Fender Design

Aim:

Design a front fender from the given skin data and the master section provided with Drip mounting, A-pillar, Sill, Bumper and Baffle (splash) Mounts.

Introduction:

Fender:

From the front bumper to the car door, a tyre fender is a piece of rubber, metal, or plastic that bends over the wheel on the side of the vehicle. Car fenders serve the primary purpose of keeping tyres and braking systems cleaner and safer by shielding them from dirt and other debris.

The wing is the term used for the fender in British English. The wing is referred to as a mudguard in contemporary English usage in Sri Lanka and India.

Car fenders are classified into two categories: front and rear car fenders.

The other classification is on full and half bumper. Size is the primary distinction between full and half bumper styles. Half bumper fenders may create two fenders per blank, however full bumper fenders are limited to making one. Automobile efficiency may be increased by the lighter half-bumper style fenders. Compared to half-bumper type fenders, full-bumper type fenders require more raw materials and this increases the economy of the half-bumper.

Manufacturing process:

Automobile fenders are made using a variety of techniques:

1. Stamping:

• This is a typical process for making car components like hubcaps and fenders.

• Metal is cut and formed into a variety of shapes using a stamping press and a set of dies.

2. Three-Step Stamping:

• This method aims to cut down on the number of dies and tooling costs.

• Through the use of many compound structures, the fender's die quantity is decreased from four steps to three steps.

• The process plan is ultimately an industrialized application, with the side flanging and side piercing, the side restriking and side piercing, all arranged in the same step.

3. Manufacturing Process for Car Fender:

• There are various steps in this process:

1. The process begins with unfolding and shearing the cold roll on a plate. First, a suitable cold roll specification is chosen. Next, the cold roll is unfolded, and lastly, it is sheared to an iron plate of the appropriate size according to production material specifications.

2. The next step involves oil pressing and punching, which involves first extending the iron plate, followed by side shearing and punching, folding and shaping, and lastly reshaping the iron plate.

3. The iron plate is machined in small initial portions of the fender. Initially, the iron plate is punched to the required outside contour blank, which is then further formed. Finally, the iron plate is punched.

4. The last step involves the installation and welding of a metal plate.

4. Injection Molding:

• Plastic automobile fenders are made using this method.

• Plasticization, heating, injection of molten plastic, clamping pressures, operation of auxiliary devices, and mould movements/part ejection all require energy.

Every one of these techniques has benefits of its own and is selected according to the particular needs of the fender design and the materials being utilized.

Designing Fender in Siemens NX:

Front fender skin design:

The flanges in the curves are a bit longer than required. So, the “Offset curve in Face” tool is used to create a cure 5mm below the top of the flanges.

The “Curve on Surface” tool is used to draw the required smooth curves on the sheet and the unnecessary flanges are trimmed off using the “Trim sheet “ tool.

Create Fender’s drip area mount:

• So when the drip area mount is designed, the curves are drawn keeping in mind the headlight fittings requirement of 150mm of space from the front end and 150mm from the back end.

• To prevent the spring-back effect, the drip area is kept between 40 and 60 mm deep.

• The given Master section is used to create the Drip Area.

• The “ Law Extension” tool is used multiple times from the flanges of the fender to create the Drip area mount sheets as per the master section provided.

• Face blend is used to provide the fillet curves at the edges, except for the edge the Darts going to provide.

• Sew tool is used to join the edge where the Dart was going to be provided.

• Two Darts (a thin metal ridge that serves as reinforcement on a part's flange) were created at that edge at a distance to divide the surface into three.

• The “Sketch“ tool is used to create the sketch of the mounting area and the holes of 5mm diameter.

• The “Project curve” is used to project the mounting area sketch to the surface.

• The datum plan is created using the curves and point option to create a flat bottom Emboss.

• Emboss is used to create the mounting area of a depth of 3.5mm.

• Protect the 5mm diameter holes to the flat surface of the embosses.

• The “Trim Sheet” is used to trim off the holes from the emboss.

• The Edge blend is used to provide fillet to Darted edges and the embosses.

Create Fender’s A-pillar mount area:

• The “Law Extension” tool is used to create the horizontal flange sheet.

• Use “Curve on Surface” to create a line and trim the side of the extension to avoid errors due to complex shapes using the “Trim sheet” tool.

• “ Face blend” is used to create the fillet at the edge.

• “Bride curve” is used to create a curve at the fillet to make the corner smooth and curvy.

• “Trim sheet” to trim the unnecessary fillet edges.

• “Offset in face” is used to create the shape of the A-pillar mount from the edges.

• “Datum plane” is used to create a flat bottom Emboss.

• “Emboss” is used to create the A-pillar mount from the sketch with a depth of 4mm.

• “Sketch” the 5mm hole.

• The “Project Curve” tool is used to project the hole’s sketch on the flat embossed surface.

• The “Trim Sheet” is used to trim off the holes from the emboss.

• The “Edge blend” is used to provide fillet emboss.

• “Bridge Curve” is used to create curses on the sharp corners and to trim it off using the “Trim sheet”.

Create Fender’s Bumper mount area:

• The “Law Extension” tool is used to create the horizontal flange sheet.

• Use “Curve on Surface” to create a line and trim the side of the extension using the “Trim sheet” tool.

• The “Sketch“ tool is used to create the sketch of the mounting area and the holes of 5mm diameter.

• The “Project curve” is used to project the mounting area sketch to the surface.

• “Datum plane” is used to create a flat bottom Emboss.

• Emboss is used to create the mounting area of a depth of 5mm.

• The “Project Curve” tool is used to project the hole’s sketch on the flat embossed surface.

• The “Trim Sheet” is used to trim off the holes from the emboss.

• “Face blend” is used to provide the fillet to the edge.

• The “Edge blend” is used to provide fillet emboss.

• “Bridge Curve” is used to create curses on the sharp corners and to trim it off using the “Trim sheet”.

Create Fender’s Splash and Spill mount area:

Both have the same procedure but the differences are only in the positions and some dimensioning.

• The “Law Extension” tool is used to create the vertical flange sheet.

• The “Sew” tool is used to join the edge.

• The “Sketch“ tool is used to create the sketch of the mounting area and the holes of 5mm diameter.

• The “Project curve” is used to project the mounting area sketch to the surface.

• “Datum plane” is used to create a flat bottom Emboss.

• Emboss is used to create the mounting area.

• The “Edge blend” is used to provide fillet emboss.

• “Bridge Curve” is used to create curses on the sharp corners and to trim it off using the “Trim sheet”.

• The “Project Curve” tool is used to project the hole’s sketch on the flat embossed surface.

• The “Trim Sheet” is used to trim off the holes from the emboss.

Conclusion:

Using the provided skin data and the master section's drip mounting, you designed a front fender. You also used your own design to create A-pillar, Sill, Bumper, and Baffle (splash) Mounts in accordance with the engineering standard you studied.