Fender Design

AIM:

• 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 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 is the american english term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well. Its primary propose is to prevent sand, rocks, mud, liquids, and other road spray from being thrown into the air by the rotating tire. Fender are typically rigid and can be damaged by contact with the road surface.

Sticly materials, such as mud, may adhere to the smooth outer tire surface, while smooth loose objects, such as stones, can be become temporarily embedded in the tread grooves as the tire rolls over the ground. These materials can be ejected from the surface of the tire at high velocity as the tire imparts kinetic energy to the attached objects. For a vehicle moving forward, the top of the trie is rotating upward and forward, and can throw objects into the air at other vehicle or pedestrians in front of the vehicle. Fender is a front outer side member of a car, which covers the wheel side. It has so many small features with ups and downs.

The Importance of car Fenders :

1. The fenders are an intricate sheet of metal covering the wheel well of your car.
   
   
2. Fenders are designed in a manner to provide resistance against wind and other roadside debris.
   
   
3. When you travel on rough terrains tour vehicle might get minor scratches and dents which look no better. Frequent road bumps can cause your cars paint to chip off which needs a paint job done.
   
   
4. 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 car fenders begin where the back doors close and terminate before the back bumpers.

Two types of Fender:

Full Bumper	The full bumper is mostly cover the wheel part almost 18% as shown in the below.
Half Bumper	Half Bumper helps reduce the weight of the fender at the same time it proves the safety of pedestrian moving motion as shown in the figure.

MOUNTING REGIONS ON FENDER :

There are 5 mounting regions on the fender , they are

• A- pillar mounting
• Body mounting
• Sill mounting
• Bumper mounting
• Drip mounting

DESIGN METHODOLOGY :

GIVEN DATA :

DESIGN 0F DRIP AREA MOUNTING :

• It is the important mounting uni of the fender . it is connected with the engine compartment , therefore the lot of design constraints are to be followed while designing the fender
• While designing the drip area we have to initially leave 200-300 mm for cowl top
• For placing the headlamp we have to leave at least 150 mm at the front while designing the fender
• Cowl top part consists pf wiper motor and its instruments
• Two darts are added on the longer side of the drip area in order to provide the stiffness and adds strength to the part . This helps the fender to not to vibrate and impact the forces outside of the fender during motion of the vehicle.
• Embossing are provided on the mounting to strengthen them during fastening

DESIGN OF SILL MOUNTING AREA :

• Sill is the panel directly below the bottom of the door supporting the floor and may be used to combine the floor and the body.
• The bottom end of the fender is mounted on the sill body for reinforcement of the fender panel , thus the sill mounting position is designed with holes and emboss.
• M5 fasteners are used to fix the fenders on the sill body.

DESIGN OF BUMPER MOUNTING AREA :

• Bumper mounting area is used to fix the plastic bumper to the fender with the help of the fasteners

DESIGN OF A-PILLAR MOUNTING AREA :

• The A -pillar is the structural pillar that combines the body to the roof.
• This make the sides of the windshield rest.
• Front fenders are fastened to the A -pillar to form a robust structure

DESIGN OF BAFFLE MOUNTING AREA :

• Baffle mounting or mudguard are clip fit type of mounting on the inner side of the fender arch over the Tyre.
• It protects the car engine compartment and pedestrians from causing injuries from chip out debris on the road when the car is in motion.
• They are mounted on the fender using a special type of locking clips which are made up of plastics.

Final View of the Fender:

Conclusion:

We have developed front fender with mounting points following the design parameters and mastersection .