Fender Design Challenge
AIM:
To create a production ready model of the given Class-A surface of a Fender complying to the European Standards.
THESIS:
The above highlighted Component in red shows where the fender is located on the car.
The Fender being a Bolt-on component, it is mounted onto the chassis of the vehicle. There are 5 mounting points for a Front Fender;
- chassis
- A-Pillar
- Sill
- Cowl
- Drip
Hence as a Design Engineer, our job is to create these features on the given fender Class-A so that it is ready for testing and manufacturing.
Manufacturing Process:
Shearing:
Shearing is also known as die cutting is a process that cuts stock without the formation of chips or the use of burning or melting. Strictly speaking, if the cutting blades are straight the process is called shearing; if the cutting blades are curved then they are shearing-type operations. The most commonly sheared materials are in the form of sheet metal or plates. However, rods can also be sheared. Shearing-type operations include Blanking,peircing,Roll slitting, and trimming. It is used for metal, fabric, paper and plastics.
Surface Repair:
We Observe a small defect in the Cowl region of the Fender. This Defect will interfere during the Thickening of the component. With the permission from the Styling department, we correct the defect as it does not majorly affect the design of the component.
Surface Defect:
Surface Repair:
The defected surface is split from the component, The edge of the surface is extracted and smoothened. and then using Multi-Section, the new surface is created, without disturbing any of the other surfaces of the component.
Creation of Chassis Flange:
In the case of the design of our Fender, the presence of the A-pillar is not extended into the Fender, Hence our Fender does not get mounted onto the A-Pillar. So, we create a Flange which holds the Fender in a position on the Body without compromising the fixture rigidity with the Lack of a A-Pillar mounting point.
The Chassis Flange mates the Fender and the Chassis or other body component, depending upon the design and manufacturer.
Creation of Bumper flange:
The Bumper flange is created in order to mate the Fender and the Bumper.
Creation of Door Sill Flange:
The Door Sill Flange mates the fender and the Door Sill. This end of the Fender secures the Fender bottom end of the Fender.
Creation of Cowl Flange:
The Cowl Flange is created in order to mount the Wheel Well Splash guard.
Creation of Drip Flange:
The Drip Flange is on of the Most important areas where the Fender has to mounted because it not only has to secure the Fender to the Vehicle, but also should block the view of the humans from seeing the other components. It also has to have clearance for the accomodation of the Headlight mounting and Other tools.
Creation of Relief cuts:
The Relief Cuts are created in order to reduce the stress concentration due to the sharp bends that are created for the flanges, as the stress concentration points may lead to other defects and also may damage easily.
FINAL OUTPUT:
Once the Final surface is created, the Surface is thickened to "0.75mm".
