Automotive Fender Design from class A surface using NX10.0

Objective: to design the mountings for drip area, sill mounting area, a pillar, bumper, baffle, a pillar for a car fender using given master section

tools used: curve on surface,offset curve on surface,thicken,sketch,project curve,datum plane,intersecion curve,face blend ,edge blend,emboss, dart etc

Description:

The main function of fender to avoid chipping of road debris to engine compartment .fender plays a major role in pedestrian safety. The fender is the only part that connects the door, bumper, cowl, sill, baffle etc.it plays major role in frontal crash requirements,Rotating tires can throw lots of water, snow or pieces of debris while driving, so fenders help mitigate some of this matter.Fenders typically form an arch made either of plastic or metal on the side of the vehicle body, around each of the wheel cutouts

Fenders are of two types

1. Full bumper type
2. Half bumper type

1. Generally half bumper type is preferred because of less material usage and reduces blank cost and can give the customer for better price.
2. Drip area is the most important mounting as it connects to the engine compartment and plays major role in frontal crash analysis.
3. Coming to the given master section, it shows the design considerations for the drip area mounting and required dimension for creating flanges for the mounting

fender with ORVM(outside rear view mirror) mountings.

master section for designing fender

tool workability is another important criteria which enables the mechanic to esaily reach the fender drip area and can easliy mount and unmount the bolts using a turner ,generally it should be 200mm or above when hood is fully open

drip area must be at a distane of minimum 10mm from the engine room so that it wont come into contact with the engine components.

Procedure:

1. Open the given part file in NX
2. Refer the master section for the drip area flange length it should be 150mm from either sides of the fender
3. To make that flange create a offset of the fender cure to 5-6mm
4. Create a datum plane for intersection
5. Create flanges for the A pillar ,and mounting holes for bumper an baffle
6. After creating flange for the A pillar create a datum plane at a offset point of 150mm from the A pillar flange
7. Now use intersection curve and insect the fender body with the datum plane.
8. Follow the master section and create the flanges for the drip area
9. Apply dart s to add strength to the flange
10. Sketch and create the embosses at 3.5mm using end cap as a flat surface
11. To create a flat surface create a datum plane using 3points to get flat surface
12. Create embosses for all the flanges add draft more than 7degree.
13. Make sure that there are no sharp corners
14. If there any abrupt corners use bridge curve and trim them off
15. Give corner reliefs for sharp edges.
16. Finally to complete the model perform thickening operation for offset of 0.75mm.

thickened fender

bumper mounting area

drip area

A pillar mounting area

baffle mounting area

sill mounting area