Fender Design

Automotive Fender Design (BiW)
AIM:

To craete a front fender Follow the given Master section to create the Drip Area For the Sill, Bumper, Baffle(Splash), and A-Pillar mount create a design according to the Engineering standards.

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 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 .

FENDER:

Fender is a part of a vehicle which frames a wheel and prevents from the sticky and hard substance such as mud, sand, rock, etc. Sticky materials such as mud may adhere to the smooth outer tire surface, while smooth loose objects such as stones can 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 tire is rotating upward and forward and can throw objects into the air at other vehicles or pedestrians in front of the vehicle. Fenders are typically rigid and can be damaged by contact with the road surface. Instead, flexible mud flaps are used close to the ground where contact may be possible.
I have properly shown the Drip area, Sillmount area, A-pillar mount region and Bumper mount region.

TYPES OF FENDER:

• Full Bumper type
• Half Bumper type

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 of the vehicle.

DESIGN METHODOLOGY:

GIVEN DATA: MASTER SECTION

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.

APPLY THICKNESS TO THE SURFACE:

The thickness of 0.75 mm inward on the final sewed surface of the fender to the sheet metal parameters.

DIFFERENT VIEWS OF FENDER :

CONCLUSION :

Finally design of fender is done with the help of NX-CAD software by following the given master section.