Challenge

Fender Design Challenge

PPolavarapu K N K S Venkata Reddy31 Jul 2022

FENDER DESIGN

OBJECTIVE:

The main objective of this project is to design a fender using design software NX - CAD

INTRODUCTION:

The design of any product starts from a requirement. The design engineer sketches the product based on the requirement. Then the 2D sketch with the proper dimensions is converted into the 3D model using advanced CAD software. Another important thing in the design is that every product that is designed should be able to manufacture so the role of the design engineer is to design a product that can be easily manufactured and with less cost-effective. This is the place where the Design for manufacturing [DFM] and Design of assembly (DFA) takes a role while developing any product. The process of development of design carries on until the design satisfies the customer's needs. Here in this project, the product that we are going to develop is a car fender.

FINDER

The main purpose of the fender is to prevent sand, mud, and locks. liquids and other road spray from thrown into air by rotating tires

There are two types of fenders are

1. Full Bumper type

2. Half Bumper type

Presently we are using a half bumper type, the reason for choosing was in the half bumper type of blank used to create the half bumper was very easy when compares to the Full bumper type so that the wastage and manufacturing cost was also reduced and reduced the scrap .so that the scrap management was also done.

In half bumper type, we reduce the usage of steel material and used lots of plastic on the bumper which in terms decreases the weight of and increases the performance

The main parts of the Finder are

Drip area
A-Piller
Body Side Area
Sill mounting
Cowl

Drip area mounting is the important part of the fender this mounting is attached to the engine compartment of the car, fender drip area is mounted via weld nuts to the engine compartment a min of 150mm distance is kept from the front side and a distance 300mm 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 area mounting depends upon 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 on the fender, this mounting is created such that it can be mounted on the body of the car it may consist of one or two bolt holes.

Sill Mounting

The sill mounting area 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.