The motor vehicle

1225 Pages·2001·130.84 MB·English

by  T K Garrett

The Motor Vehicle
This Page Intentionally Left Blank
The Motor Vehicle
Thirteenth Edition
T.K. GARRETT
CEng, FIMechE, MRAeS
Sometime Editor of Automobile Engineer
If,. NEWTON
MC, BSc, ACGI, AMInstCE, MIMechE
Late Assistant Professor, Mechanical and Electrical Engineering Department,
The Royal Military College of Xcience
W. STEEDS
OBE, BSc, ACGI, FIMechE
Late Professor of Mechanical Engineering,
The Royal Military College of Xcience

~ U T T E RWO RTH
i~IE I N E M A N N
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI
Butterworth-Heinemann
Linacre House, Jordan Hill, Oxford OX2 8DP
225 Wildwood Avenue, Woburn, MA 08101-2041
A division of Reed Educational and Professional Publishing Ltd
-~A member of the Reed Elsevier plc group
First published by Iliffe & Sons 1929
Eighth edition 1966
Ninth edition 1972
Tenth edition published by Butterworths 1983
Eleventh edition 1989
Twelfth edition 1996
Reprinted 1997
Thirteenth edition 2001
(cid:14)9 Reed Educational and Professional Publishing Ltd 2001
All rights reserved. No part of this publication may be reproduced in any material
form (including photocopying or storing in any medium by electronic means and
whether or not transiently or incidentally to some other use of this publication)
without the written permission of the copyright holder except in accordance with the
provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a
licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Rd,
London, England W 1P 9HE. Applications for the copyright holder s written
permission to reproduce any part of this publication should be addressed
to the publishers.
British Library Cataloguing in Publication Data
A catalogue record for this book is av ailable from the British Library.
Liblary of Coagrn~ OItalagi~ in l~bHeatio, l)ala
A catalogue record for this book is available from the Library
ISBN 07506 4449 4
Typeset by Replika Press Pvt Ltd, Delhi 110 040 (India)
Printed Great Britain by Clays Ltd, St. Ives plc
DLANT A
FOR EVERY TITLE THAT WE PUBLISH, BUTTERWORTH-HEINEMANN
WILL PAY FOR BTCV TO PLANT AND CARE FOR A TREE.
Contents
Preface to the thirteenth edition vii
Units and abbreviations ix
Part 1 The Engine
1 General principles of heat engines 3
2 Engine balance 25
3 Constructional details of the engine 47
4 Six-, eight- and twelve-cylinder engines 137
5 Sleeve valve and special engines 177
6 Diesel injection equipment and systems 186
7 Distributor type injection pumps 252
8 Some representative diesel engines 311
9 The two-stroke engine 326
10 Fundamentals of carburation 349
11 Some representative carburettors 385
12 Petrol injection systems 424
13 Induction manifold design 479
14 Emission control 516
15 Fuel pumps and engine intake air conditioning 549
16 Turbocharging and supercharging 556
17 Fuels and their combustion 590
18 Friction, lubricants and lubrication 619
19 Engine cooling 641
20 Electric propulsion 655
21 Alternative power units 669
22 Bearings, gearing, chains and belt drives 698
Part 2 Transmission
23 Transmission requirements 709
24 Clutches 720
25 Why is a gearbox necessary? 750
26 Constructional arrangements of gearboxes 760
27 Epicyclic and pre-selector gearboxes 792
28 Torque converters and automatic gearboxes 806
vi Contents
29 Semi-automatic gearboxes and continuously variable
transmissions 841
30 Universal joints and driving steered wheels 864
31 The differential 876
32 The back axle 892
33 Axle constructions 900
34 The double reduction axle 907
Part 3 The Carriage Unit
35 The basic structure 915
36 Vehicle safety 924
37 Brakes 956
38 Servo, power operated, and regenerative braking systems 983
39 Anti-lock brakes and traction control 1015
40 Front axle and steering mechanism 1043
41 Wheels and tyres 1085
42 Suspension principles 1109
43 Suspension systems 1144
44 Six-wheel vehicles 1177
Index 1191
Preface to the 13th edition
Because of the continuing phenomenally rapid rate of progress in automotive
technology, the revision for this the 13th edition of The Motor Vehicle has
been on a major scale. No fewer than seven new chapters have been created.
Of these, three are entirely new, while the remaining four comprise mainly
new material that could not have been accommodated in existing chapters
without making them too long and cumbersome.
Of the entirely new chapters, one is on electric propulsion which, owing
to pressure of legislation is now beginning to be taken seriously by the
industry. It covers all the alternatives, from conventional lead-acid, and other,
battery-powered vehicles to fuel cells and hybrid power units. A second
covers both static and dynamic safety which, again because of pressure of
legislation, is a field in which enormous progress has been made. This progress,
which embraces almost all aspects of automotive design, has become possible
largely because of the development of computer aided control. The third of
these entirely new chapters deals with wheels and tyres. Over the past few
decades, wheels and especially tyres have moved on, from being simply
components that the designer chose largely on the basis of dimensional and
commercial considerations, to becoming an integral part of the tuned suspension

