Fender Design Challenge

AIM: Creating drip area, Bumper Mount, Sill Mount, A-Pillar Mount and Baffle Mount design on fender.

THEORY:

FENDER

The fender is the car body part that frames the wheel. Its purpose is to prevent sand, dirt, rocks, and other road spray from being thrown into the air by rotating tire and close the engine component. When a vehicle is moving, tries pick up stones and other and hurl them in all directions. Fender are basically present to prevent any injuries to pedestrians and contain the motion of these particles. A pair of front and rear fenders can be found on each side of a vehicle.

TYPES

* Full bumper type

* half bumper type

FENDER LOCATION

MOUNTING POINTS ON A FENDER

* Drip Area

* Bumper mounting

* Sill mounting

* A-Pillar mounting

* Splash/Baffle mounting

MASTER SECTION TO CREATE DRIP AREA

MANUFRACTURING OF FRONT FENDER:

1.Process planning: The purpose of process planning of automotive panels is to identify the number of operations, the task in each operation, and the content of each task. This research purpose of automatic reasoning procedure based on expert experience and the law of physics.

2. Blank size calculation.

3. Trimming task: The trimming task is separated into two parts.

4. Restriking task: The restriking task is necessary when surface deform because of springback after drawing and trimming, or the accuracy requirement is high because a surface overlaps another surface of another panel during assembly. To over the springback of sheet metal restriking is required.

5. Piercing task: Each hole feature requires a piercing task. Hole features can be classified as basic holes, lock holes, and enlarge holes based on their different functions during assembly. aA basic hole is for locating the panel, and a lock hole is for locking panels.

6. Buring task: Removing the sharp edges and harmful burs from the components.

PROCEDURE TO CREATE DRIP AREA:

* While designing the drip area, a 150mm clearance is maintained from the front-end for headlight fittings and 200mm clearance from the rear-end for the wiper motor assembly(cowl top area).

* The depth of the drip area is maintained at less than 60mm so as to avoid the spring-back effect.

* Ribs are provided at the fender drip area to increase strength in that area.

STEP 1: Use law extension from the given flanges of the fender following the master section.

STEP 2: Give face blends to all the law extended flanges.

STEP 3: Sketch the mounting area face and holes of 5mm dia, holes should have 10mm dia flat surface.

STEP 5: Create a datum plane to give emboss to that respect.

STEP 6: Give emboss of 3.5mm

STEP 7: Trim sheet for holes.

STEP 8: Give face blends to emboss.

STEP 9: Create dart in the middle of two emboss.

STEP 10: Give edge fillet and make sure there are no any sharp edges and should have smooth transition of surface.

PROCEDURE TO CREATE SILL AREA MOUNTING

STEP 1: Extend the sheet of the fender from its edge of the sill area.

STEP 2:Create a datum plane with respect to the extended surface.

STEP 3:Sketch the mounting area face and holes of 5mm dia, holes should have 10mm dia flat surface.

STEP 4:Give an emboss of 3.5mm with an end cap as the plane we create earlier.

STEP 5:Trim sheet for holes

STEP 6:Give face blends to emboss.

STEP 7:Sketch relief area on both sides of the sill mounting area.

STEP 8:Trim the sheet for relief area.

STEP 9:Bridge curve on sheet to remove sharp edges.

STEP 10:Trim the sheet with bridge curves making sure that there are no any sharp edges and should have smooth transition of surfaces.

RELIEF AREA

* Relief areas are the areas which use to avoid the stress concentration on a particular region.

* Relief is provided because after couple of time at corner a chip happens and the corners comes up.

* This happens because of the smooth surface, the stress flows over and that particular part goes under stress then that corners accumulate all the stress from the surface.

PROCEDURE TO CREATE BUMPER AREA MOUNTING

STEP 1:Use law extension to the 90 degrees of the face and 20mm length.

STEP 2:Bridge the curve to the both corners of the extended sheet.

STEP 3:Trim the sheet to avoid sharp corners.

STEP 4:Create a dart in the middle of the extended sheet and fender flange.

STEP 5:Give an edge blend of 3mm.

STEP 6:Create a datum plane with respect to the extended sueface.

STEP 7:Sketch the mounting area face and holes of 15mm dia, holes should have 10mm dia flat surface.

STEP 8:Give an emboss of 3.5mm with an end cap as the plane we created earlier.

STEP 9:Trim sheet for holes.

STEP 10:Give face blends to emboss making sure that there are no any sharp edges and should have smooth transition of surface.

PROCEDURE TO CREATE A PILLAR AREA MOUNTING

STEP 1:Bridge the curve to the both corners of the extended sheet.

STEP 2:Trim the sheet to avoid sharp corners.

STEP 3:Create a datum plane with respect to the extended surface in the offset of a few millimeters above the surface and select the sketch orientation.

STEP 4:Sketch the mounting area face and holes of 5mm dia, holes should have 10mm dia flat surface.

STEP 5:Project the sketch on the oillar area surface.

STEP 6:Create another datum plane with respect to the extended surface.

STEP 7:Give an emboss with an cap as the plane we create earlier.

STEP 8:Trim sheet for holes.

STEP 9:Give face blends to emboss making sure that there are no any sharp edges and should have smooth transition of surface.

PROCEDURE TO CREATE SPLASH/BAFFLE AREA MOUNTING

STEP 1:Offsetting the curve of face blend edge to 5mm below.

STEP 2:Creating bridge curve from offsetted curve to edge of the fender to show smooth transition of surface after trim at three portions of fender to create baffle mounting.

STEP 3:Trimming the surface as shown in the picture below.

STEP 4:Create a plane few millimeter above the surface of the fender.

STEP 5:Sketch the two circles of 5mm dia, holes should have a 10mm dia flat sueface between them.

STEP 6:Project the sketch to the surface.

STEP 7:Trim the sheet to show the holes on the baffle area.

STEP 8:Do the same for the reat of two baffle areas as shown in the picture below.

STEP 9:Thicken the fender part.

CREATING SIDE LIGHT SLOT

STEP 1:Sketch an ellipse on the Yz plane.

STEP 2:Project the sketch on the body of the fender along vector X direction.

STEP 3:Trim the fender with an ellipse curve along vector X direction.

STEP 4:Use law extension definition and extend the ellipse edge by a few millimeters along vector X direction.

STEP 5:Use face blend to remove the sharp edge.

NOTE:Have to create holes for side light mounting on fender.

RESULT:

Designing front fender and the necessary mounting are done as per the master section with the design parameter an final model is shown: