Fender Design Challenge

CAR FRONT FENDER DESIGN:

What is Fender:

Fender is the American English term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown into the air by the rotating tire.

The fender is the metal structure that extends between your front door and your front bumper, providing necessary protection for your front wheels.

Types of Fenders:

1. Full Fenders:

Early days cars fenders are longer in size, weight and also having the more cost.

2. Half Fenders:

To reduce the weight of vehicle as well as cost Half fender is designed.

Manufacturing Process:

Embossing:

Embossing is a metal forming process for producing raised or sunken designs or relief in sheet material by means of matched male and female roller dies, theoretically with no change in metal thickness, or by passing sheet or a strip of metal between rolls of the desired pattern.

Metal sheet is drawn through the male and female roller dies producing a pattern or design on the metal sheet. Depending on the roller dies used, different patterns can be produced on the metal sheet.

Characteristics of the metal embossing process include:

• Its ability to form ductile metals,
• Its use in medium to high production runs,
• The ability to maintain the same metal thickness before and after embossing,
• The ability to produce unlimited patterns, depending on the roll dies, and
• The ability to reproduce product with no variation.

Bending:

Blanking:

Different Fender Mountings:

1. A- Pillar mounting

2. Sill mounting

3. Bumper mounting

4. Drip Area

5. Splash mountings

Design in NX CAD

Data given is,

Process:

First we have to design A-pillar mounting as shown,

Then we need to design the Drip area as per given master section,

We have provided Embosses and the ribs(Drats) to increase its strength with mounting holes.

After that we have created mounting for the Sill area with Embosses and the respective holes as shown below,

Then we have created the Bumper mounting,

Then we have created the Splash montings as below,

Final Result:

File is available at Google drive:- https://drive.google.com/drive/folders/1pdxLYPBz55EPXqDF1FJx19xFfnbjZ-A7?