Fender Design

FENDER DESIGN

AIM: To design a front fender of a car by following the given master section as per the design consideration of OEM.

INTRODUCTION:

Fender is the front outer side member of a car that covers the wheel side. Fender's purpose is to prevent sand, mud, rocks, liquids, and other particles. Fender is a closure component, closing the engine compartment and outer compartment. The major role of Fender is to avoid the chipping inside the engine compartment. During the motion, the wheel picks sand, mud, and small stone particles and throws them inside the car and these fenders will be helpful in preventing them by hitting inside the engine compartment and car body. These fenders will have a plastic part that lies on the wheel arch area. The fender plays a major role to avoid problems for pedestrians. Fenders are typically rigid and can be damaged by contact with the road surface. It is often also called a Mudguard. Fender is the US English term for the part of a vehicle body that frames a wheel inside it. Its primary function is to prevent sand, mud, liquid, and other materials from being thrown into the air by rotating air. 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 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.

TYPES OF FENDER:

1.FULL BUMPER TYPE

2.HALF BUMPER TYPE

Presently we are using half bumper type. The reason is when we were using a full bumper type fender, the blank which we were using is very big, and we have quite lots of wastage from the blank. But in the case of half bumper type, the case is the opposite. Here is the amount of scrap production is very low. Because the material can makes a major role in automotive industries. when we are using full bumper type it requires more material and weight of the car also increased. So because of that reason we use half bumper type.

MOUNTING REGIONS ON FENDER:

There are 5 mounting regions on the fender, they are

A-pillar mounting

Body mounting

Bumper mounting

Drip mounting

MASTER SECTION:

DESIGN OF DRIP AREA MOUNTING:

It is the important mounting unit of the fender. It is connected to the engine compartment, therefore a lot of design constraints are to be followed while designing the fender.

While designing the drip area we have to initially leave 200-300mm for cowl top.

For placing the headlamps we have to leave at least 150mm at the front while designing the fender.

The cowl top part consists of a wiper motor and its instruments.

Two darts/Beads are added in order to provide stiffness and adds strength to the part. This helps the fender not to vibrate and impact the forces outside of the fender during the motion of the vehicle.

Embossing is 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 may be used to combine the floor and the body. The bottom end of the fender is mounted on the sill body for reinforcement of the fender panel, thus the sill mounting position is designed with holes and emboss. M5 fasteners are used to fix the fenders on the sill body.

DESIGN OF BUMPER MOUNTING AREA:

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

DESIGN OF A-PILLAR MOUNTING AREA:

The A-pillar is the structural pillar that combines the body with the roof. This makes the sides of the windshield rest. Front fenders are fastened to the A-pillar to form a robust structure.

DESIGN OF BAFFLE MOUNTING AREA:

Baffle mounting or mudguard are clip fit type of mounting on the inner side of the fender arch over the tire. It protects the car engine compartment and pedestrians from causing injuries from chip out debris on the road when the car is in motion. They are mounted on the fender using a special tire of locking clips which are made up of plastics.

APPLYING OF THICKNESS TO THE SURFACE:

The thickness of 0.75mm inward on the final sewed surface of the fender to the sheet metal parameters.