Fender Design Challenge

Introduction:-

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. Fenders are typically rigid and can be damaged by contact with the road surface.

There are two types of fenders
1. Full Bumper Type.
2. Half Bumper Type.

Full Bumper type
This type of fender is used in olden days, it is no more in use due to its heavyweight of the structure and consumes more raw material in manufacturing.

Half Bumper Type
Half Bumper Type fenders are widely used now, due to its mini size and the scrap or wastage is less compared to the full bumper type.

Fender Design Detail:-

OBJECTIVE:-

In this project we are going to design the mounts for the Front fender such as drip, sill, bumper, A-pillar, cowl and baffle for this we are going to design mounts.

Master sketch :-

As per the master sketch we are going to design the drip mount and we will follow the design parameters as per industry for the other mounting area too.

Fender is mounted basically on 5 important regions. They are following
1.  Drip Area
2. A-Pillar Mounting Area
3. Sill Mounting Area
4. Bumper Mounting Area
5. Baffle Mounting Area

           

Fender Design Procedure:-

FEATURES/TOOL USED:

• SKETCH
• OFFSET IN FACE
• CURVE ON SURFACE
• BRIDGE CURVE
• EMBOSS
• TRIM SHEET
• LAW EXTENSION
• FACE BLEND
• EDGE BLEND
• DART
• THICKEN

Drip Mounting Area :-
So first we are going to work on the drip mount which will mounted to the engine compartment.

The area at which the fender gets attached to the engine housing through fasteners. It is the major mounting for the fender. Mountings at the drip area are designed leaving a clearance of 200mm from the back of the fender for the cowl setup. And clearance of 150mm from the front of the fender for a headlamp housing unit.

                                                                                            

A-Pillar Mounting Area :-
While creating this mount was tricky one as we have create a emboss on curved surface so for that we have used datum plane and according to that we have created the sketch.

This Mounting region is located near the cowl of the vehicle where the fender is fastened with the bottom edge of the windshield. This mounting is covered with the side rear-view mirror.

                                                                                     

Sill Mounting Area :-
Like drip mount we have created the sill mount too and we made sure that we didn’t have any sharp corners and we provided relief to it.We did this by using bridge curve and trim sheet.

The area at which the bottom of the fender gets connected to the floor near the bottom edge of the door. The Embossed sill mounting of the fender is attached with the fasteners

                                                                                         

Bumper Mounting Area :-
As you can see we have created the bumper mount using emboss, dart and bridge curve to cut out the sharp corners.

The bumper mounting region is located beneath the bumper. The fender gets attached before the installation of the bumper. After fixing the fender with fasteners the bumper will cover the bumper mounting

                           

Baffle Mounting Area :-
For baffle mounting we didn’t made any kind of emboss we have created the mounting holes for it and we have created the baffle flange on which the holes are there.

After creating the mounts we finally thicken it which gives thickness to the sheet met

In this region, the baffle gets installed to the fender with the help of clips which holds the baffle with the fender along the wheel arch.

                                                                   

Final Fender Design:-

Fender Manufacturing Process:-

The manufacturing of the fender majorly involves these operations.

1.Embossing
2.Bending
3.Cutting and Blanking

Embossing:-

Embossing is a metal forming process for producing raised or sunken designs or relief in sheet material using 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.

Bending:-

Metal bending is a process by which metal can be deformed when applying force to the subject, which causes it to bend at an angle and form the anticipated shape, which often results in it being in a ‘V’ or a ‘U’ shape. This is done through the application of force on a workpiece. The force on the work piece can be mechanical, pneumatic or hydraulic.

Cutting and Blanking:-

Cutting processes are those in which a piece of sheet metal is separated by applying a great enough shearing force to cause the material to fail.

Blanking is a steel manufacturing process in which a flat, geometric shape is created by feeding a coil of sheet metal into a press and die. In this process, the blank is punched out from the large metal sheet.

CONCLUSION:-

As we successfully learn about the Fender objectives, its types and feature/tools of front fender and made it in NX CAD and we have learn the commands involved in fender design.