analysis