Fender Design Challenge

FENDER DESIGN (NX)

What is fender:-

• Fender on a car are panel that extend from the bumper to the car's door.
• Primary purpose of fender is to avoid sand, mud, rock, water or any other particle to be thrown be the wheel.
• Fender avoids motion of the rocks which can be hit the pedestrains.

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 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 fender at the same time by slightly increare the raw sheet. and to reduce the weight & cost mostly bumper fender are been produced.

Design:

Sheet thickness: 0.75mm

STYLING DATA:

There are 5 mounting area in a fender:
1. Drip area
2. Sill Mounting
3. Bumper mounting
4. A-piller mounting
5. Splash cover mounting

DRIP AREA

• It is the area which the fender is to be attached to engine housing through bolts. There are some standards to design the drip area, from the backside of the fender there should be 200mm clearence for cowl mounting and from the front the side the clearence should be 150mm for the head lamp.
• Considering the above design wen have to design emboss, holes to attach the fender to housing & some stiffners to provide strength to the drip area.
• Engine components should not be visible from outside for this we have purposely given 3 degree of angle and 9mm length is given.

DATA GIVEN FOR DRIP AREA

SILL MOUNTING

This mounting is use to link the fender with the sill (underside of the door) of the car. Emboss & holes are given to attach the fender to sill.

BUMPER MOUNTING

A mounting area of the fender to bumper. Bumpers are usually made of plastic which covers the front of the car & protect it at time collisions. Emboss & holes are given to attach the fender to Bumper.

A-PILLAR MOUNTING

The mounting of this area is a joint where we have to ensur that the hole provided for mounting the fender shouldn't affect the clearence at the joint and the aesthethics of the vehicle.
and also provideing the single hole to redure the complexity while mounting.

SPLASH COVER MOUNTING

There are additional holes are provided to support the fender lining. it is a Plastic which is used as a barrier between fender & outside particles, dust, rocks. Plastic cover is used to protect the dust & rock and it is mounted on Fender via Trim clips.

Splash cover Trim clips

MANUFACTURING PROCESS:-

A car Fender bumper is made by a process called reaction injection molding (RIM), which basically consists of making a special polyurethane compound and introducing it into a large fender. RIM is a process that conserves raw materials and reduces costs. It is similar to injection molding except thermosetting polymers are used, which requires a curing reaction to occur within the mold. Common items made via RIM include automotive bumpers, air spoilers, and fenders.

DRAFT ANALYSIS:-

Once the design was ready, the Fender was anaylzed for manufacturability. here draft analysis shows that all parts are clearing when core is removed from cavity.

FINAL FENDER DESIGN

ISOMETRIC VIEW

FRONT VIEW

CONCLUSION:

Fender Design in completed by using UG NX. and satisfying all the requirments with the given data.