Fender Design Challenge

                                                                                                               FENDER DESIGN REPORT

Fender is an important exterior component of an Automobile. Fender is the connecting link between the Bumper and the Sidedoor Panel. This is not the only purpose of the Fender. The Fender has a few very important functions to perform. They are - 

1. To protect the Engine Block and the Engine Components from getting hit by the little Sand & Rock particles that are thrown up by the fast-moving wheel. 

2. For aesthetic purposes. This fills the hole left after all the necessary components are added i.e; Hood, Bumper & Side Panel. 

3. Lastly and most importantly, to prevent the rocks and sand particles from hitting the Pedestrians nearby. It's made sure that all the particles hit the Baffle region of the Fender. 

                                                                                                

Fenders are classified into two types. They are - 

1. Full Fender Models -

Full Fender Models were predominantly used in the early years of Car marking where usage of Plastics were very minimal. They used to make a single Sheet metal Blank for the entire Fender component. This method resulted in a lot of wastage of Raw Material. And since the introduction of Plastics in the Automotive Industry it was found that a few components in the Fender itself can be replaced by Polymers (Baffle etc.,).  

                                                                                    

2. Half Fender Models - 

Half Fender Models became quite popular after the introduction of Polymers in the Automotive Industry. This helps decrease the wastage of Sheet metal during the Blanking process. 

                                                                                   

Fender Mounting Points 

There are 6 critical mounting points for a Fender. They are - 

1. Side Body Panel.

2. A-Pillar.

3. Sill.

4. Baffle. 

5. Bumper. 

6. Drip. 

Design of Mounting Locations - 

1. Side Body Panel 

As seen in the pictures below, we provide two seperate small mounting points on the Side Door Panel in order to improve the Strength of the Mount.

                                                                                        

                                                                                       

A panned out view of the region to be joined with the Side Door Panel is shown.

                                                                                                       

2. A-Pillar Mount Region 

This is the main Mount created for the A-Pillar region. This is supported by the mount we made in the middle on the Side Door panel region (Shown in previous section). 

                                                                                                  

3. Sill Mount Region 

                                                                                    

                                                                                            

The pictures above show the Mounts we made for the Sill area. We made a mount on each side of the Fender Wall. 

4. Baffle Mount Region 

Baffle is the plastic component that sits above the wheels and are below the Wheelwells. It's area is expansive and thus needs two different Mounting Locations for the Clamps. 

                               

                                                                                        

The picture is of a panned-out Baffle Area. 

5. Bumper Mount Region

As the name suggests, this is the mounting region that connects the Fender with the Bumper region. This mounting area is present usually in Half Bumper Models only. Full Bumper Models don't need a Bumper mounting.

                                                                                   

6. Drip Mount Region

This is the most important Design element of the Fender Design. Because, this region makes for the primary mounting/fastening point. So, the design rules for this sub-component are very important to follow. 

                                                                                

                                                                 

As we can see, there are Darts along the platform of the Drip Mounting Area. This is because Drip mount is a long element and there is need to strengthen the Platform and the Darts help in providing that. 

                                                                              

A cross-sectional view of the Drip area is shown above. Every single element must follow a Masters section failing which will lead to failure in the component entirely. This is because Drip area is a very important Technical feature (not an aesthetic feature).

DIFFERENT VIEWS OF THE FINISHED FENDER DESIGN