Fender Design

FENDER:

• THE FENDER IS THE PART OF THE VEHICLE BODY THAT COVERS THE WEELS AND ENGINE COMPARTMENT, IT IS ALSO KNOWN AS THE WING IN SOME REGIONS, THE FENDER PRIMARY FUNCTION IS TO PROTECT THE WEELS AND VEHICLES BODY FROM DEBRIS, DIRT, AND ROAD SPRAY THAT MAY BE THROWN UP BY THE ROTATING TIRES. FENDERS ALSO CONTRIBUTE TO THE OVERALL AERODYNAMICS AND AESTHETICS OF THE VEHICLE.

TYPES OF FENDER:

• STANDARD FENDER
• FLARED FENDERS
• VENTED FENDERS
• CARBON FIBRE FENDERS
• ARTICULATED FENDERS

IN FENDER DESIGN WE HAVE TWO TYPES

HALF BUMPER TYPE AND FULL BUMPER FENDER

FULL BUMPER TYPE: FULL BUMPER IS NOT USED NOWADAYS, IT REQUIRES LARGE SIZE OF BLANK TO PRODUCE THE PAER AND IT OCCUPIES MORE SPACE

HALF BUMPER TYPE: HALF BUMPER TYPE IS HALF BUMBER ITS USED TO REDUCE THE WASTE OF MATERIAL AND CAN PRODUCE TWO FENDERS AT THE SAME TIME BY SLIGHTLY INCREASE THE RAW SHEET AND IT REDUCE THE WEIGHT ALSO

DESIGN PARAMETERS:

FENDER IS INFLUENCED BY SEVERAL FACTORS

VEHICLE TYPE: THE DESIGN OF FENDER VARIES BASED ON WHETHER THE VEHICLE IS SEDAN , SUV, TRUCK, OR OTHER TYPES

WHEEL SIZE: FENDER MUST ACCOMMODATE THE SIXE AND WIDTH OF THE WHEELS TO PREVENT RUBBING OR SCRAPING

AESTHETICS: FENDERS CONTRIBUTE TO THE VEHICLE OVERALL DESIGN AND AESTHETICS, AND THEIR SHAPES CAN VARY BASED ON THE CAR'S STYLE

MATERIAL: FENDERS ARE COMMONLY MADE FROM STEEL, ALUMINUM OR PLASTIC EACH OFFERING DIFFERENT PROPERTIES IN TERMS OF STRENGTH, WEIGHT, AND COST

MASTER SECTION OF FENDER:

• MANUFACTURING PROCESS:THE MANUFACTURING PROCESS FOR FENDERS DEPENDS UPON THE MATERIAL USED, BUT THE GENERAL STEPS MAY INCLUDE
• DESIGN AND PROTOTYPING: ENGINEERS CREATE A 3D DESIGN OF THE FENDER, AND PROTOTYPES ARE DEVELOPED FOR TESTING AND VALIDATION

• MATERIAL PREPARATION: WHETHER USING STEEL. ALUMINUM OR PLASTIC THE RAW MATERIAL IS PREPARED FOR FORMING OR MOULDING
• FORMING / MOLDING: STEEL OR ALUMINUM FENDERS ARE TYPICALLY STAMPED OR PRESSED INTO SHAPE USING SPECIALIZED MACHINERY. PLASTIC FENDERS MAY BE INJECTION MOLDED
• FINISHING: FENDERS UNDERGO VARIOUS FINISHING PROCESSES, INCLUDING PAINTING , COATING, OR POLISHING TO ENHANCE THEIR APPEARANCE AND DURABILITY
• MOUNTING: ONCE FENDERS ARE READY, THEY ARE ATTACHED TO THE VEHICLE USING THE CHOSEN MOUNTING METHOD

