Fender Design Challenge

Fender design

Objective

To design the car front fender with the help of using skin data shared by the styling team and make it ready for manufacturing.

Introduction

Fender is the American English team for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well. Actually, it is a part that is in contact with the different parts of the vehicle like the A-pillar, sill, etc. typically fenders are rigid and house the wheels, inner body parts both at the front and back sides of the vehicle.

This fender plays a major role in pedestrian safety while a car is in motion. When it is in motion the wheel carryover the small stones, mud particle and throw away which may harm the pedestrian. So while designing these considerations are to be taken into account.

Types

1. Full bumper type

These are the fenders that cover the entire wheel of a vehicle and mainly it is used in earlier manufacturing as shown in the figure below.

2. Half bumper type

This fender is also the same as the above but with slight modifications by putting the cost and weight into considerations is changes were implement and made the fender aesthetically good as shown in the figure below

Purpose:-

The purpose of the fender is to put the car aesthetically good by covering the engine compartment and also to prevent the debris such as small stones, mud particles from being thrown outwards the vehicle while it is in motion, which may cause damage to the beside vehicles and also pedestrians.

Design consideration

1. As per the master section provided the location of drip should be at 150mm from the bumper side and the gap of 200mm from A pillar.
2. Check for the wheel arch radius and design of the fender outer by following the different regulations.
3. Allow the draft, which should be manufactured without an error.
4. The clearance distance should be maintained between the hood and the base drip area of about 200mm when the hood is at an open angle.
5. Clearance should be provided for the nutting tool to assemble the fender with the body of the car.

Manufacturing process

1. As per the design plan for tools to make ready the product for assembly.

1. Snipping or blanking operation should be done for taking the piece of a sheet from the long rolled one.
2. Bending and resulting are performed to get the desired shape.
3. Trimming is performed to trim the unwanted sections from the working sheet.
4. Piercing should be performed to make the required holes on the sheet.
5. Embosses are created by doing the deep drawing by considering the good draft angle.
6. Burning is the process of clearing the burns and edges like sharp corners after operations.

7.Burning is the process of clearing the burns and edges like sharp corners after operations.

Mountings of fender

• Body mount
• Drip mount
• Bumper mount
• Sill mount
• A-pillar mount
• Splash mount

Design procedure

Class – A surface

This obtained from the styling team as skin data, with the help of this fender is prepared.

Drip area

It is the most important mount of fender which is attached to the car body and near the engine compartment. This is designed by following the considerations such as the distance between the fender and engine room, clearance length between the hood, and the base area of the drip.

Bumper area

This is designed by consulting the bumper design team to share the model of assembly techniques.

Baffle area

In the section, holes are created which allow the baffle to be fitted with good tolerances.

A-pillar area

This is designed in such a way that the fender is assembled along its own angle as shown in the figure.

Sill area

This area is created by applying the embosses according to the data shared by the sill assembly technical team.

Conclusion

The fender of the automobiles is checked for the wheel arch radius as per European regulations and designed the front half fender of a car by following the pedestrians safety and in order to guard the engine compartment and beside the vehicle.