system.
In the 12th edition, only one chapter was devoted to the compression
ignition engine. Now, owing to a major extent to the widespread application
of diesel power to cars and light commercial vehicles, so much new equipment
has been developed that it has now been expanded into three chapters. One
of these comprises mainly the original subject matter, while the other two
contain a considerable amount of new information on aspects such as common
rail injection, recently developed distributor type pumps, and electronic control
of injection.
Two chapters now cover automatic, semi-automatic and continuously
variable transmissions. These contain some of the original material but also
information on the Porsche Tiptronic and Alfa Romeo Selespeed semi-automatic
transmissions, the latter being basically the Magneti Marelli system. Chapter
39 has been added to contain much of the original material on anti-lock
brakes together with new information on some of the latest developments for
improving stability by means of computer aided control over both braking
and traction. In the next chapter, a significant amount of space is devoted to
both the basic considerations and the practice of electrically actuated power-
assisted steering, which now looks set ultimately to render hydraulic power
assistance systems redundant.
In addition to the introduction of new chapters, many of the original ones
have new sections coveting recent developments such as hydraulically damped
vii
viii Preface to the 13th edition
engine mountings, which are desirable refinements for some vehicles, especially
diesel powered cars. New material has been added on the subject of fuel
filtration. Particularly interesting are the latest developments of the Merritt
engine. By virtue of its recently developed novel ignition system, it can fire
consistently from a b.m.e.p of 10 bar fight down to idling speed on air : fuel
ratios ranging from 30" 1 to 137"1 respectively. Moreover, it might be
possible even to dispense altogether with catalytic conversion of the exhaust
gases, while still keeping within the stringent emission limits under
consideration at the time of writing.
Most of the remarkable advances made, especially those over the past ten
to fifteen years, have been rendered practicable by virtue of the application
of electronic and computer technology to all aspects of automotive engineering,
from design, through development, to production and actual operation of the
vehicle. Many have been driven by new legislation aimed at increasing safety
and reducing atmospheric and other pollution.
In general, the two original aims of the book have been maintained. In
short, it remains, as the authors originally intended. First, it was intended to
be a book that the student could buy that will furnish him or her with all they
need to know, as regards automotive engineering; secondly, it will then serve
as an invaluable a work of reference throughout the rest of their career.
Granted, many students will require knowledge of other peripheral, though
no less essential, subjects such as electronics, metallurgy, and production
engineering, but these are aspects of general engineering that fall outside the
sphere of pure automotive technology. Some details of, for example, electronic
systems are given in this book, but it has had to be assumed that readers who
are interested in them already have some knowledge of the relevant basic
principles.
T.K. Garrett
Units and abbreviations
Calorific value kilojoules per kilogram kJ/kg
megajoules per litre MJ/1
Specific fuel kilograms per kilowatt hour kg/kWh
consumption
Length millimetres, metres, kilometres mm, m, km
Mass kilograms, grams kg, g
Time seconds, minutes, hours s, min, h
Speed centimetres per second, metres per second cm/s, m/s
kilometres per hour, miles per hour km/h, mph
Acceleration metres-per-second per second m/s 2
Force newtons, kilonewtons N, kN
Moment newton-metres Nm
Work joules J
Power horsepower, watts, kilowatts hp, W, kW

Pressure newtons per square metre N/m 2
kilonewtons per square metre kN/m 2
Angles radians rad
Angular speed radians per second rad/s
radians-per-second per second rad/s 2
revolutions per minute rev/min
revolutions per second rev/s
SI units and the old British units:
Length 1 m = 3.281 ft 1 ft = 0.3048 m
1 km = 0.621 mile 1 mile = 1.609 km
Speed 1 m/s = 3.281 ft/s 1 ft/s = 0.305 m/s
1 km/h = 0.621 mph 1 mph = 1.61 km/h
Acceleration 1 m/s2= 3.281 ft/s 2 1 ft/s 2 = 0.305 m/s 2
Mass 1 kg = 2.205 lb 1 lb = 0.454 kg
Force 1 N = 1 kg m/s 2 = 0.225 lbf 1 lbf = 4.448 N
Torque 1 Nm = 0.738 lbf ft 1 lbf ft = 1.356 Nm
/x