Fender Design

AIM:-  Fender Design

OBJECTIVE:-Follow the given Master section to create the Drip Area

For the Sill, Bumper, Baffle(Splash), and A-Pillar mount create your own design according to the Engineering standard that you learned.

Prepare a report with all the relevant images included for the mounting points created.

INTRODUCTION:-

A fender is the part of a car that protects and frames its wheels and keeps mud from splashing it.

Most modern vehicles have fenders on their front wheels.

When you get into a minor car accident, you can call it a "fender bender," and it's possible that your fenders did get slightly dented.

This article is about the part of an automobile that frames a wheel well.

It is not to be confused with Bumper (car), the part of an automobile designed to absorb minor impacts.

Fender is the American English term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well (the fender underside).

 Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray 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 tire is rotating upward and forward, and can throw objects into the air at other vehicles or pedestrians in front of the vehicle.

In British English, the fender is called the wing.

(This may refer to either the front or rear fenders.

However, in modern unibody vehicles, rear fenders may also be called quarter panels.)

The equivalent component of a bicycle or motorcycle, or the "cycle wing" style of wing fitted to vintage cars, or over tires on lorries which is not integral with the bodywork, is called a mudguard in Britain, as it guards other road users – and in the case of a bicycle or motorcycle, the rider as well – from mud, and spray, thrown up by the wheels.

Trucks and automobiles

Early automobile fenders set over the wheels to prevent mud, sand and dust being thrown on to the body and the occupants.

 Fenders typically became a more integral part of overall auto bodies by the mid-1930s.

 In contrast to the slab-sided cars, the Volkswagen Beetle had real bolt-on fenders over both its front and rear wheels.

In current US auto industry nomenclature, usually only the panels over the front wheels are called fenders

The auto industry changed from rear fenders bolted onto a quarter panel to an enlarged welded-on quarter panel that fulfilled both functions. 

Bicycles

There are original manufacturer-designed and aftermarket generic fenders for bicycles that can be fitted to most bicycle frames.

These catch and redirect road spray thrown up by the tires, allowing the rider to remain clean.

They are increasingly common on bicycles in the more car dependent English-speaking countries, since bikes in these countries tend to be sports-oriented, with minimal clearance between tires and frame tubes for fenders, or were ridden only in mild conditions, although there are a few fenders that are designed to be attached to the seat post.

The trend towards urban biking, which has doubled in the past decade, led to a production, import, and use boom in utility bikes

Motorcycles

In the UK it is a legal requirement that a motorcycle should be fitted with mudguards.

While motorcycles are invariably fitted with mudguards, only touring cycles generally have fully functional mudguards.

Some machines can be seen with a stub of a mudguard only a few inches long, which satisfies the legal requirements but does not actually provide any protection from thrown mud and spray.

Sporty-styled or racing motorcycles sometimes come with, or have added as an aftermarket accessory, a "hugger" rear fender, attached to the rear swingarm and very close to the tire, rather than attached to the rear subframe and away from the tire

Areas to be considered while designing a fender:

Drip area

Bumper mounting area

Sill mounting area

Body mounting area

The drip area is the connection of the fender with the engine compartment

DRIP AREA:

It is the area through which the Fender is attached to engine housing through fasteners.

There shold be some consideration followed to design the drip area, from back side of the fender there should be 200mm clearence for cowl mounting area and from the front there should be 150mm clearence for the head lamp housing unit.

  Considering the above design constrains we have to design the drip area. Embosses are provided to increase strength, corners of the flanges are smoothen to ease of the production.

Uniform wall thickness of 0.75mm.

Design Consideration for drip area are150mm distance from front end of the fender and the gap is filled with headlamp200mm distance from rear end of the fender and the gap is filled with wiper motor assembly.

Initially 3-degree angle and 9mm length is given while creating a drip area because the engine component should not be visible from outside.

The depth of the drift should be between 40 to 60mm.

If the depth exceeds from 60mm then forming is not feasible due to spring back and wrinkles.

Embosses and ribs are given to drip area to give strength. Embosses dimensions are a depth 3.5mm and 15 degree of angle for all three embosses.

A PILLAR AREA:

A Piller is on the cars either side of the front windshield which is the reason the windshield in the place.

  It is Mounted on the A Pillar by means of fasteners and these are covered by outer side view mirrors.

Here, the proper embossing are provided along with holes for fastener

Law extension dimensions are 42mm length and 90 degree of angle.Offsetting the law extension face 5mm.

Creating a sketch and law extension feature is used 6mm length and 95 degree of angle.

SIL MOUNT AREA:

 The Sill Mounting area is in the bottom of the fender.

 It is mostely gets connected with the door region of the car.

 Here, proper embossing and holes for the fasteners are provided.

 The ribs are provided to improve the strength.

Extend sheet to 15mm to make the sheet length 30mm.

Giving relief by manual like creating a sketch and trim the sheet both sides.

Emboss dimensions are depth 3.5mm and 15 degree of angle.Edge blend is 3mm.

Trim sheet is used to create a 6mm hole on sheet

BUMPER MOUNTING AREA:-

In this Mounting, the Fender connects with the bumper.

 The Bumper Mounting region must be rigid in order to withstand the force acting upon it during collision. So, the Mounting space can be larger.

Law extension length 20mm and 75 degree of angle.Skew to join the two surfaces.

Dart angle 45 degrees, depth 4mm and radius 3.75mm.

Create two darts in existing spaces as shown in figure 7.

Trim sheet is used to create a hole of dia 5mm.

For skew use 3mm edge blend and for dart and embosses 2mm edge blend.

BAFFLE AREA:-

Creating holes for baffles.

Trim sheet feature 

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