Fender Design

Aim:

To design Drip Area, Bumper, Baffle, Sill, and A-Pillar mount for Fender.

Procedure:

1. Surface Check:
   
   
   
   1. First, we will check the surface quality by checking for surface defects or gaps between the surfaces.
   2. In our case our reference surface has one surface with wrinkles and one surface with a gap issue.
   3. To cure this issue first we will make our Class-A surface by Extracting the given Top surface and all the flange except the defective surface. (don’t extract fillet as it also gives problems)
   4. Now we will join all the top surfaces.
   5. We will get a connexity error, meaning there is no continuity in surfaces, i.e. the gap between surfaces.
   6. We will delete this surface and we will create our surface using the blend command.
   7. After creating this surface, we will join all surfaces which will make our top surface.
   8. We will use the same procedure as above for the flange’s bad surface but here we will use a multi-section surface instead of the blend to get more surface curvature control.
   9. After joining all the surfaces in the flange, we will use a shape fillet to create the fillet between the top and flange surfaces.
   10. We will give a 5 mm fillet so that there will not be any problem while thickening the surface.
   11. Now we will proceed over to drip area design.
2. Drip Area Mount:
   
   Drip Area
   
   1. First we will use the border lines of the fillet we made before as a reference line to trim the extra flange surface and offset it below by 5mm using the parallel curve command.
   2. As shown in the Master Section of the drip area, we need to give 200mm clearance from A-pillar and 150 mm clearance from the headlight for their mounting.
   3. Now we do not want sharp cut-outs so we will use a spline to give edge relief to the cut-out.
   4. We will split the surface with a curve to trim out the unwanted surface.
   5. Now to create a surface with a 45-degree angle we will use sweep with the reference surface.
   6. We will use sweep with draft direction and use Y Component as draft direction to create a vertical surface with a 5-degree angle.
   7. We will adjust the surface's length by checking the surface's distance from the top surface border, which should be under 40mm.
   8. Similarly, we will use a sweep with a reference surface to create a flat surface for embossing and mounting holes.
   9. To create emboss, we first have to create a tooling axis.
   10. To create a tooling axis, first, we will create a plane by the three-point method in which three points can be any of the three points on the edge of the sweep surface.
   11. Now we will create the line by normal to surface method in line command and we will use this plane as reference.
   12. After creating the tooling axis, we will offset the plane we created by 6 mm below the surface.
   13. Now to create a flat surface for mounting emboss we will create a rectangle in a sketch on the offset plane.
   14. We will create a surface in the rectangle by using the fill command.
   15. We will use sweep with draft direction using the tooling axis as a reference.
   16. Sweep should be more than 7 degrees to clear the tool properly.
   17. After this, we will proceed further to create other mountings.
3. Sill, Baffle, Bumper, and A-Pillar mountings
   
   Bumper Mounting
   
   Baffle Mounting
   
   Sill Mounting
   
   A-Piller Mounting
   
   1. Trim procedure will be the same procedure as we did for the drip area.
   2. After trimming, for Bumper and A-Pillar mounting, we will use a 90-degree sweep and for Sill and Baffle, we will simply extrapolate the surface.
   3. We will same procedure of drip area for all the mounting embosses.