Fender Design Challenge

Aim:

The main aim is to design the fender model with the necessary mounts using the class-A surface.

Mounts:

1. Bumper
2. A-Pillar
3. Sill
4. Cowl
5. Drip

Theory:

Fender:

A fender is a part of an automobile that frames a wheel well (Fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road sprays from being thrown into the air by the rotating tire. The fender's openings for the wheel wells tend to be much larger than the diameter of the tire because they do not move with the tire suspension and consequently must be large enough to allow the full range of tire motion on the suspension without touching the interior of the wheel well.

Types of Fender:

Full front fender:

If the fender covers the tire, the wheel well surrounding the tire, and it is not directly visible from above the car body. It increases the weight and scrap of the component.

Half front fender:

It reduces the weight and scrap. It creates only half of what the full front fender does and the other part is created with the bumper part.

Procedure:

1. Creating the sections:

• After Opening the File, Check the model and create the mount area layouts.
• Use parallel curve option to offset the line to 5mm and split option cut the class A to create a space for the mountings.
• Now, join the split surface excluding the top surface.

2. Creating the Mount part:

• To create the mount regions, use the sweep option near the space created for the mountings.
• After the sweep is done as per the design model given, join the surface created.

3. Creating the embosses and relief:

• After the mounts are created, we need to create embosses and holes are to be given.
• To create emboss, create a sketch with the required shape. Project the sketch onto the mounting area but before that extract the surface.
• Now, split the surface to create a hole near the projected area to create an emboss.
• Use the sweep command near the cut section. Now, offset the extracted surface.
• Trim the surfaces together and create a relief hole which is given to such that the screw is fitted into that hole.
• For the Drip Mount part, follow the details given and design the product.
• To create beaks, create the surface in a way that is angular and then trim the surfaces together.

4. Giving the Fillets:

• Once the surface is trimmed, give the fillets near embosses and beads.
• Use the Extrude command followed by the edge fillet to create the sharp edges to the curved parts near the mountings.

5. Creating the Solid:

• After the Surface is created, go to the part workbench and define the part body.
• Use the thick surface option to create the solid with a thickness of 1mm.

Result:

The fender model is created with a thickness of 1mm with the given mounts and embosses.

Final Model:

Drip Mount:

Sill Mount:

Bumper Mount:

Cowl Mount:

A-Pillar Mount:

Terms Used:

Embosses:

Sheet metal embossing is a stamping process for producing raised or sunken designs or relief in sheet metal. This process can be made by means of matched male and female roller dies, or by passing a sheet or a strip of metal between rolls of the desired pattern. It is often combined with foil stamping to create a shiny, 3D effect.

The metal sheet embossing operation is commonly accomplished with a combination of heat and pressure on the sheet metal, depending on what type of embossing is required. Theoretically, with any of these procedures, the metal thickness is changed in its composition.

The 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. The pressure and a combination of heat actually "irons" while raising the level of the image higher than the substrate to make it smooth. The term "impressing" refers to an image lowered into the surface of a material, in distinction to an image raised out of the surface of a material.

In most of the pressure embossing operation machines, the upper roll blocks are stationary, while the bottom roll blocks are movable. The pressure with which the bottom roll is raised is referred to as the tonnage capacity