Fender Design Challenge

Aim:

To design the car fender according to the given design parameter related to industry standard.

Objective:

• To develop the front fender according to Euro Standards.
• Follows Design rules, inorder to satisfy the DFM & DFA.

Introduction:

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 air by rotating tire. Fender can be of two types, FULL BUMPER and HALF BUMPER. Nowadays half bumper type is widely used. The cost of sheet metal blank is reduced as we can produce two half bumper type fender in single blank. This is also leads to reduction of scrap.

Fenderwheel arch is having some standard specifications, for example if you see the car from the front, if you see the wheel outside fender it does nore chipping and it causes a lot of danageto pedesrtainsand alsso to the car.

In ordeer to manitain the pedestrains saftey we have to position the tire wheel inside the fender.

For European requirement he clearence between the wheel and the fender outer most skin is mm.

This requiremnt chsnges from country to country based up on the road condition.

AssemblyApproach:

There are two types of assembly, they are

• Bottom_up assembly
• Top_Dwon assembly

Bottom_up Assembly:

The bottom up assembly is the most preferred approach for creating assembly models. In this type oa assembly the components are created in part design work bench (As nx cad part) file. Part are conceived in assembly design workbench using product strcuture tool. After inserting each component, constarints are applied to position them properly in the 3D space with respect to the other components. This assemblies is preffredd for large assemblies, Especially those having intricate indivdal components.

Top_Dwon assembly:

In the top assembly design approach, Components are ceated inside the assembly design work bench. Therefore, there is no need to create sepatre file of the components. This design approach is completely different from the bottom-up design approach. Here you created the product file first and the one by onecreate the product file, they are saved and opended individually one by one when they are needed. Here the construction and the assembly takes places simultaneously.

There are 5 ounting regions on the fender, they are

• A-Pillar mounting
• Body Mounting
• Sill Mounting
• Bumper Mounting
• Drip Mounting

Design Parameter:

Design of Drip Area Mounting:

• It is the importance mounting unit of the fender. It is connected with the engine compartment of the design constraints are to be followed while designing the fender.
• While designing the drip area we have to initially leave 200-300 mm from cowl top.
• For placing the headlamp we have to leave at least 150mm at the front while designing the fender
• Cowl top part consists of wiper motor and its instruments.
• Two darts are added on the longer side of the drip area in order to provide the stiffness and adds strength to the part. This helps the fender to not to vibrate and impact the forces outside of the fender during motion of the vehicle.
• Embossing are provided on the mounting to strengthen them during fastening.

Design of SILL Mounting Area:

Sill is the panel directly below the bottom of the door supporting the floor and may be used to combine the floor and the body. The bottom end of the fender is mounted on the sill body for reinforcement of the fender panel, thus the sill mounting position is designed with holes fender panel, thus the sill mounting position is designed with holes and emboss and M5 fasteners are used to fix the fenders on the sill body.

Design of Bumper Mounting Area:

Bumper mounting area is used to fix the plastic bumper to the fender with the help of the fasteners.

Design of A – Pillar Mounting Area:

The A-Pillar is the structural pillar that combines the body to the roof. This makes the sides of the windshield rest. Front fenders are fastened to the A- Pillar to form a robust structure.

Design of Baffle Mounting Area:

Baffle mounting or mudguard are clip fit of mounting on the inner side of the fender arch over the Tire. It protects the car engine compartment and pedestrians from causing injuries from chip out debirs on the road when the car is in motion. They are mounted on the fender using a special type of locking clips which are made up of plastics.

Thickness Condition of the surface:

The thickness of 0.75 mm inward on the final sewed surface of the fender to the sheet metal parameters.

ScreenShot Images:

Conclusion:

The Fender is finally completed with all parameters and mounting points by following the master sections.