Challenge

Fender Design

For the Sill, Bumper, Baffle(Splash), and A-Pillar mount create your own design according to the Engineering standard that you learned.

Prepare a report with all the relevant images included for the mounting points created.

INTRODUCTION :

Design of any product starts from an requirement . The design engineer sketches the product based on the the requirement . Then the 2D sketch with the proper dimensions is converted into the 3D model using the advanced CAD software's . The another important thing in the design is that , every product that is designed 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 . This is the place where the Design for manufacturing [DFM] and Design of assembly [DFA] takes a role while developing any product . The process of development of design carries on until the design satisfies the customer needs .Here in this project the product that we are going to develop is a car fender

Fender:

A fender is the curved part of the car's body that sits over and houses the wheels.
The function of the wheel arch is to protect from mud, and stone and during accidents help pedestrians and consider wrap-around distance for head impact.

Types of Fenders:

They are two types of fenders

Full Bumper types:

This style of bumper was present on earlier models of vehicles but is not currently manufactured. It will cover the area from the side door to the car's headlight.

Half Bumper types:

This type of bumper is used in modern day because of the reduced raw material wastage, reduction in car weight to improve performance and manufacturing cost is low compared to full bumper type.

Design Parameter:

Types of mounts in Fender:

Drip Mounting Area:

The drip area would be recognizable fom the opening between Hood and Fender.
This mounting is attached to the engine compartment of the car.
A min 150mm distance is kept from the front side and a distance 300mm or less can be kept on the rear side .
This is to avoid the springback during the manufacturing . the edge of the mounting should atleast 10mm away from any nearby component in the engine.
The drip area should be less than 40mm.
The embosess that are created on the drip mounting should be flat with respect to the curvature.
A dart is provided at the edge of the drip mounting to increase the stiffness.

Sill Mounting Area:

This is palced basically at the botom of the fender. The mounting part is created such that it firmly fits to the sill.
The embosess that are created on the drip mounting should be flat with respect to the curvature.

A-Pillar Mounting Area:

A-pillar mounting is a vertical support on a vehicle. It holds the windshield set up and just downside to the A-pillar fender is mounted to hold the position.

Bumper Mounting Area:

It is placed at the front side of the fender,the bumper mount area of fender, mounts on the chassis to hold the position.
Since Bumpers are mounted over the fender it is called Bumper Mounting Area.

Baffle or Linear Mounting Area:

Usually a baffle is mounted on the fender of the car . It is mounted on the wheel arch area .
A plastic unit is placed which is called baffle/splash fender linear mounting is placed.
These mountings are created for fixing the baffle/splash mounting.

Manufacturing process:

Embossing:

Embossing is the process of giving a 3-dimensional look to a material or product. Pressure is applied to the surface of the material and results in an image will project on the surface of the material. ‘Relief’ is another term used to encompass the process of embossing.

Bending:

It involves applying for to the sheet metal workpiece to produce a curvature. In generally bending are used to produce simple curvature surface instead of complex. Amount of pressure is important to change the sheet metal surface into the given shape.

Drill:

Drilling a hole in sheet metal with a twist drill is a rather straightforward operation. You start off by drilling a small diameter pilot hole, and then drill gradually larger holes until you get to the size you need.

Conclusion:

Fender design is done using NX Siemens software and design has been created under given parameters.

Ship work like this
in your own course.