Fender Design Challenge
Aim: To design fender by following Class A surface and Master sections using NX Cad software
Fender:
A fender is a part of an automobile that frames a wheel well (Fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road sprays from being thrown into the air by the rotating tire. The fender's openings for the wheel wells tend to be much larger than the diameter of the tire because they do not move with the tire suspension and consequently must be large enough to allow the full range of tire motion on the suspension without touching the interior of the wheel well.
Fender Types:
Full Face Fender: This fender is large in size extends upto the bumper on the front side of vehicle and there is cutout of headlight on it.
Half Fender type: This fender is small size and are most commonly used nowdays,It uses less material to manufacture and scrap is also less it is designed is such a way that from one operation we get two split peices other one can be used in the opposite side if vehclie reducing scrap cost to minimum
Design of Fender:
After getting the Class A surface from CAS Team first we check for wheel arch regulations whether they follow the regions guidelines for passanger safetywe give our feedback to CAS team then we proceed with creating engineering features on Class A surface received.
Engineering featurs Required:
1. Drip Area Mounting
2. Bumper Mounting
3. A-Pillar Mounting
4. Sill Mounting
5. Splash Cover Mounting
So we need to provide the moutings to fender for that first we need to create master section at each mounting area we have some guidelines to be followed for the optimum design of fender which are mentioned below:
After Creating the master section we create the surfaces following master section guidelines
CAD Construction:
Class A surface as input
Now will create Drip mounting Surface as per master section
We need to make sure mountings provided are on the plane surfaces so that during assembly there should not be any play between components and as the draw is more for the mounting surface then to increase strength we have given darts which will prevent part from bending and provide stiffness
A Pillar Mounting
Bumper Mounting
Sill Mounting
Splash Cpver Mountings
After Creating flanges for mounting surfaces we need to make sure our part is free from sharp edged and fillet flow is smooth so that there are no any stsmping defects over the part
Manufacturing Aspects:
Fender is manufactured by stamping process(sheet metal) both LH & RH are made in single stamping operation. If the material of fender is plastic then it is made by injection molding process and as it is Class A surface and plays very important role in deciding aesthics of the vehicle and also have vital role in padesrtian safety.
Embossing:
Sheet metal embossing is a stamping process for producing raised or sunken designs or relief in sheet metal. This process can be made by means of matched male and female roller dies, or by passing a sheet or a strip of metal between rolls of the desired pattern. It is often combined with foil stamping to create a shiny, 3D effect.The metal sheet embossing operation is commonly accomplished with a combination of heat and pressure on the sheet metal, depending on what type of embossing is required
Final Part model
Orthographic Views:
