Fender Design

Fender Design using Seimens NX CAD :

Fender :

It is a aesthetic component of the car which acts as a housing for the wheels. It protects engine compartment and pedestrains from sand,dust, rocks, pebbles etc that is thrown into air and carried by rotating wheels of the car. This prevents the particles from spewing or damaging car parts on the car's underbody and other vehicles aswell which are driving by.

The front fenders are seperate components wheras the rear fenders are integrated features of body sides.

Types:

• Full Bumper type:

These types of fenders were used in earlier models of vehicles. They contribute to major increment of the steel weight by just covering the front headlights with respect to the bumper region. The issue associated with this kind of fender is there is wastage of blank and every extra inches of material still accumilatively costs big values to the industry.

• Half Bumper Type :

These fenders are mainly used for serving the purpose of cost cutting and reducing enough proportions of the steel weight resulting in reduction of overall weight of the vehicle which is a desirable result. They can be economically manufactured, ie by slightly increasing blank size we can produce two fenders at a time. This saves material and reduces cost also reduces production time.

Design Considerations:

Front fender has five mounting positions with respect to other components. They are as follows :-

1. Drip area mounting
2. Bumper mounting
3. A-pillar mounting
4. Sill mounting
5. Splash/Baffle mounting

Mounted by use of fastners.

1. Drip area mounting :

• Drip area mounting is a critical mounting. It is located inside engine compartment. Drip area mount is fastned to a L-shaped bracked which then is fixed inside engine compartment.
• Drip mount created following master section and clearences given as follows: 1. 200-300mm from A-pillar side for Cowl top. 2. Min 150mm from Headlight side for Housing of Headlight.
• Draft opening of 3deg given for Drawing feisiblity.
• Dart command used to create stiffners/ribs to provide ridgidity and strength to the mounting. When vehicle is in motion open ends of components tend to vibrate, stiffners used to reduse vibrations as they increase the stiffness.
• Embosses given for better fastening. Holes for fastening bolts have clearence of 5mm radius of flat surface.

2. Bumper mounting :

Bumper mounting area is used to fix the plastic bumper to the fender with the help of fastners.

Stiffner created for additional strength. Embosses for better fastening.

3. A-pillar mounting :

A-pillar is a structural pillar that combines the body to the roof. Cowl top is mounted in this area which includes wiper moter and its mounting is installed.

4. Sill Mounting :

Sill is the panel directly below the bottom of door supporting the floor and may be used to combine floor and the body. The bottom enf of the fender is mounted on the sill for reinforcement of fender panel, thus the sill mounting position is designed with holes and emboss.

5. Baffle mounting :

Baffle mounting or Splash guard are clip fit type mounting on inner side of fender arch over the tyre. It protects the engine compartment and pedestrains from causing injuries from chip out debris on the road which are carried by rotating tyres into the air. Special type of locking clips are used which are made up of plastics.

Applying Thickness to final surface:

Thickness of 0.75mm applied towards inner side of the final swed surface of Fender.

Different Views:

Conclusion:

All necessary mountings created for Fender design from skin data provided by styling team and by refering to provided master section. All design requirements and considerations were followed.