Fender Design

OBJECTIVE:

Design a front fender from the given skin data and the master section provided with Drip mounting, A-pillar, Sill, Bumper and Baffle (splash) Mounts.

FENDER:

Fender is a panel that covers the wheel well and is mainly located on the side of the vehicle.

• It's main function is to protect the car's body from dirt, debris, and other things on road that can be kicked up by the wheels while running.
• It prevents the stones, dirt, water, snow, and other materials that can cause scratches, dents, or other types of damage to the car's body and does not enter into the engine compartment.
• It protects the pedistrains that debris and other things not to hit them while running the vehicle.
• It improves the asthetic appreance of the vehicle and covers the Engine compartment in front completly.
• It also help to improve aerodynamics by directing airflow around the wheels and tires.
• Materials used for Fender Manufacturing
  • Mostly sheet metal and alloy materials are used while manufacturing the fendors , but these increase the weight of the automobile but gives the maximum rigidity to it.
  • Some of the automobiles are still using the plastic , fiber sheets materils to reduce the manufacturing cost and weight of the automobile.
  • Some automobile manufactures uses the Alluminum Alloys and Iron Alloy sheets of 0.75mm thicknes maximum.
  • These are again coated with the layers of paint to the asthetic appreance.
  • Some of the automobile companies uses the Sound absorbent and insulation materials to improve the NVH of automobile.

Types of Fenders :

Front Fenders:

• These covers the Engine compartment , doors , sill area etc in the front section the automobile.
• It lies in between of Hood , Front Bumper, Door, and Sill area.
• It has the both Left and Right that covers the wheels.

In the old generation automobiles have the exterior and extended Fenders , these are massive and gives the agressive look for automobile

Rear Fenders :

• It covers the Rear Wheels .
• It protects the rear doors , trunck rear glass and as well as the Fuel Tank.
• It also consists of Left and Right side that covers the Wheels.

 

Fender Design:

• It is the asthatic part of the automobile , mostly the OEM's are self manufacturing these components to avoid the copyright violations.
• It is basically the improvaisations of the previous generations and old model automobiles.
• These have the mastersection of its mounting and other components allowence is also need to be considered.
• The outer part of fender is degigned by the Sytlyig surface team and the internall mounting is done by the design team.
• In the previous fendors are made in full type , that increase the manufacturing cost and has the lot of sheet metal is gone wastage.
• Now the Fender is splitted into two halfs and reduces the scrap and manufacturing cost.
• Half bumper type is also easy to replace while on accidents and less costlier than full fenders.
• The gap of 200 mm minimum is maintained for the fitting of the Cowl part(Plastic parts that Wiper mountings are installed).
• It is also helps in the opening of Hood completly with out touching the fender , A piller and front glass when it is fully opened.
• The gap of minimum 150mm is provided for the assembly of Light in the front section.
• It is mounting to the 5 Parts mainly
  • 1. Bumper : the front part of fender is covered with bumpers using the fastners, The bumper back part covers the fastners.
  • 2. A Piller: it is the mirror side and beside of the front mirror. Here the mirror assembly covers the fastners .
  • 3. Sill : It is the bottom side of the automobile frame and the door bottom side. It is under of the automobile so the fastners is not visible.
  • 4. Cowl : It is mounted to the Wiper mountings and its plastic parts. It is the back side of the hood .
  • 5. Drip : it is the immportant area that it is attached to the engine mountings and covered by the hood. Here the design complications are ocured.
  •  Some plastic sheets or the baffels are attached to it to avoid the hitting of stones into the automobile and other inner parts and it also protects it's self while running.

Full Fender design

Half Fender Design

Mounting of Fender

Car Body: External Parts > Fender > Front Fender & Fender Liner" />

Baffels

Manufacturing of Fender:

• Fender is the Sheet metal component , that is mostly made by the Die pressing by using the molds.
• Some of the fenders are made by the casting method , mostly alluminum and its alloy parts.
• Some of plastic fenders are made by the Reaction Injection molding , Injection Molding.
• Most of the fenders are made by the Foaming or Die pressing methods.
• Some of the fiber sheet Fenders are made by the hands with help of the dies and fiber glass sheets and epoxy coatings.

Drip Design Constarins:

• The desin is made according to the mastersection and design constrains already given.
• The clearence should be provided for the other mounting and assembly to it.
• The total depth of Drip area should not be larger than the 40mm, to avoid the bending and assembly them easily.
• The intial opening should be only 3Deg to avoid the visibility of internal area of the engine and its mountings outside. It is not asthetically good.
• It shouldhave the some clearence angle as per the mastersection that satisfies the design constarins.
• Fillets and Darts are provided to strengthen the Drip area.
• The bottom surface of the Drip area and other mountings should be the flat to get the maximum contact surface while mounting.
• The holes for mounting are made with the help of the vector direction , easy to assemble with other components.
• The extenssion length should be the maximum of 40mm and not to exceed the 60mm to reduce the vibrations and loose its rigidity.
• The clearence of minimum of 10mm form the last contact point or last edge of Engine assembly to the Drip area.
•  Provide the minimum fillets and smooth transissions for the cut sections and extended profiles. so that there will be no errors or improper surfaces while thickening and manufacturing of the component or Fender.

Other Mountings

• There is no mastersection provided for the other mountings of the Fender , so that design the appropriate profile for them.
• These also should have the flat surface of the fastners and mounting contact area , it there is the curvature on the suface then it cannot rigidly tighten to the mountings and causes the vibrations.
• The holes for th fastners are provided in the possible vector direction only.
• These also should have the fillets and smooth curves on the edges .
• provide the relifs at the corners for the sress relief and easy manufacturability.
• now thicken the sheet metal for 0.75mm
• Check the parametrs of 5mm clearence on the all directions to the design .
• The holes also should have the 5mm clearence fram all sides.
• The fillets should not overlap eachother.
• The Drat should have the minimum value so that it will not effect the design.

Here attached the Front fender designed part.

Drip Mounting

Sill Mounting

Body and A piller Mounting

Baffels Mounting

Bumper Mounting

Flat surface on emboss - Infinate radius of curvature

Clearence for head lights assembly front 150mm minimum

Clearence for Wiper mounting area 200 mm minimum

Total distance fender mounting maximum of 40mm or less than it.

Different iews of the Model

Tree structure