Fender Design Challenge
OBJECTIVE:
To develop the front fender using NX CAD for the following dimension by using the given Master section. This includes drip area, sill, cowl, A-pillar mounting, and number attachment.
INTRODUCTION:
The front fender is a part of the vehicle that frames the wheel. The primary purpose of the fender is to prevent sand, mud, rock, etc., from being thrown away into the air by the rotating tires.
It provides safety to passengers and pedestrians also
Fender has been classified into two types,
- Full Bumper type
- Half Bumper type
MOUNTING AREAS:
- Drip Area: Drip area mounting is the important part of the fender, this mounting is attached to the engine compartment of the car. The fender drip area is mounted via weld nuts to the engine compartment. A minimum of 150 mm distance is kept from the front side and a distance of 300 mm or less can be kept on the rear side. The total length of the drip area from the top of the fender should be less than 40mm, this is to avoid the springing back during the manufacturing. The edge of the mounting should be at least 10mm away from any nearby component in the engine. A rigidity bead is provided at the end to increase the strength of the mounting.
- A-Pillar Area: The A-pillar's mounting depends on the A-pillar of the car. The mounting can also be provided with ribs to strengthen the part. This mounting is critical in design as it has to be mounted on A-pillar properly.
- Body side Area: Another mounting point is created for the body side of the fender. this mounting is created such that it can be mounted on the body of the car. It may consist of one or more bolting holes.
- Sill Area: Sill area mounting is also an important mounting part. This mounting point is basically on the bottom of the fender. The mounting part should be created such that the fender is firmly attached to the sill.
- Cowl Area: Sometimes fender is also provided with the cowl area mounting. This mounting is on the top side of the fender.
FENDER DESIGN DATA:
Design consideration for Drip Area:
- A distance of 150 mm from the front end is kept for the headlamps in the bumper.
- A distance of 200 mm from the rear end is kept for the wiper assembly, sometimes it may exclude and less also.
- Engine components should not be visible from the outside. For this purpose initially, 3 degrees of angle and 9mm is given.
- Embosses are given to the drip area to increase the strength.
- The gap between the drip area and the engine compartment is not less than 10 mm.
- To avoid the spring back effect, we kept the depth drip below 40mm.
- Relief is provided so that maintenance low-cost production and the portion withstand the higher load.
1) drip Area:
It is a very important connection offender to the engine compartment with the help of fasteners. Bead is provided at the outer edge to increase the rigidity of the part.
2) A-Pillar Mount:
A pillar where the fender is connected by fasteners with the body of the car and also an A-Pillar provide the car some strength. Ribs are provided to increase the strength of the A-Pillar mounting point. Other factors for the mounting flange will depend upon the A-Pillar design of the car.
3) Bumper Mount:
4) Sill Mount:
The sill mount area is near the door downside part where the fender and body are connected with fasteners and provide proper support.
5) Baffle Mount:
It allows to hold the fender uniformly and provides proper balance to the fender. It improves the NVH in the car and is mounted on the wheel arch area.
Note:-
- All sketches should be fully constrained.
- Appropriate feature groups should be created for feature works.
- Distance should be maintained between two holes following the design rule of 2*r (Radius of a hole) or more than 2r.
Turn Signal/Indicator Mounting:
CONCLUSION:
All the mounting areas are designed as per the manufacturing requirement and considered all the factors for crash analysis emboss and ribs are provided to strengthen the component and provide stiffness. Also, a thickness of 0.75 mm is provided for the component.
