Challenge

Fender Design Challenge

FENDER DESIGN USING NX CAD

Objective

Introduction

Fender is a part of vehicle body that frames a wheelwell.
Its primary purpose is to prevent sand, mud, rocks, liquids, and other road sprayfrom being thrown into the air by the rotating tire.
Fenders are typically rigid and can be damaged by contact with the road surface.
Sticky materials, such as mud, may adhere to the smooth outer tire surface, while smooth loose objects, such as stones, can become temporarily embedded in the tread grooves as the tire rolls over the ground.
These materials can be ejected from the surface of the tire at high velocity as the tire imparts kinetic energy to the attached objects.
For a vehicle moving forward, the top of the tire is rotating upward and forward, and can throw objects into the air at other vehicles or pedestrians in front of the vehicle.
For vehicles with a narrow car body that exposes the tire, the fender is an exposed curve over the top of the tire. For wide body vehicles that cover the tire, the fender forms the wheel wellsurrounding the tire, and is not directly visible from above the car body.
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.

Given Master Section

Dimensions should be considered as shown.

Fender design should be carried out by considering the mounting regions mentioned below:

Drip Area Mounting

The drip area must be minimum of 150 mm from the front edge so that the mountings are away from the head lamp mounting.
Also it should be 200 mm away from the back edge such that engine compartment is away from mounting.
At first, two datum planes are created at required distances then intersection curves are created.
Using the curves, curve on surface is created to trim the unwanted surface.
Following the master section flanges are created with appropriate length and angle.
Finally embosses are created for mounting purpose. To get a flat surface embosses are created with reference to a datum plane.
For fasteners hole trim sheet operation is used after sketching.
Required blends are done which improve the aesthetics also smooth finish.
Since the drip area created is long, to reduce the NVH effect darts are added.

Sill Mounting

For sill mounting, exact position is identified and the remaining surface is trimmed.
Law extension is used to create extended sheet, sharp corners are trimmed off by creating profiles on them.
Embosses are created using the sketch, and also fastener holes are created.
Blends are done for the smooth finish.
Darts are added to reduce the NVH effect.

Bumper Mounting

For bumper mounting, exact position is identified and the remaining surface is trimmed.
Law extension is used to create extended sheet, sharp corners are trimmed off by creating profiles on them.
Embosses are created using the sketch, and also fastener holes are created.
Blends are done for the smooth finish.

A-Pillar Mounting

For A-Pillar mounting, exact position is identified and the remaining surface is trimmed.
Law extension is used to create extended sheet, sharp corners are trimmed off by creating profiles on them.
Embosses are created using the sketch, and also fastener holes are created.
Blends are done for the smooth finish.

Baffle mounting

The baffle mounting is designed to fit a splash mounting on it which protects the engine compartment from debris that enter while driving.
For that three mounting areas are identified, remaining surface is trimmed off.
Holes for fasteners are also created.

After all the mountings are created, the part is thickened 0.75 mm

Views of fender

Conclusion

Fender with all its mountings are designed as per the requirement.

Ship work like this
in your own course.