Fender Design Challenge

DESIGN OF CAR FENDER:

Fender is a part of an automobile ,motocycle or other vehicle body that frames a wheel well.A fender is the curved portion of the cars body that sits over and houses a wheel.

WHAT IS THE PURPOSE OF FENDER:

Fender primarily purpose is to prevent sand,mud rock,liquid and other road spray from beign thrown into the air by the rotating tire.Fenders are typically rigid and can be damaged by contact with the road surface.

Sticky material such as mud ,may adhere to the smooth outer tire surface while smooth loose objects such as stones can become temporarily embeded in the thread groove as the tire rolls over the ground.These material can be ejected from the surface of the tire at high velocity as the tire impacts kinetic energy to the attached objects.For a vehicle moving forward the top of the tire is rotating upward and forward and can thrown objects into the air at other vehicle or pedestrians in front of the vehicle.

Early automobile fenders set over the wheeels to prevend mud,sand and dust being thrown on to the body and the occupants.Fender typically become more integral part of overall autobodies by the mid 1930s.In contrast to the slab sided cars,the volkswagen Beetle had real bolt on fender over both its front and rear wheels.

In auto industry nomenclature usually only the panels over the front wheel are called fenders.The auto industry changed from the rear fenders bolted onto a quarter panel to an enlarge welded on quartet panel that fulfilled both functions.

The fender openings openings for the wheel wells tend to be much larger than the diameter of the tire because they do not move with the tire suspensions and consequently must be larger enough to allow the full range of tire motion on the suspension without touching the interior of the wheel well.

Fenders are often made of fibre glass or ABS platic to ensure Flexibility and light weight, however some trucks and SUVs come with the metal fender flares to ensure better durability

DO CARS NEEDED FENDER:

Making sure that the tires are protected with Mud flaps and fender is important to prevent causing harm to someone or damaging the vehicle behind you.plus its a part of being a good neighbour on the road.

Fender is a front outer side member of a car which covers the wheel side.Fender purpose is to prevent sand,mud,rocks,liquids and other particles.

Fender is a closure component closing the engine compartments and the other compartments.The major role of the fender is to avoid the chipping inside the engine compartment.During the motion the wheel picks a sand mud and small stone particles and throw it inside the car and these fenders will be helpful in preventing them by hitting inside the engine compartment and car body.These fender will have a plastic part which lies on wheel arch area.The fender plays a major role to avoid problems for pedestrian also.Fender are typically rigid and can be damaged by contact with the road surface.It is often also called as Mudguard.

TYPES OF FENDER:

• FULL FENDER TYPE
• HALF FENDER TYPE

FULL FENDER TYPE:

It is not used now a days because they requires bigger size blank to produce the part and the larger scarp is also produced

HALF FENDER TYPE:

Half fender type are used in present and future also became the blank size is less and the wastage or scrap is less comparing to full fender type.

USES OF CAR FENDER:

• Car Fender limits the exposure of yours cars body and engine to external elements that are harmful
• Fender flares are attached to ensure that both the body and engine have minimal contact with corrosive elements
• Car Fender provides safety to the driver and the passenger at the time of accidents or collisions.They are manufactured in a way to provide bond during front and side collision
• Car Fenders are designed to avoid wind resistance and make your car more Aerodynamic
• Car Fender enhance the overall look of yours cars.Fender flares are available in distinctive design in the market.Mostly you find universal fender flares but you can get customized car.

AREAS TO BE CONSIDERED WHILE DESIGNING FENDER:

• Drip Area
• Bumper Mounting Area
• Sill Mounting Area
• Body mounting Area

DRIP AREA:

The drip area is the connection of the Fender with the Engine compartment.It is the area through which the Fender is attached to the Engine hosting through fasteners.There should be some consideration followed to design the Drip area from back side of the Fender there should be 200mm clearance for cowl mounting area and from the front there should be 150mm clearance for the head lamp housing unit.

Considering the above design constraints we have to design the drip area Embosses are provided to increase strength corner of the flanges are smoothen to ease of the production uniform wall thickness of 0.75mm.

Design consideration for drip area are 150mm distance from the front end of the fender and the gap is filled with head lamp 200mm 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 40mm to 60mm if the depth exceeds from 60mm then forming is not feasible due to spring back and wrinkles.Emboss and ribs are given to drip area to give strength.Emboss dimension depth are 3.5mm and 15 degree of angle for aall three emboss

A PILLAR AREA:

A pillar 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 mirror.Here the proper embossing are provided along with holes for fasteners.

Law extension dimension 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.Trim sheet to create a hole of 5mm diameter,Edge blend and face blend are 2mm.

SILL MOUNT AREA:

The sill mounting area is in the bottom of the fender.It is mostly gets connected with the door region of the car.Here proper embossing and holes for the fasteners are provided.The ribs are provide 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 side.Emboss dimension depth are 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.Draft angle 45 degree,depth 4mm and radius 3.75mm.

Create two draft in extisting space.Trim sheet is used to create a hole of dia 5mm.For skew use 3mm edge blend and for draft and emboss 2mm edge blend.

BAFFLE AREA:

CONCLUSION:

Developed the Drip,Bumper,Sill,A Pillar and Baffle Mounting Areas by design requirements of the Fender Design.