Fender Design Challenge

FENDER DESIGN

Objective: In this project we will design the fender drip area, sill mount area, bumper mount region, A pillar mount and baffle mount.

Fender:

Fenders typically form an arch made either of plastic or metal on the side of the vehicle body, around each of the wheel cut outs. Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown into the air by the rotating tire., so fenders help mitigate some of this matter. Fenders can take a beating from the environment and daily driving conditions. They provide protection against outside conditions plus rocks and other types of debris thrown by wheels.

Types of Fender: -

There are two types of fenders, they are:

1. Full Bumper type.
2. Half Bumper types.

Full Bumper type:

Half Bumper type:

However full bumper is not used as the blank for the full bumper type is huge and involves lots of wastage. On the other side if we slightly increase the blank size for the half bumper type, two fenders can be produced at a same time. Also, plastic can be in cooperated into this type thus reducing the steel material, making it lighter and increasing the performance of the car.

Master section for the Fender Design: -

Design criteria: -

1. Embosses are provided to increase the strength.
2. Smooth curves are designed for easy manufacturing of panel.
3. Ribs are provided to drip area mount to give structural support.

Mounting points in Fender: -

1. Drip mount
2. A pillar mounts.
3. Sill mount
4. Baffle mount
5. Bumper mount

A. Drip Area mount: - Drip mount area is connected inside the hood with fasteners near engine cabin. We have given a additional gussets on one side of drip area for strength and additional structure on other side to reduce the tendency of vibration for sheet to achieve less NVH levels. We have given flat surface embosses for proper fittings and provide to increase the strength.

Design considerations for drip area:

1. It should be having 150 mm distance from front end is kept for the head lamps in bumper region.
2. It should be having minimum distance of 200 mm from rear end is kept for the wiper motor assembly.
3. Engine components should not be visible from outside, for this purpose initially 3 degree of angle and 9mm length is given.
4. The drip depth is should be 40 to 60 mm, if depth increase from 60mm the spring back effect will also increase.
5. Embosses are given to drip area to increase the strength.

B. Sill mount: Sill mount is the bottom most mounting point of the fender to mount rigidly. In this area we use relief’s for relieving the stresses while occurring.

C. A pillar mount: A pillar is on the cars either side of the front windshield glass, and it is mounted on the A pillar by means of the fasteners and these are covered by outer side view mirrors.

D. Bumper mount: Bumper mount is part of fender which is connected with bumper by using fasteners.

E. Baffle Area: These are the additional holes provided to support the accommodation of fender lining in our design. It is a plastic sheet used to cover the metallic part of the fender which acts as barrier between metal fender and foreign bodies to reduce corrosion by sticking foreign bodies on metal fender. Hence every vehicle is an accommodation with fender ling and mud flaps to reduce the expose of fender to foreign bodies.