The body of an automobile is categorized according to the number of
doors, the arrangement of seats, and the roof structure. Their roofs are
conventionally supported by pillars on each side of the body in recent
times, there are convertible models with retractable fabric tops that rely
on the pillar at the side of the windshield for upper body strength, as
convertible mechanisms and glass areas are essentially nonstructural. The
glass areas have been increased for improved visibility and for aesthetic
reasons. New designs are usually programmed on three- to six-year cycles
with generally minor refinements appearing during the cycle.
Redesigning was a tough job in the past, when as much as four years of
planning and new tool purchasing was needed for a completely new design.
Computer-aided design (CAD) and computer-aided manufacturing (CAM)
techniques may now be used to reduce this time requirement by 50 percent or
more.
Sheet steel is generally used to make automotive bodies. Elements are added
to the alloy to improve its ability to be formed into deeper depressions
without wrinkling or tearing in manufacturing presses. Steel is used because
of its general availability, low cost, and good workability. Other materials
for certain other materials are also used. Other materials, such as
aluminum, fiberglass, and carbon fiber reinforced plastic are used because
of their special properties.
For more toughness and resistance to brittle deformation, Polyamide,
polyester, polystyrene, polypropylene, and ethylene plastics have been
formulated. Tooling for plastic components generally costs less and requires
less time to develop than that for steel components.
Painting and priming processes are used to protect bodies from corrosive
elements and to maintain their strength and appearance. Bodies are first
dipped in cleaning baths to remove oil and other foreign matter and then
they go through a succession of dip and spray cycles. Enamel and acrylic
lacquer are both in common use.
Electrodeposition of the sprayed paint, a process in which the paint spray
is given an electrostatic charge and then attracted to the surface by a high
voltage, helps assure that an even coat is applied and that hard-to-reach
areas are covered. To speed up the drying process in the factories, ovens
with conveyer lines are used. In those body areas that are more susceptible
to corrode, galvanized steel with a protective zinc coating and
corrosion-resistant stainless steel are used.