Fender Design

Fender Design

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

Introduction :

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

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 trie is rotating upward and forward and can throw objects into the air at other vehicles or pedestrians in front of the vehicle. A 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 intricate sheets 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 your vehicle might get minor scratches and dents which look no better. Frequent road bumps can cause your car to paint to chip off which needs a paint job done.
   
   
4. The car fender is 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

Types of Fenders :

There are two types of fenders.

1. Full Bumper Type
2. Half Bumper Type

Full Bumper Type :

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

Half Bumper type :

This type of fender is most commonly used. The cons of the full bumper type are satisfied in this design, and the blank area of wastage while producing the part is drastically reduced by scrap management.

Purposes of Fender :

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

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

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.

General Appearance: Looks better with fender,  gives a finished look and looks more streamlined.

Front Fender Desing :

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

1. Drip Area
   
   
2. Sill Mount
   
   
3. Bumper Mount
   
   
4. A-Pillar Mount
   
   
5. Splash/Baffle Mount
   
   

Design of Drip Mount Area :

Master Section To Fellow and Create Drip Design :

Skin Data 

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

From the master section, we have optimized the value for draft, drawing, and assembly points to view. Such as the distance from the engine compartment being 10mm, the height of the fender, etc.

Design Criteria : 

• Embosses are provided to increase strength.
  
  
• Smooth curves are designed for easy manufacturing of panels.
  
  
• Ribs are provided to drip area mount to give structural support and extra strength.
  
  
• Maintain an extra 10mm from the flat surface for the fastener holes.
  
  
• All fillets should maintain a 2 or 3-mm radius in most regions.
  
  
• The thickness of the fender is 0.75mm.

Drip Mounting Area :

Sill Mounting Area 

Bumper  Mounting  Area :

A-Pillar Mounting Area 

Splash/Baffle Mounting Area 

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