Design of Automotive Metal and Composite Chassis Structures

Joseph      C. England; Homayoun      Hadavinia; Denis      R. Marchant; Akbar      Aboutorabi

doi:10.2174/2212797611003030211

Abstract

This paper reviews recent patents covering automotive metal and composite chassis structures. Automotive chassis are very complex structures and the variety of different types is vast. This paper attempts to reveal modern chassis design looking at composite structures, bonding methods, front sub-frames, complete space-frames, uni-body, integral frame and monocoque structures. Automotive chassis designs have had considerable developments in recent years. This is attributed to recent legislation taking particular interest in after service disposal and more prominently crash, impact and occupant safety. Automotive manufacturers continue to develop new, innovative and novel approaches to achieving rigidity and stiffness in torsion and bending to achieve optimal suspension geometry, safety and occupant comfort. Recent patents in automotive chassis design refer mainly to stiffening support structures, composite structures, retractable roofs and by far the most common, front crash sub frames.

Keywords: Chassis, metal chassis, composite chassis, bonded chassis, crash box, sub frames, spaceframe, monocoque, heat affected zone, epoxy resins, Cycom 977, honeycomb sandwich material, resin transfer moulding, RTM, Cabriolet space-frame, CNC bending, computer controlled welding, fibre-reinforced plastic sheets, multi utility vehicle, Audi spaceframe (ASF) chassis, resilient aluminium alloy, frontal collision, FRP COMPOSITES, torsion beam, Rear sub-frame, Shock absorbing crash element, Honeycomb core profile, noise and vehicle harshness