Fender Design Challenge

FENDER DESIGN USING NX CAD

Objective:

The objective of the prject is to design body in white front fender of a car with is mounting using the information provided by the styling team. The skin data and master sketch are the information provided by the styling team.

Introduction:

Fender:

Fender is the American english term for the part of an automobiles, 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 in to the air by the rotating fire. Fenders are typically rigid and can be damaged by contact with the road surface.

Sticky materials, such as mud , may other to the smooth outer tiresurface, while smooth loose objects, such as stones, ecome tempararily embedded in the tread grooves as the tirerolls over the ground. These materials can be ejected from the surfase of the tire at high velocity as the tire impacts kinetic energy to the attached objects. for a vehicle moveing forword, the top of the tire is rotating upword and forword, and can through objects into the air at other vehicles or pedestrain in fron of the vehicle. .

The importance of car fender:

Fenders are an intricate sheet of metal coverong the wheel well of your car.

Fenders are d in desiigened in amanner.provide recistanse against wind and other roadside debris.

When you travel on rough terrains your vehicle might get minor scratches and dents which look no better.

the car fender are located on either side of the front and rear wheels. the front car fenders begin where the front door hinges run and end just before the bumper. the rear cor fenders begin where the back doors close and terminate before the back bumpers.

Types of fenser is based upon the area covered:

1.Full fender type

Full fender type is traditional type fender where more material consumption is observed. this type of fender is used in old design of automobles where it increase the overall weight and thus reduces the performace of car.

2. Half fender types.

Half fendr type is modern design where less material consumption is observed so productivity increase by reducing size of blank and thus providing more performance. The maintenance also relatively low compared to full bumper type.

Skin data and master sketch:

In order to fix the fender mounting are essential in our design we classified the mounting in 5 areas.

1. A piller mounting
2. bumper mounting
3. Drip are ounting
4. Baffel mounting
5. Sill mounting

Design the A Piller

• First the skin data provided by the styling team needs to be extracted.
• Then the outer edge of the fender was offset inword to particuler length.
• Then by using the curve on surface command the unwsanted portion where trimmed out using trim sheet.
• By using the law extension, the A Piller where extended and trimmed on he sides to get a flat edge.
• For creating a flat emboss which was used to mount the fender with the A-piller a datum plane was created.
• Then the required sketch was drawn on the datum plane and projected to the surfase.
• Then for creating a fastener hole which needs to be around 5mm gap around it trim surface command where used .
• Then the required blends where added using face blend and edge blend.

Design Bumper mounting:

• The unwanted portions were trimmed off useing curve on surface and trim surface command.
• Then car creating a flat surface emboss a datum pane was created.
• Then the required sketch drawn on the datum plane was projected to the surface and the required emboss were created.
• The holes were trimmed by using trim sheet after creating emboss.
• Emboss created with a draft so that it satisfied the manufacturing requirements.
• Finally, the required blends were applied.

Design the buffle mountings:

• The buffle munting was designed fit a splash mounting on it which helps the engine compartment to protect it from the debris that enteiring in to while driving.
• For creating it three mounting areas were created with therequired holes on it for the fasteners.
• For creating the holes, a datum plane was created on all three mounting and projected on to the surface.
• By selecting the required vector deselecting the project on both side option the holes were created.

Design the drip area mounting:

• By using the information in the master section provided the drip mounting were created.
• The drip area must be minimum 150mm apart from the front edge so that the drip mounting won't disturb the head lamp mounti
• From the backword the drip area must be 200mm apart from back edge to avaid the coincidence with the engine cables.
• For creating the drip area at the required distance two planes were created and then the intersection curve was used to create the curve on surface as required.
• Then the remaining unwanted portions were trimmed out.
• The desin takes a vital role in avoiding the human eye seeing the insides of the car through the gap between the hood and fender.
• So the drip area was created in particuler angles as required by the master section the required emboss were created.
• After creating the law extension as required by the master section the required emboss were created.
• For creating enboss a datum plane was generated and the sketch drawn in it was projected and the emboss feature wereapplied.
• Then for creating the fastener holes the trim sheet option were used.
• Then the required blends were created for improving the adesthetic of the fender.
• Since the drip area was longer without any support it increase the NVH while driving so to educe the NVH effect while driving the drip area must be strenthened.

Design the sill mounting

• For creating the sill mounting the extra portions were the trimmed out.
• THen the datum was created and the required sketch swas drawn and then projected.
• THen emboss were generated and blended the edges together.
• The fastener holes were created by using trim surface feature.

Some views of the Fender

Conclusion

Fender dsign are complited as per the Masrter section. Design are feasibilty to manufacturing the fender