Challenge

Fender Design

RRohith Gadale28 Mar 2023

FENDER DESIGN

Objective:-

The main objective of this project is to design a Fender of the car using a design software NX-CAD.

Introduction:

Aluminium automotive components made using a hot blow forming process are reducing vehicle weight and increasing the fuel efficiency of today's cars. However, before General Motors (GM) and the Department Of Energy(DOE) sponcered research in this technology, blow forming of aluminium was not a viarable process for automakers. The prior blow forming process called super plastic forming, was not suitable for the industries high -production -rate demands, and the materials required for SPF were too expensive three times the cost of standard, non-SPF, aluminium sheet metal. Therefore, bringing spf to the automotive industry required developing low-cost spf alloys and faster forming cycles. Reducing the cost of spf alloys also required demonstrating the variability of spf to both the automotive and aluminium industries. DOE initiated a program of joint-funded research between GM and Kaiser aluminium with the Pacific Northwest National Laboratory(PNNL) providing a catalyst to encourage GM to develop aluminium blow forming processes. Based on early research, General Motors recognized the inheritant limitations of super plastic forming and moved forword with the commercialization of an advanced blow forming process, called quick plastic forming. The result is cost effictive, higher-volume manufacturing technology that is producing lightweight components for today's automobiles with the recognition of environment, all the governments have the strict standards of the letting epilogue. so, reducing the heavy material is becoming the key of the automobile dvelopment. One of the means of reducing the heavy material of the automobile is using aluminiumalloy and magnisium alloy. Alluminium for its low density compared to steel, is the most promising material for achieving weight savings in future automotive body structure. Aluminium alloy has the larger spring back and lower plasticity all of charecters are difficulty for the stamping of complex shape of aluminium alloy car. As well known, Aluminium alloy is one of the superplastic material which have larger elongation and no spring back under superplastic state. These advantages of superplastic forming process are the possibility to realize the very complex part in one single operation and the low tooling costs. According to the capability of aluminium of aluminium alloy and the advantages of spf, a study of Finate Element Analysis of superplastically formed front fender of aluminium aluminium alloy has been carried out. Considering the cost of the formed part, a commersial alluminium alloy sheet 5182 i.e it's material properties, which are used in FEA of stamping processes of car panels, is selected as analytical materials. The front fenders of an all alluminium micro car.

Fender:

The Fender acts as a housing for the wheel and protects everything else by keeping the dirt and debries contained within the curved enclosure. This prevents the particles from spewing or damaging car parts on the car's underbody and even other vehicles driving by.

All the car tyre grip the road and turn forcefully to propel the car. But, as it does that, it also grips sand, tiny rocks, branches, and everything else, throwing it upward as it turns. That would be very damaging to the car and hazardous to other road users too.

Types of Fender:

There are two types of Fenders, They are

1. Full bumper type

2.Half bumper type

Full bumper type:

Half bumper type:

A Fender is different than a bumper because it's matel structure that frames the wheel well of car, instead of the front or back. The fender extends between the front door to the front bumper covering the front wheels of the vehicle.

Assembly:

There are two types of assembly,

1. Bottom-up assembly:

this type of modelling is a post-centric modelling method where the assembly design is started with a principal structural or functional element, and individual parts are designed in relative isolationfrom the over all assembly.

2. Top-down assembly:

In top-down assembly design , one or more fatures of a part are defined by something in an assembly, such as a layout sketch or the geometry of the another part. The design intent comes from top , which is the assembly, and move down to the parts.

Mounting regions on Fender:

There are five mounting regions on a fender; they are

A-PILLER MOUNTING
BODY MOUNTING
SILL MOUNTING
BUMPER MOUNTING
DRIP AREA MOUNTING

DESIGN METHODOLOGY

GIVEN DATA:

DESIGN OF DRIP AREA MOUNTING:

It is the important unit of the fender. It is connected with the engine compartment, Therefore the lot of design constrains to be followed while designing the fender.
While designing the drip we have to initially leave 200-300 mm for cowl top.
For placing the head lamp we have to leave atleast 150 mm at front while designing the fender
Cowl top part consists of PF Wiper motor and its instruments.

DESIGN OF SILL MOUNTING AREA:

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