Fender Design Challenge
FRONT FENDER DESIGN
AIM
The objective of this challenge is to create the design of the front fender from the given fender skin data using NX-CAD.
THEORY
FENDER:
Fender is the US English term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well (the fender underside). 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. Fenders are present at both front and rear sides. Fenders are manufactured as separate parts then mounted on vehicles.
TYPES
- FULL BUMPER TYPE
The full bumper type is the traditional type of fender where more material consumption is observed. This type of design of automobiles where it increases the overall weight and thus reduces performance. The maintenance is also relatively more due to more surface.
- HALF BUMPER TYPE
Half bumper type is the modern type of fender where less material consumption is observed, so productivity increases by reducing the size of the blank and thus providing more performance. The maintenance is also relatively low compared to the full bumper type. Only one full bumper can be produced from one sheet but two half bumper can be produced from one sheet so we can scrap.
DESIGN CONSIDERATIONS
MASTER SECTION
DESIGN METHODOLOGY
- MOUNTING REGIONS
- Drip area mounting.
It is the most important mounting region in the Front fender because this is the portion that attaches to the engine compartment. The vertical height of this drip area should not exceed 40mm in order to avoid the spring-back effect. One end must be at a distance minimum of 200mm and a maximum of 300mm from the A-pillar mounting area in order to accommodate the cowl mounting. And the other end must be at a minimum distance of 150mm from the bumper mounting to house the headlight unit.
- Sill mounting.
It is located at the bottom end of the ender. It will be connected to the body frame so it should have proper emboss and mounting points. Fasters are used to attach this.
- A-pillar mounting.
The car body consists of pillars that are nearly vertical and provide support to the car body. The pillars in the car are named alphabetically from A to D starting from front to rear. A-pillar is the one that comes in the front and the mounting area corresponding to that is referred to as A-pillar mounting.
- Baffles mounting.
Baffles are provided on the wheel arc area to prevent the mud and other road sprays to get accumulating on the lower car frame. These are mostly made of plastic and are light in weight. So appropriate
holes need to be created and in case of this mounting, we try not to give emboss to the holes because emboss will create a gap between the wheel arc and the baffle while mounting which is not favorable.
- Bumper mounting.
Bumper area mountings are used to fix the bumper to the fender using fasteners so proper holes and emboss needs to be created.
- EMBOSS AND DARTS/BEADS.
Proper emboss and darts to be made to give strength to the component.
FINAL DESIGN
CONCLUSION
From the given skin data prepared a complete front fender design by taking all the design considerations.