Fender Design Challenge

AIM

Design Fender mountings such as Drip area, Sill mount, Bumper Mount, Baffle Area mount and A-pillar Mount.

INTRODUCTION

• A fender is the curved portion of the car’s body that sits over and houses the wheels. 
• The purpose of a fender is pretty simple. Its purpose is to keep mud, rocks, and other road debris from being thrown around by the tires. In other words, the fender is a housing for the wheels that keeps road debris contained. If there was nothing covering the wheels, all kinds of debris would be kicked up by the rotating tires.

Types of Fenders:

• Full Bumper Type

The full bumper type fender was used in old cars, it covers the full area until the front lighting. But it has a lot of sheet metal material which is unnecessary and increases the weight of the fender. These type fenders are no longer used in the automobiles.

• Half Bumper Type 

Half bumper fender is used because the waste of material is less & can produce two fender at the same time by slightly increare the raw sheet. and to reduce the weight & cost mostly bumper fender are been produced. It is the area which the fender is to be attached to engine housing through bolts.

DESIGN RULES

• As per the master-section provided the location of drip should be at 150mm from the bumper side and the gap of 200mm from the A-pillar.
• Check for the wheel arch radius and design of the fender outer by following the different regulations.
• Allow the draft, which should be manufactured without an error,
• 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.
• Clearance should be provided for the nutting tool to assemble the fender with the body of the car.

-Fender Wheel Arc :

•  The wheel arch is an arch-shaped cavity in the body of a vehicle, which houses a wheel. It has two important functions. It serves for the safety of pedestrians and other cars because the wheel is situated in the body of a vehicle.
• For the European  requirement the clearance between the wheel and the fender outer most skin is 5mm.
• This requirements changes from country to country based up on the  road conditions.

-Assembly Types:

There are  two types of assembly , they are

• Bottom-up assembly
• Top-down assembly

 Bottom -up assembly: The bottom-up assembly is the most preferred approach for creating assembly models . In this type of assembly the components are created in part design work bench ( As nx cad part) file. Parts are conceived in assembly design workbench using product structure tools . After inserting each component,constraints are applied to position them properly in the 3d space with respect to the other components. This assembly is preferred for large assemblies, especially those having intricate individual components .

Top -down assembly :

In the top assembly design approach, components are created inside the assembly design workbench . There fore , there is no need to create separate part files of the components. This design approach is completely different from the bottom-up design approach. Here you have to create the  product file first and then one by one create all the components. Note that even then the parts are created the product file , they are saved and opened individually one by one  when they are needed . Here the construction and the assembly takes place simultaneously .

Mounting Regions

DESIGN PROCEDURE

Input From Styiling team:

Dip Area:

• It  is the important mounting uni of the fender  . it is connected with the engine compartment , therefore the lot of design constraints are to be followed while designing the  fender
• While designing the drip area we have to initially leave 200-300 mm for cowl top
• For placing the headlamp we have to leave  at least 150 mm at the front while designing the fender
• Cowl top part  consists pf wiper motor and its instruments  

Bumper Area :

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

A-Pillar Mounting:

The A -pillar is the structural pillar that combines the body to the roof . this make the sides of the  windshield rest . front fenders are fastened to the A -pillar to form a robust structure.

Baffle Mounting Area:

Baffle mounting or mudguard are clip fit type of mounting on the inner side of the fender arch over the Tyre  . 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 type of locking clips which are made up of plastics .

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.

VIEWS

TREE STRUCTURE