Fender Design

AIM: To design a front fender of a car by following the given master section as per the design considerations of OEM.

OBJECTIVES: To design a frontal fender of half fender type of a car as per given designs mentioned in the Master Sections of the project given above based on the design considerations of Original Equipment Manufacturer (OEM). For the Sill, Bumper, Baffle(Splash), and A-Pillar mount we have created our own design according to the Engineering standard that we have learned from various sources.

DESCRIPTIONS:

Fender is the American English term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well. Its primary propose is to prevent sand, rocks, mud, liquids, and other road spray from being thrown into the air by the rotating tire. Fender are typically rigid and can be damaged by contact with the road surface. Sticky materials, such as mud, may adhere to the smooth outer tire surface, while smooth loose objects, such as stones, can be become temporarily embedded in the tread grooves as the tire rolls over the ground. These materials can be ejected from the surface of the tire at high velocity as the tire imparts kinetic energy to the attached objects. For a vehicle moving forward, the top of the tire is rotating upward and forward, and can throw objects into the air at other vehicle or pedestrians in front of the vehicle. Fender is a front outer side member of a car, which covers the wheel side. It has so many small features with ups and downs.

What is a Fender?

Fender 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.

Types of Fender:

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.

PROCEDURES:

Design:

1) Open NX-CAD OR NX-12.

2) Go to Files ->Open ->Select the file "Fender_Skin.prt"

3) Select the lines from the intersecting surfaces to create offsets using Offset Curves in Face.

4) Then create curves intersecting the offset curves and edges with Curve on Surface.

5) Then with the intersecting curves and offsets curves, use Trim Sheet command to get the cutout areas for mountings.

6) Through the cutouts, we create the mountings namely, drip, body sill, etc. through Law Extensions and Extend Sheet.

7) In that mountings, emboss, face blend, edge blends, and holes are done as per given master section.

8) The holes in the mountings are done through sketches made on the surface of the mountings.

9) Then the sill mounting is given with Darts, with equal and equidistant dimensions.

10) The design calculations for the drip mountings extensions are given below.

Calculations:

cos(45)=3/H

H=3/cos(45)

H=4.24mm

P=H*sin(45)

P=3*tan(45)

P=3mm

cos(15)=2/h

h=2/cos(15)

h=2.0705mm

p=h*sin(15)

p=2*tan(15)

p=0.536mm

Therefore, upper part(U)=5-(3+0.53)=1.46mm

OUTPUTS:

3D Model:

Navigator Tree Structure:

INFERENCE:

Thus, all mounting areas for the fender designed from skin data and master section is done by following all design rules. The design was completed and it's .prt file was attached below.