Fender Design
A REPORT ON FENDER DESIGN USING CATIA
Aim:To design a front fender using given skin data and master section provided with drip mounting ,A pillar,sill,Bumper and baffle points.
Theory:
The main function of fender is to prevent stones and other substances from entering the car body.While designing pedestrian safety is also considered as these stones may hit the pedestrians and may cause serious injury .Like any other automobile car body part fender also serves the purpose of hiding the engine components .The front fender is fitted in car using fasteners
Front fender consist of two types:
1.Full bumper fender
2.Half bumper fender
This is the commonly used fender in automobiles now as it reduces scrap from the raw material and is aesthetically better than full bumper type .
Manufacturing processes:
The fender is produced in two stages
1.Stage 1:Unfolding
The raw material for this operation is a cold roll.In unfolding a proper cold roll specification is selected at first,the cold roll is then unfolded .
2.Stage 2:Shearing
The unfolded cold roll obtained from stage 1 is sheared in a shearing machine to an iron plate of the corresponding size according to production requirements .
Design Parameters:
There should be no mounting provided in the 200 mm clearance marked in the photo (in the rear end of front fender )as the clearance is necessary for wiper and wiper motor mounting.
Also there should be no mounting provided in the 200 mm clearance marked in the photo(in the front end of front fender ) as the clearance is necessary for headlamp housing unit.
Master sections for the mountings:
Fender skin provided in the challenge:
Fender mountings:
1.Drip area mounting
Drip mounting connects the fender with the engine compartment and is designed considering the 150mm fender front area clearance and 200mm rear fender area clearance as explained in the design parameters.
2.A pillar mounting
Front A pillar is mounted using this mountings .Considerable fillets are provided on corners and edges for aesthetics and safety purpose
3.Sill mounting
Embosses are provided to increase strength of the mountings.The mounting is on the rear end of the fender where the wheel arch area ends
4.Bumper mounting
Fender is fitted to bumper with the help of these mountings.These mounting is provided on the front end of the fender where wheel arch area starts
5.Baffle (splash) mounting
These mountings are provided in the inner portion of wheel arch area.Holes are provided in embosses for fasteners
Result:Hence the design of Fender mountings is completed considering the design parameters and master section.0
Note:Part and stp file in zip file attached for the same.