Challenge

Fender Design

VVedant Meher1 Oct 2022

FENDER DESIGN

OBJECTIVE:

The main objective of the project is to design a fender using a new age design software – NX-CAD

INTRODUCTION:

The design of product start from a requirement. The design engineer sketches the product based on the requirement. Then the 2D sketch with the proper dimension is converted into the 3D model using the advanced CAD software’s. another important thing is the design is that, every product that is designed the product should be able to manufactured. So, the role of the design engineer is to design the product that can be easily manufactured and with less cost effective.

FENDER:

The main purpose of the fender is to prevent sand, mud, rocks, liquid and another road spray from being thrown in the air by the rotating tire.

TYPES OF FENDERS:

There are two types of fenders, they are

Full bumper type
Half bumper type

Presently we are using the half bumper type, the reason for choosing the half bumper type is that when we choose the full bumper types the blank used for creating it is very large and also has the lot of wastage, but in the case of the half bumper types we have possibility to reduce the scrap. This is what we called as scrap management
In half bumper types we reduce the usage of steel material and uses the lots of plastic on the bumper which in term decreases the car weight and increase the performance

FENDER WHEEL ARCH:

Fender wheel arch is having some standard specifications, for example if you see the car from the front, if you see the wheel outside fender, it dies more chipping and it causes lots of damage to the pedestrians and also to the car.
In order to maintain the pedestrian’s safety, we have to position the tire wheel inside the fender
For the European requirement the clearance between the well and the fender outer most skin is 5mm
These requirements change from country based up on the road conditions

ASSEMBLY:

There are two types of assembly, they are

Bottom-up assembly
Top-down assembly

Bottom-up assembly:

The bottom-up assembly is the most preferred approach for crating for assembly models. In these types of assembly, the components are created in part design work bench
(as NX CAD part) file. Parts are conceived in assembly design workbench using product structure tools. After inserting each compartment, constraints are applied to position them properly in the 3d space with respect to the other components. This assembly is preferred for large assemblies, especially those having intricate individual components.

Top-down assembly:

In the top assembly design approach, components are created inside the assembly design workbench. Therefore, there is no need to create separate part files of the components. This design approach is completely different from the bottom-up design approach. Here you have to create the product file first and then one by one create all the components. Note that even then the parts are created the product file, then they are saved and opened individually takes place simultaneously.

MOUNTING REGIONS ON FENDER:

There are 5 mounting regions on the fender, they are

A – pillar mounting
Body mounting
Sill mounting
Bumper mounting
Drip mounting

DESIGN METHODOLOGY:

GIVIN DATA:

DESIGN OF DRIP AREA MOUNTING:

It is the important mounting unit of the fender. It is connected with the engine compartment; therefore, the lot of design constraints are to be followed while designing the fender.
While designing the drip area we have to initially leave 200-300mm for cowl top.
For placing the headlamp, we have to leave at least 150mm at the front while designing the fender.
Cowl top part consists pf wiper motor and its instruments.

Two darts are added on the longer side of the drip area in order to provide the stiffness and adds strength to the part.
Embossing is providing on the mounting to strength them during fastening.

DESIGN OF SILL MOUNTING AREA:

Sill is the panel directly below the bottom of the door supporting the floor and may by used to combine the floor and the body. The bottom end of the fender is mounted on the sill body for reinforcement of the fender panel, thus the sill mounting position is designed with holes and emboss. M5 fasteners are used to fix the fenders on the sill body.

DESIGN OF BUMPER MOUNTING AREA:

Bumper mounting area is used to fix the plastic bumper to the fender with the help of the fasteners.

DESIGN OF A-PILLAR MOUNTING AREA:

The A-pillar is the structural pillar that combines the body to the roof. This makes the sides of the windshield rest. Front fenders are fastened to the A-pillar to from a robust structure.

DESIGN OF BAFFLE MOUNTING AREA:

Baffle mounting or mudguard are clip fit types of mounting on the inner side of the fender arch over the type. It protects the car engine compartment and pedestrians from causing injuries from chip out debris on the road when the locking clip which are made up of plastics.