Fender Design
FENDER:
It is an aesthetic component/part of a car that frames the wheels. Prevention of sand, mud particles, and other road contaminants from being thrown into the engine compartment and also to the pedestrians by the rotating tires are the main purpose served by the fenders.The front fenders are separate components whereas the rear fenders are integrated with the body sides.
MANUFACTURING PROCESS:
Stamping — also called pressing — involves placing flat sheet metal, in either coil or blank form, into a stamping press. In the press, a tool and die surface form the metal into the desired shape. Punching, blanking, bending, coining, embossing, and flanging are all stamping techniques used to shape the metal.
TWO TYPES OF FENDERS:
1)FULL BUMPER TYPE:
These types of fenders were used in earlier models of vehicles. They contribute to the major increment of the steel weight by just covering the front headlights with respect to the bumper region. The problem associated with this kind of fender is there is a lot of wastage in the blank and every inch of a material is a cost to the industry.
2)HALF BUMPER TYPE:
These fenders are mainly used for serving the purpose of cost-cutting and reducing enough proportions of the steel wait resulting in a reduction of the weight of the vehicle slightly. They can be economically manufactured, i.e by slightly increasing the blank size, we can produce two fenders at a time.
MASTER SECTION:
FENDER MOUNTING REGIONS ARE:
1)A- pillar mounting
2)Body mounting
3)Sill mounting
4)Bumper mounting
5)Drip mounting
The following image represented the fixing location of the fender,
1)DRIP AREA:
Created the offset curve in face to move edge for 5mm.The 3degree line is already presented in the given input so i need to create it.Next use law extension command to create the next surface of length 8mm and angle as 40degree.Next I created the surface following the angle as 5degree and the length of the surface should lie 40mm or less than 40mm.Next create a law extension of 25mm following the angle as 0degree.we need to create a drat to provide reinforcement.so i created the drats in the necessary location.Now to create the 45degree line of length 4.24mm(These values are calculated using Pythagoras theorem).create another flat surface of length 1mm at 0degree.Finally create the 2.5mm length surface at an angle 15degree.Also create face blends following mastersection.Also create the sketch for mounting fastners.Use emboss command with datum plane option so we will get flat surface finish.
Sketch of Emboss and Hole creation
Drats
2)A PILLAR AREA:
Use offset curve command and create shape by using points .Then the unnecessary surfaces.Now use law extension command at angle of 0degree.To make the surface normal create a line and project it on that surface and use trim sheet as well.Now extend the surface,also create a sketch and project it on the required surface.Create Datum plane and use emboss command and cut that with datum plane for flat surface for the mounting of the fender.Also create drats to increase the strength of the sheet.
Drats
Sketch of Emboss and Hole creation
3)BAFFLE MOUNTING:
Make a offset curve first for the locations and trim the extra regions.Just use law extension command and create a sketch.Just we need to make a hole on the surface.After sketch creation project it on the required surface and trim that as well.Here i created three baffle mounting areas.
Sketchs of Emboss and Hole creation
Position1:
Position 2:
Position 3:
4)SILL AREA:
Use law extension to extend the surface.Create sketch and draw a holes for mounting the fender.Project it on the required surface and trim them.
Sketch of Emboss and Hole creation
5)BODY AREA:
In this area the door hinge will be placed and that need to perfect.so we are not created the fender mounting on this area.
Final Output:
Finally Thicken the model for 0.75mm.Important note is that Fender should not contain any sharp edges and radius of 3.75mm or above should be followed for blends.All the Sketches should be Fully constrained .