Fender Design Challenge

• DESIGN A FENDER USING NX CAD

REQUIRED:

The objective is to design a front fender from the given surface with drip area,bumper mount,sill mount and A piller mount

THEORY:

Fender is the US English term for the part of the part of an vehicle body that frames a wheel well,its primary purpose is to prevent sand,mud,rock,liquids and other road spray from being thrown into the air by the rotating tire,It is BIW in omponent whose purpose is to avoid water and other tiny rocks or dust splashing into passenger compartment ,fender has no contribution to the sructural rigidity of the vehicle in comparision to the body frame

• Nowdays fender is designed in such a way to reduce air drag by fallowing areodynamics principles for improving the performance of the vehicle
• It doesnt provide any stuctural rigidity to the frame but protect both passenger compartment and pedestrains from the prrojection of water,mud and stones
• Most passengers automobiles have four fenders ,one over each wheel,for vehicle with the narrow car body that exposed curve over the top of the tire .For wide body vehicles that cover the tire ,the fender forms the wheel well surrounding the tire and is not directly visible from the above the car body
• When well tend to be much larger than the diameter of the tire ,because they do not move with the tire suspension and consequently must be large enough to allow the full range of tire motion on the suspension without touching the interior of the wheel well

MANUFACTURING PROCESS FOR CAR FENDER

The manufacturing process includes the fallowing 

MOUNTING:

For fixing the fender ,Mounting are essential.In our design we classified these mounting  as fallow

• Drip Area Mounting
• Bumper Mounting
• Sill Mounting
• A-Piller Mounting
• Baffel Mounting

• These are joined  using fastners and not brackets,thereby improving the NVH factor (Noise,Vibration and Hardness).

DESIGN OF DRIP AREA MOUNTING:

1. 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 fallowed while designing the fender 
2. while designing the drip area we have to intially leave 150-300mm for the crowl top we have to leave atleast 150 mm at the front while designing the fender for placing the head lamp 
3. embossing are provided on the mounting to stenghen them during fastening

DESIGN OF SILL MOUNTING AREA:

Sill is the panel directly 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 reinforement of the fender panel thus the sill mounting position is designed with the holes and emboss.

DESIGN OF BUMPER MOUNTING AREA:

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

DESIGN OF A PILLAR MOUNTING AREA:

The A pillar is the structural pillar that combines the body to the roof .This makes the sides of the windsheild rest .front fender are fastened to the A pillar to form a robost structure

DESIGN OF BAFFLE MOUNTING AREA:

Baffle mounting are clip fit thype of mounting on the inner side of the fender arch over the tyre .It protects the car engine compartmemt and pedestrains from causing inguries from the chip out debris on the road when the car is motion ,they are mounted on the fender using a special type of locking chips which are made up of plastics 

APPLYING THICKNESS  TO THE SURFACE:

The thickness 0.75 mm inward on the final sewed surface of the fender to the sheet metal parameters

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