Fender Design Challenge

FENDER DESIGN

OBJECTIVE :

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

INTRODUCTION :

Design of any product starts from an requirement . The design engineer sketches the product based on the the requirement . Then the 2D sketch with the proper dimensions is converted into the 3D model using the advanced CAD software's . The another important thing in the design is that , every product that is designed should be able to manufactured . so the role of the design engineer is to design the 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 needs .Here in this project the product that we are going to develop is a car fender

FENDER :

The main purpose of the fender is to prevent sand,mud, rocks,liquids and another road spray from being thrown into the air by the rotating tire .

USES OF FENDER :

• Get other vehicles or pedestrians on the road side dirty
• Hurt pedestrians
• Scratch the bodies of other vehicles
• Cause minor, and even major damage to other vehicles

PURPOSE OF FENDER:

Cleanliness : Protect the car, occupants and passers by from items, water, mud, snow, ice, thrown off the tires as you drive.

Safety : Protects pedestrain from the wheel, e.g. its better to be it by a laterally moving fender than a rolling tire, keeps loose, streaming items from being wrapped up in a rolling wheel.

Aerodynamics : Smooths the car profile so you don't get a lot of drag off the uncovered wheels. Some fenders are enclosed on the side for this.

General Appearance : Looks better with fender, gives a finished look, looks more streamlined.

TYPES OF FENDER:

There are mainly two types of fenders :

1. Half bumper type

This half bumper type is used for mainly cost and material cutting purpose as this type is also provides ease of manufacturing and the strength is also improved for half bumper type fender.

2. Full bumper type

The full bumper type model is used in the olden days this creates much wastage of material and the unnecessery cost is increased.

INPUT DESIGN PARAMETERS:

MOUNTINGS :

DESIGN OF DRIP :

• The curve selection command is used for creating curves on the surface of flange to trim the extra sheet metal.
• The position is considered as 200 mm from cowl and 150 mm from headlight position.
• The flange should be about 7 degree, then 40 degree down and 5 degree down which should be total length of 40 mm or less from top of fender.
• Then the flat length of 25 mm is given.
• The last projection is followed as per dimensions using pythogrous theorem.
• Then the flange holes were created for mouting points.

A-PILLAR MOUNT :

• The consideration is taken from the place at cowl is placed.
• It is taken at the back of the drip mount.

BUMPER MOUNTING:

• The bumper mounting is placed at the mating of head light position.
• This is also has a flange with holes for mountings.

SILL MOUNTING:

• The sill mounting is done by extension of sill area flange
• After extension of flange holes were made for mountings.
• Embosses were created for the hole moounting points that provides more strength

WHEEL ARCH MOUNTING :

• The wheel arch design is always depends on regulations based on different countries like European, Japan, US etc.
• The flange provided for the wheel arch is provided with just holes for push pin clips to mount wheel arch.

DIFFRENT VIEWS OF FENDER: