Fender Design
Title : Follow the given Master section to create the Drip Area, For the Sill, Bumper, Baffle(Splash), and A-Pillar mount create your own design according to the Engineering standard that you learned.
Objective : To design Drip area, Sill, Bumper, Baffle(splash), and A-pillar mount for the given fender as per master section.
Tool used :
Curve on surface
Datum plane
Offset curve
Law extension
Trim sheet
emboss
Bridge curve
Edge Fillet
Face fillet
Sketch tools
Description : Fender
- Fender is the US english term given to the vehicle body that frames the wheel well
- Its purpose is to prevent sand, mud, liquid and other spray from being thrown into the air by the rotating tire.
- When vehicle is moving tires tend to pick up small stones and hurl them in all direction. Fenders are basically present to prevent any injuries to the pedestrians and contain the motion of these particles.
- Body mounting.
- Sill mounting.
- Cowl mounting.
- A-pillar mounting.
- Drip area mounting.
Drip area connects the fender to the engine compartment which is the most important part of the the vehicle and it also connects other parts like, the A pillar which connects the roof to the lower body, sill mount area which connects bottom part, Bumper mount which connects front part and Baffle mount area is basically part which protects the lower part of the vehicle from small debris and dust.
Design consideration for drip area :
- Front clearance to be maintended is 150mm for mounting head lamp and rear is 200mm to give proper clearnce to cawl mounting area.
- Total drip length maintained is less than 40mm to avoide spring back effect which is flange hanging loose if the length increases and also at this length the tool does its punching opeartion, so it is economical to produce part at this length.
- 3 dgrees angle is provided to flange drip area for the tool drawing opeartion during manufacturing, below this, it will be difficult in drawing the tool and slant clearance is given to hide the visibility of screws to the naked eye.
- At least 10mm clearnce is kept between the end most part of the drip area and engine room.
Steps followed for the above challenge :
As per the master section provided for the drip area, total height of the drip area is kept less than 40mm with base flange 25mm and front and rear clearance is maintained at 150mm and since the master section in not provided for the other mounting areas it is assumed as per design consideration.
- First the outer curve of the fender is offset to 5mm than with the help of curve on surface points are marked and the sheet is trimed to get proper shape of flange for all the mountings sections, A piller, sill mount, Bumper mount and Baffle mount.
- Now for drip area, a datum plane is taken on the offset curve and it is offset to 150mm from the front and rear.
- Now with the help of three point plane, sketch is done for the drip area on the selected datum plane as per the master section provided.
- With the help of law extenion tool a curve is extended to the given dimension and angle and then face fillet is provided to obtain required geometry.
- After creating the flange for the drip area emboss are created on the surface of drip area to provide stregth and to the mount and darts are provided to avoid spring back effect and it add stregth to the flange.
- Finally proper edge fillets are provided to the edges of the emboss.
Similar process is followed for the A pillar, sill mount, Bumper mount, Baffle mount.
- Datum plane is taken for the each flange.
- sketch is done for the flange on which than emboss are made and a hole cut out is left for screws.
- same opearation is repeated for the other mounting parts.
- At last proper edge fillets are provided for better surface finish.
- Finally thickness of 0.75mm is given to obtain the required body.
Thankyou