Challenge

Fender Design

SSabhavath Eswar Naik30 Oct 2022

FENDER DESIGN

Objective:-

The main objective of this project is to design a fender using a new age design software - NX - CAD

Intoduction:-

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 less 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

Aim:-

To desing the car fender according to the given design parameters related to industry standard.

Fender:-

The main purpose of the fender is to prevent sand,mud, rocks,liquids and another road spray from being thrown into the air by the rotating tire .

Uses Of Fenders:-

Get other vehicles or pedstrains on the road side dirty
Hurt pedestrain
Scratch the bodies of other vehicles
ause minor, and even major damage to other vehicles

Types Of Fenders:-

There are two types of fenders , they are

FULL BUMPER TYPE:-

This half bumper type is used for mainly cost and material cutting purpose as this type is also provides ease of manufacturing and the strength is also improved for half bumper type fender.

2. HALF BUMPER TYPE:-

The ful bumper type model is used in the olden days this creates much wastage of material and the unnecessery cost is increased.

Presently we are using the half bumper type , the reason for choosing the half bumper type is that when we choose the full bumper type the blank used for creating it is very large and also has the lot of wastage , but in the case of the half bumper type we have the possibility to reduce the scrap . This is what we called as scrap management

In half bumper type we reduce the usage of the steel material and uses the lots of plastic on the bumper which in term decreases the cars weight and increases the performance

Mounting Region On Fendre:-

There are 5 mounting regions on the fender , they are

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

Design Methodology:-

MASTER SECTION

Design Of Drip:-

Design 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 A-Pillar Mountig 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

Appl

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 .