IT CAN BE MOUNTED BY BOLT-ON OR WELD ON

1. BOLT-ON: BOLTS AND SCREWS ARE USED AND IT ALLOWS FOR EASIER REPLACEMENT AND REPAIR
2. WELD ON: FENDERS ARE DIRECTLY WELDED TO THE VEHICLES BODY, PROVIDING A MORE PERMANENT ATTACHMENT

DESIGNING OF FENDER:

USING NX-CAD WE ARE GOING TO DESIGN FENDER MOUNTINGS BY REFERRING MASTER-SECTION

GIVEN SKIN DATA

IN THIS WE ARE GOING TO PROVIDE MOUNTINGS

• DRIP MOUNTING AREA
• SILL MOUNTING AREA
• A-PILLAR MOUNTING AREA
• BUMPER MOUNTING AREA
• BAFFLE MOUNTING AREA

DESIGN OF DRIP MOUNTING AREA:

• THIS AREA IS A VERY IMPORTANT MOUNTING UNIT OF THE FENDER, WHERE ITS CONNECTED TO THE ENGINE COMPARTMENT, SO IT HAS DESIGN CONSTRAINTS TO BE FOLLOWED
• 200-300mm WE HAVE TO LEAVE FOR COWL TOP
• FOR PLACING HEADLAMPS, WE HAVE TO LEAVE AROUND 150mm AT THE FRONT WHEEL DESIGNING FENDER
• COWL TOP PART CONSISTS OF A WIPER MOTOR AND INSTRUMENTS
• TWO DARTS ARE ADDED ON THE LONGER SIDE OF THE DRIP AREA TO PROVIDE THE STIFFNER ADDS STRENGTH TO THE PART, THIS HELPS THE FENDER TO NOT VIBRATE AND MAKES NOISES WHILE THE VEHICLE IS IN MOTION
• 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 ITS USED TO COMBINE THE FLOOR AND THE BODY, THE BOTTOM END OF THE FENDER IS MOUNTED ON THE SILL BODY OF THE REINFORCEMENT OF THE FENDER PANEL, AND SILL MOUNTING AREA IS DESIGNED WITH HOLES AND EMBOSS. M5 FASTENERS ARE USED TO FIX THE FENDERS ON THE SILL MOUNTING AREA

DESIGN OF BUMPER MOUNTING AREA:

• THE BUMPER MOUNTING AREA IS USED TO FIX THE BUMPERS TO THE FENDERS WITH THE HELP OF FASTENERS

• 

DESIGN OF A-PILLAR MOUNTING AREA:

THE A-PILLAR IS THE STRUCTURAL PILLAR THAT COMBINES THE BODY WITH THE ROOF, THIS MAKES THE WINDSHIELD REST

DESIGN OF BAFFLE MOUNTING AREA:

BAFFLE MOUNTING ARE CLIP FIT TYPE OF MOUNTING ON THE INNER SIDE OF THE FENDER ARCH OVER THE TYRE, IT PROTECTS THE CAR ENGINE COMPARTMENT AND PEDESTRIAN FROM CAUSING INJURIES , THESE ARE MOUNTED USING A SPECIAL TYPE OF LOCKING CLIPS WHICH ARE MADE UP OF PLASTIC

THICKNESS:

WE HAVE GIVEN 0.74mm THICKNESS TO THE FENDER

DIFFERENT VIEWS OF FENDER

COMMANDS USED IN NX CAD TO DEISNG FENDER MOUNTING AREAS

• OFFSET IN FACE
• SKETCH
• CURVE ON SURFACE
• TRIM SHEET
• LAW EXTENSION
• EMBOSS
• MEASURE
• DATUM PLANE
• INTERSECTION CURVE
• FACE BLEND
• EDGE BLEND
• BRIDGE CURVE
• PROJECT CURVE
• RAPID DIMENSION
• SEW
• DART
• THICKEN

CONCLUSION: WITH THE MASTER SECTION AND SKIN DATA THE MOUNTING AREAS ARE DONE BY FOLLOWING DESIGN RULES