Fender Design Challenge

BIW DESIGNING OF THE FRONT FENDER OF A CAR WITH ITS MOUNTINGS

OBJECTIVE:

The objective of the project is to design a Body in the White front Fender of a car with its mountings using the information provided by the styling team. The Skin data and Master sketch are the information provided by the styling team.

INTRODUCTION:

Fender is the American English term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well. Its primary purpose is to prevent sand, mud, rocks, liquids, and other roads spray from being thrown into the air by the rotating tire. Fenders 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 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 vehicles 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.

The Importance of Car Fenders:

• Fenders are an intricate sheet of metal covering the wheel well of your car.
• Fenders are designed in a manner to provide resistance against wind and other roadside debris.
• When you travel on rough terrains your vehicle might get minor scratches and dents which look no better. Frequent road bumps can cause your car's paint to chip off which needs a paint job done.
• The car fenders are located on either side of the front and rear wheels. The front car fenders begin where the front door hinges run and end just before the bumper. The rear car fenders begin where the back doors close and terminate before the back bumpers.

There are two types of Fenders:

• Full bumper type
• Half bumper type

FULL BUMPER TYPE:-

Full bumper fender is not used nowadays because they required a bigger size blank to produce the part & waste material is also there while manufacturing.

HALF BUMPER TYPE:-

Half bumper fender is used because the waste of material is less & can produce two fenders at the same time by slightly increase the raw sheet. and to reduce the weight & cost mostly bumper fender are been produced.

SKIN DATA AND MASTER SKETCH:-

DESIGNING THE A-PILLAR:-

• First, the skin data provided by the styling team needs to be extracted.
• Then the outer edge of the fender was offset inwards to a particular length.
• Then by using the curve on surface command the unwanted portions were trimmed out using the trim sheet.
• By using the law extension the A-Pillar was extended and trimmed on the sides to get a flat edge.
• For creating a flat emboss which was used to mount the fender with the A-Pillar a datum plane was created.
• Then the required sketch was drawn on the datum plane and projected to the surface.
• Then for creating a fastener hole which needs to be around a 5mm gap around it, the trim surface command was used.
• Then the required blends were added using face blend and edge blend.

DESIGNING THE BUMPER MOUNTING:-

• The unwanted portions were trimmed off using Curve on surface and Trim surface command.
• Then for creating a flat-surfaced Emboss a datum plane was created.
• Then the required sketch drawn on the datum plane was projected to the surface and the required emboss was created.
• The holes were trimmed by using a trim sheet after creating emboss.
• Emboss was created with a draft so that it satisfies the manufacturing requirements.
• Finally, the required blends were applied.

DESIGNING THE COWL MOUNTING:-

• The cowl mounting was designed to fit a splash mounting on it which helps the engine compartment to protect it from the debris that entering into it while driving.
• For creating it three mounting areas were created with the required holes on it for the fasteners.
• For creating the holes a datum plane was created on all three mountings and projected onto the surface.
• By selecting the required vector and deselecting the ‘project on both’ side option the holes were created.

DESIGNING THE DRIP MOUNTING:-

• By using the information in the master section provided the drip mounting was created.
• The drip area must be a minimum of 150mm apart from the front edge so that the drip mounting won't disturb the headlamp mountings.
• From backward the drip area must be 200mm apart from the back edge to avoid the coincidence with the engine cables.
• For creating the drip area at the required distance two planes were created and then the intersection curve was used to create the curve on the surface as required.
• Then the remaining unwanted portions were trimmed out.
• The design takes a vital role in avoiding the human eye from seeing the insides of the car through the gap between the hood and fender.
• So the drip area was created in a particular angle as required in the master section.
• After creating the law extension as required by the master section the required emboss was created.
• For creating emboss a datum plane was generated and the sketch drawn in it was projected and the emboss feature were applied.
• Then for creating the fastener holes the trim sheet options were used.
• Then the required blends were created for improving the aesthetic of the fender.
• Since the drip area was longer without any support it increases the NVH while driving, so to reduce the NVH effect while driving the drip area must be strengthened.
• So to increase the stiffness of the drip area a DART was produced on its center.

DESIGNING THE SILL MOUNTING:-

• For creating the Sill Mounting the extra portions were trimmed out.
• Then the datum was created and the required sketch was drawn and then projected.
• Then emboss was generated and blended the edges together.
• The fastener holes were created by using the trim surface feature.

SOME VIEWS OF THE FENDER:-

CONCLUSION:

Hence the fender designed by the given class-A surface. Designed With proper mountings and angles for manufacturability and tools workability.