Fender Design

AIM: To design a front fender of a car and follow the given Master section to create the Drip Area

FENDER

It is an aesthetic component/part of a car that frames the wheels. Prevention of sand, mud particles, and other road contaminants from being thrown into the engine compartment and also to the pedestrians by the rotating tires are the main purpose served by the fenders.

The front fenders are separate components whereas the rear fenders are integrated with the body side.

TYPES OF FENDERS:

Based on fender location on the car

Rear and Front: Based on the image shown fender are classefied on the bases of location that is Front and Rear fender.

Based on Matrerial consumption:

1)Full bumper Type:

The full bumper type is the traditional type of fender where more material consumption is observed. This type is used in the old designs of automobiles where it increases the overall weight and thus reduces performance. The maintenance also relatively more due to more surface.

2)Half bumper Type:

Half bumper type is the modern design where less material consumption is observed, so productivity increases by reducing the size of the blank and thus providing more performance. The maintenance also relatively low compared to the full bumper type.

We are changed from full bumper type to half bumper type to reduce the scrap rate per blank. In the full bumper, we can only produce one Fender per blank, whereas as a half bumper type we can produce 2 fenders per blank.

Design Consideration:

1)Minimum Draft Angle is 7`

2)All area must be Fillet with Radius =3+tmm(t =thickness of sheet)

3)Distance between Corner fillets or emboss are Min 6-8mm.

Fender Mounting Design:

There are 5 Regions for Mounting:

Drip Area Mounting.
A-Pillar Mounting.
Sill Mounting.
Bumper Mounting.
Baffle Mounting.

1)Drip Area Mounting: This region is mounted below the hood inner panel which needs to be in flush when the hood is in closed condition and also there should be very less gaps.and it is the most important mounting in a fender, it is the point where the fender has to be attached to the engine compartment.

A minimum gap of 200 mm should be maintained from the rear end of the fender. This is because to have spacing for cowl mounting.
The second thing is to maintain a minimum gap of 150 mm front end of the fender for headlamp mountings.

Master Section is Given Below:-

2)A-Pillar Mounting/cowl mount:

A-pillar is a region where the A-pillar of the car is mounted from the front fender. It is located at the top right corner of the fender.Here this region is mounted to the A-pillar frame of the chasis so that it is rigidly attached to the body of the car.

3)Bumper Mounting:

It is the front portion of the fender where the bumper is mounted with the help of brackets.

4)Splash mount/Baffle Mounting:
The Splash area also plays a vital role in anti-chipping.
It protects the dust particles, spray particles from being entered inside the car.
Thus Splash plays a vital role in the fender.
Due to use of Push Clips No need of Emboss,which helps in Reduce the cost.

5)Sill Mounting:Sill mounting is created on the bottom portion of the fender for attaching to the sill.