Fender Design Challenge

OBJECTIVE: Design the car front fender along with the Sill , Bumper , A-piller , Baffle and Drip Area with the help skin data provided.

INTRODUCTION:

The fender is an automobile body part that frames the wheel and helps to prevent sand, dirt, rocks, and other external particles being thrown into the air by the rotating tire which causes damage to vehicle (particularly engine compartment) and people surrounding close to the vehicle.

When a vehicle is moving, tires pick up stones and others and hurl them in all directions. Fenders are basically present to prevent injuries to pedestrians that due to the motion of these particles. A pair of front and rear fenders can be found on each side of a vehicle.

Apart from keeping your vehicle clean, car fenders gives good aesthetics and improves car's aerodynamics.

Fig.1: FENDER

Fig.2: FRONT FENDER Fig.3: REAR FENDER

TYPES OF FENDER:

FULL BUMPER TYPE: In full bumper type ,the wheel arch area is more and the fender covers the half of the wheel which will increase in material cost and also add weight to the car.

Fig.4: FULL BUMPER TYPE

HALF BUMPER TYPE: Half bumper type are the one's used in new generation vehicle to reduce the weight , material and also cost of the vehicle.Here the scrap can be saved during material stamping or cutting process by using the half bumper type.

Fig.5: HALF BUMPER TYPE

FENDER DESIGN:

DATA PROVIDED:

Fig.6: DRIP AREA DESIGN DIMENSIONS

Fender Thickness Information = 0.75mm

DESIGN CONSIDERATIONS:

CONDITIONS:

• Wheel arch must be verified according to the standard in which the fender is being designed.
• Distance must be measured between outer tangent point created through side reference line (SRL is drawn 45° to the ground) to the inner most point , the obtained value should not be greater than 47.5mm.

If any of the above conditions was not met by the skin data produced , then it must be reverted back to styling team with results. After passing above test the following parts need to be designed.

FENDER MOUNTINGS TO BE DESIGNED:

• A- pillar
• Drip Area
• Body or Baffle
• Sill
• Bumper

Fig.7: FENDER MOUNTINGS

A-PILLER MOUNTING:

There are 3 types of pillers when refering to the design of the car - A,B, and C .

• The A-piller on your car hold either side of the front windscreen in place.They are the ones you see as you look stright at the car from the front.
• B-piller starts where the driver and passenger -side windows end as you look backward along the length of the car.
• C-piller holds the sides of the car's rear window in place.
• Some cars also have a D piller such as estate cars for example.D piller holds the sides of the window of the car in place and can also sometimes serve as housing for the rear lights like indicators ,breakes and alike.

Fig.7: A-PILLER MOUNTINGS

DRIP AREA MOUNTING:

1. It is the area through which the fender is attached to the engine housing through fastners.
2. There should be some considerations followed to design the drip area of the fender.
3. From back side of front fender there should be 200mm clearence for cowel(wiper moter) mounting area.
4. From front side of front fender ,there willl be a clearence of 150mm clearence for head lamp housing unit.
5. Remaining area we can use to design a drip area.
6. Height of fender can be minimum 80mm for child and adult (94mm,WAD 1700MAX ,this +14 for increase in inertial force due to accident)impact.
7. Parting will minimum 5 not more than 50mm from SRL( a rreference line on hood side,a point on fender makes from a line of 45 degree from ground level).
8. Drip area will not reach the engine assembly due to restriction of 40mm length ,so there will some L-shaped Bracket to connect with it.

Fig.8: 200mm clearence from A-piller Fig.9: 150mm clearence from Bumper

Fig.10: DRIP AREA

Darts has been provided to produce stability and reduce spring back effect.

BODY OR BAFFLE MOUNTING:

This is the mounting where baffle i.e shelid to hold external particles enter in to vehicle.

Fig.11: BAFFLE MOUNTING

SILL MOUNTING:

The mounting area at the panel (metal plate) directly below the bottom of the door supporting the floor and may be used to combine floor and the body.

Fig.12: SILL MOUNTING

BUMPER MOUNTING:

A mounting area of fender to bumper.

Fig.13: BUMPER MOUNTING

The positioning data of all the above mounting area will be provided by the respective part devoloping departments.

COMPLETE FENDER:

CONCLUSION:

By considering all the design considerations the fender has been devoloped succesfully with A-piller, Drip area, Sill , Bumper & Baffle mount are done . Also, the design was executed under the european safety standards and hence satisfies fender safety both for vehicle and the pedestrians.