Fender Design

Underbody Coating

• Objective: -

The aim of this project is to design the front fender of a car by considering all the design considerations required in the design of front fender.

• Introduction: -

A fender is an American English term for the part that makes up the frame for wheel well of an automobile, motorcycle, or other bodywork. Its main purpose is to prevent sand, rocks, mud, liquids, and other road debris from being thrown into the air by spinning tires. Fenders are usually stiff and can be damaged by contact with the road surface.

Hard substances such as mud can adhere to the smooth outer surface of the tire, while smooth loose objects such as rocks are temporarily embedded in the grooves of the tread as the tire rolls over the ground. These materials impart kinetic energy to the object to which the tire is attached and can be thrown off the surface of the tire at high speed. In forward-moving vehicles, the top of the tri rotates forward, allowing it to throw airborne objects at other vehicles or pedestrians in front of the vehicle. Fenders are the front outer longitudinal members of a vehicle that cover the wheel sides. There are so many little features with their ups and downs.

• Importance of Fenders: -

1. Fenders are complex metal plates that cover the wheel wells of your vehicle.
2. Fenders are designed to provide resistance to wind and other roadside debris.
3. Touring vehicles can get small, unsightly scratches and dents when driving over rough terrain. Frequent crashes on the road can strip the car's paint and require refinishing.
4. Car fenders are on both sides of the front and rear wheels. The front fender starts at the front door hinge and ends just in front of the bumper. Rear vehicle fenders start where the rear doors close and end in front of the rear bumper.

• Types of Fenders: -

1. Full Bumper Type
2. Half Bumper Type

1. Full Bumper Type: -

This type of car fender was used for old cars with long bonnets, and full bumper fenders were used accordingly. These fenders cover most of the wheel so road spray doesn't fall off the road, but the downside to this was the weight of the fenders and the materials used to make them.

However, the automotive industry Another type of automotive fender emerged as progress was made in, and the full bumper fender became an absolute.

This type of bumper is not commonly used as this design generates a lot of scrap during manufacturing. There is more scrap in the steel or aluminium blanks used to make this type. This type is not easy to manufacture economically.

2. Half Bumper Type: -

This types of fenders are the most commonly used. The shortcomings of the full bumper type are met with this design, and the waste free space during part manufacturing is greatly reduced by scrap management.

This is because this fender uses half as much material as the full bumper type. That’s why this type of fender is very much used in all modern cars today.

• Materials used for fenders:

There are many different types of materials on the market that can be used to create fenders such as: Materials such as steel, aluminum, and olefin-based thermoplastic elastomers are determined by the vehicle type, application, and cost of the vehicle, as is the case with sports cars. Made from aluminium or carbon fiber to reduce weight and increase vehicle strength.

• Purpose of the fender:

1. Cleanliness:Protectsvehicles,occupantsandpassers-byfromobjects,water,mud,snowandicethrownupfromtireswhile
2. Safety:ProtectpedestriansfromAfenderthatmovessidewaysisbetterthanarollingtire,preventinglooseandflowingobjectsfromgettingentangledintherollingwheel.
3. Aerodynamics:Byflatteningtheprofileofthevehicle,ittakeslessdragfromuncoveredForthispurposesomefendersareincludedonthesides.
4. GeneralAppearance:Betterfendercompatibility,finishedlookandmorestreamlined

• Design Considerations of the fender:

When designing fenders, several design parameters should be considered, such as:

1. Determining requiredsectionsfordripareas,rockerpanelassemblies,bumperassemblies,A-pillarassemblies,
2. Howmuchthicknessshouldbegiventoaccountforangleswhendesigningdripareasandminimumradiusvalues​​suchasfenders?

• Different mountings provided on the fender:

1. Already given master section to create the drip area and
2. The still mount, Bumper mount and A-pillar mount create your own design according to the engineering standard.

Refer below snaps for overview of detailed design of Fender:-

1. The drip area: -
2. The Drip Mounting Area: -

This is the main part of the fender that gives stability when designing the fender. The location of this area should be calculated from the master section 200mm space is required for bonnet mounting and wiper motor mounting, so when designing fenders, you should allow enough space, and also consider 150mm for headlight assembly. The maximum depth of the drip tray should not exceed 40 mm. Otherwise, a spring-back effect will occur during assembly of the drip tray. Proper holes must be drilled in the drip area for secure mounting to the vehicle frame.

3. The A Pillar mounting & Side Indicator Mounting: -
4. The Slash & Baffle Mounting area: -
5. The Front Bumper Mounting area: -
6. The Still Mounting area: -
7. The A Pillar Mounting area: -

• Conclusion: -

Therefore, we designed all front fender brackets and used the skin data provided according to the fender main section to identify the various design considerations involved in fender design and what should be observed at each attachment.

Having learned something important, we completed the front fender with considering each mounting provided on for different parts.