Fender Design

CHALLENGE : FENDER DESIGN

A) Objective :

1) The main object of this project is to design the BIW(Body in white) of front fender using the fender skin data and master section as the into data by using NX CAD.

B) Introduction :

1) Front fender is a part of the vehicle that frames the wheel. the primary purpose of the fender is to prevent sand , mud , rock etc from being thrown away into the air by rotating tire.

2) fender can be of two types,full bumper type and half bumper type,nowadays half bumper type fender is typically used because the cost of sheet metal blank is reduced as we can produce two half bumper type fender in single blank,this also leads to reduction of scrap

a) Full Bumper Type :

1) This type of bumper is not commonly used because this design is more scrap producing one during manufacturing. The blank of steel or aluminum usedto produce this type has more wastages. This type is not economically good to manufacture.

b) Half Bumper type :

1) This types of fenders most commonly used. The con's of full  bumper type is satisfied in this design, and the blank  area of wastage while producing the part is drastically reduced by scrap management.

C) Purpoes of Fender :

1) Cleanliness : 

Protect the car, occupants and passers by from items, water, mud, snow, ice, thrown off the tires as you drive.

2) Safety : 

Protects pedestrain from the wheel, e.g. its better to be it by a laterally moving fender than a rolling tire, keeps loose, streaming items from being wrapped up in a rolling wheel.

3) Aerodynamics : 

Smooths the car profile so you don't get a lot of drag off the uncovered wheels. Some fenders are enclosed on the side for this.

4) General Appearance : 

Looks better with fender,  gives a finished look, looks more streamlined.

D) Mounting region of fender :

There are  5 mounting regions on the  fender,they are

1) A- pillar mounting

2) Body mounting

3) Sill mounting

4) Bumper mounting

5) Drip mounting

E) DESIGN PARAMETERS :

1) Master Section :

2) Skin Data :

1) It is most important mounting unit of a fender. Its connected with the engine compartment and therefore a lot of design constraints are to be followed while designing the drip area.

2) It should have sufficient clearance from the front and rear end of the  fender to accommodate  the cowl mounting region  and the  headlamp housing unit respectively.

3) From the master section we have optimize value for draft , drawing and assembly point  to view. Such as distance from the engine comportment is 10mm, height of fender etc.

3) Design Consideration :

1) Embosses are provided to increase the strength.

2) Smooth curves are designed for easy manufacturing of panel.

3) Ribs are provided to drip area mount to give structual support and extra strengh.

4) Maintain extra 10mm from the flat surface  for the fastner holes.

5) All fillets should maintain 2 or 3mm radius in most regions.

6) Thickness of fender is 0.75mm.

F) Design Procedure :

1) Drip Mounting Area :

a) It  is the important mounting of the fender, it is connected with the engine compartment, therefore the lot of design constraints are to be followed while designing the fender

b) Four 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.

2) Sill Mounting Area :

a) 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

b) 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.

 

3) Bumper  Mounting  Area :

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

 

4) A-Pillar Mounting Area :

a) The A -pillar is the structural pillar that combines the body to the roof,this make the sides of the windshield

b) front fenders are fastened to the A -pillar to form a robust structure.

5) Splash/Baffle Mounting Area :

a) Baffle mounting or mudguard are clip fit type of mounting on the inner side of the fender arch over the Tyre

b) It protects the car engine compartment and pedestrians from causing injuries from chip out debris on the road when the car is in motion

c) They are mounted on the fender using a special type of locking clips which are made up of plastics .

G) Different views of fender :

H) CONCLUSION : 

Thus, all mounting areas for the fender  designed from skin data and master section is done by following all design rules.