Fender Design Challenge

Fender Design:

Fender is a part of a vehicle that frames the wheel along with protecting the engine compartment against sand, mud, rocks, liquids and other road spray from being thrown into the air by rotating tyre.

Tyes of fender:

1. Full Bumper

2. Half Bumper

figure 1 Types of Fender

Objectives:

1. To design a drip area as per the master section
2. To design Sill Mount Area
3. To design Bumper Mount Area
4. To design A-Pillar Mount Area
5. Baffle Mounting Area

Given Data:

• Fender Skin Data
• Master Section for Drip Area

Fender Skin Data:

figure 2. fender skin data

Master Section For Drip Area Mounting:

figure 3. Master section

Since, there was some irregularities in the skin data as shown in the figure(4). A smooth surface was created using through curve mesh after trimming off the irregular surface as shown in the figure(5).

figure 4. Rough Surface figure 5. Smooth surface

1. Designing the Drip Area as per the Master Section.

figure 6. Drip mounting area

• After creating all the flanges for this region, 2 darts were provided between the sheets as shown in the figure() to reduce the NVH factors.
• The fender drip area is mounted to weldnuts to the engine compartment.
• A minimum of 150mm is kept from the front side and 300mm or less from the rear side as shown in the master section.
• The total length of the drip area should be less than 40mm to avoid the spring back during manufacturing.

2. Designing the Sill Mount Area

figure 7. Sill mounting area

The mounting point is at the bottom of the fender. The mounting should be created in such a way that the fender is firmly attached to the sill.

3. Designing the Bumper Mount Area

figure 8. Bumper mounting area

• This region is mounted to the bumper with the help of nuts and bolts.
• At this as well, 2 darts were provided to reduce the NVH factors and to provide addition strengths to that region.

4. Designing A-Pillar Mounting Area

figure 9. A-pillar mounting area

• This region is mounted to the A-pillar of the car with the help of nuts and bolts.
• Darts can also be provided to maintain structural integrity.

5. Baffel Mounting Area

figure 10. Baffel mounting area

• No embosses are provided at this section instead holes are created which allows the baffel to be fitted with good tolerances.
• Baffel mounting are clip type of mounting on the inner side of the fender arch over the tyre.
• It protects the car engine components and pedestrains from causing inhuries. They are mounted on the fender using special type of locking clip which are made up of plastics.

Conclusion:

Hence, a fender is designed with all the required mountings such as drip area, sill mounting area, baffel mounting area, A-pillar mounting area and front bumper mounting area also considering the European Standards.