06. FENDER DESIGN

FRONT FENDER DESIGN

AIM: To design a front fender of a car by following the given master section as per the design considerations of an OEM.

FENDER

It is an aesthetic component of a car that frames the wheels. It Prevents jet spray of sand, mud particles, and other road contaminants from being thrown into the engine compartment and also to the pedestrians by the rotating tires are the main purpose served by the fenders.

The front fenders are separate components whereas the rear fenders are integrated with the body sides.

TYPES OF FENDERS

1. FULL BUMPER TYPE: These types of fenders were used in earlier models of vehicles. They contribute to the major increment of the steel weight by just covering the front headlights with respect to the bumper region. The problem associated with this kind of fender is there is a lot of wastage in the blank and every inch of a material is a cost to the industry

1. HALF BUMPER TYPE: These fenders are mainly used for serving the purpose of cost-cutting (i.e., sheet utilization) and reducing enough proportions of the steel weight (w) resulting in a reduction of the weight of the vehicle slightly. They are economic to manufacture, i.e., by slightly increasing the blank size, we can produce two fenders at a time.

DESIGN CONSIDERATIONS: -

The front fender has mainly five mounting positions w.r.t. the other components. They are as follows:

1. Drip Area Mounting.
2. A-Pillar Mounting.
3. Sill Mounting.
4. Bumper Mounting.
5. Baffle Mounting.

To create the Drip Area Mounting, given Master Section is followed, and the other mounting points are created by assuming appropriate positions with the respected components.

MASTER SECTION

1. Drip Area Mounting:

• The drip area is the point where the fender has to be attached to the engine compartment. So, it is an important mounting point.
• The drip area should be designed in such a way that it should be at least 150mm away from the front end of the fender to have enough space for mounting headlamps housing and wirings. It is maintained by creating a plane normal to the curve at that area.
• From above fig and mostly drip area starts from 200mm away from the rear end of the fender, to have enough space for the cowl which also carries the wiper equipment which is given in photo. It is maintained by creating a plane normal to the curve at that area.
• Also embosses and darts are provided at required areas to ensure strength and stability.

Measurements are

Also the plane positioning has done accordingly.

2. A-Pillar Mounting:

• This mounting position used to attach the fender to A Pillar of the vehicle.
• The mounting is created by taking the reference from the A-pillar of the vehicle.
• Sufficient clearances should be given for the easy mounting of the wiper equipment

3. Sill Mounting: Sill mounting is created on the bottom portion of the fender for attaching to the sill.

4. Bumper Mounting: This mounting point is created for attaching the bumper to the fender. It should have enough strength to hold the bumper steadily.

5. Baffle Mounting: These mounting points are created for attaching plastic components i.e baffle which prevents chipping inside the engine compartment.

DIFFERENT VIEWS

Top View

Isometric View

Side View

CONCLUSION

The front fender is designed according to the given master section as per the OEM Standards.