Fender Design Challenge

FENDER WHEEL DESIGN CHALLENGE

FENDER

Fender is the part of an automobile, motorcycle or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown into the air by the rotating tire.

Fenders are typically rigid and can be damaged by contact with the road surface.

• FENDER WHEEL ARCH

Fender Wheel Arch is the curvature arch present in Fender in line with the curvature of wheel, with maintaining certain amount of clearance, such that there is no contact between both the entities.

The Fender Wheel Arch is designed with a view of protecting the engine compartment of the vehicle and passenger compartment, from avoiding of the projection of mud particles, stones and fluid particles.

The Fender Wheel Arch is also a major part of car design, with a view of making the car look aesthetic and in the same line helping in reduction of the total overall weight of vehicle. Hence, making the car more efficient in terms of performance.

The Fender is not same in all countries, as the design varies accordingly – with respect to the standard regulations followed in each country, with a view of having safe ride, protecting both the passengers and the pedestrians from accidents.

• TYPES OF FENDERS

There are two types of Fenders: -

• Full Bumper Type.
• Half Bumper Type.

• FULL BUMPER TYPE: - The Full Bumper Type Fender is the type of Fender used in olden days, where the Wheel arch was guided up-to Half the size of wheel.

• HALF BUMPER TYPE: - The Half Bumper type Fender is the upgraded version of the Full Bumper Type Fender.

The main reason for adoption of Half Bumper type fender is to reduce the metal cost incurred to the overall weight of the car. The metal reduction in terms of overall weight of the car, increases the fuel efficiency of the car.

Half Bumper Type Fender plays a vital role in waste management.

• FENDER DESIGN

The Fender design is developed based on the type of Flanges that are created on the Fender, for mounting in Car.

There are 6 types of mounting regions on the fender, as follows: -

• Drip Area Mounting.
• A- Pillar Mounting.
• Baffle Mounting.
• Bumper Mounting.
• Sill Mounting.
• Door-Side Mounting.

• DRIP AREA MOUNTING

The Drip Area Mounting is the Important Mounting in the FENDER.

The Design Methodology Followed for The Development of Drip Area is based on the Design Inputs taken from the drawing shown below,

In the Above Drawing, the design considerations take are shown below,

• The Flanges for Drip Area starts from a distance of 200 to 300 mm from Cowl top/A-pillar Region.
• The Flanges for Drip Area Ends at a distance of 150mm behind the Headlamp Region.
• The Mountings on The Flanges are provided based on the placement of Fender in the car. The Necessary angles and extensions Provided for flanges makes sure that, the Fender provides minimum spring action after its mounting on the car. The more spring action of Fender leads to more vibration during the motion of the car.
• The minimum vertical distance for Tool Workability to mount the fender should be 200mm or more than 200 mm, staring from the mounting point, when the hood is in fully open condition.

The Embosses are created on the Mounting region and The DARTS are placed in intermediate positions of embosses to increase the Stiffness and strength of the DRIP AREA.

• A-PILLAR MOUNTING

The A-Pillar Mounting is Provide in The Cowl Top Region of the car.

The A- Pillar Mounting is a sophisticated mounting, as the embosses provided in it are at an angle, with respect to the Cowl-top of the car, which further combines body to the roof.

• BAFFLE MOUNTING

The Baffle Mounting is designed in accordance to the wheel arch of Fender.

The Flanges for Baffle Mounting are provided in inner side, thus protecting the car engine compartment from damages incurred due to debris taken from the road, during the motion of car.

• BUMPER MOUNTING

The Bumper Mounting Region is located near the Head-Lamp area of the Car below the Bumper.

The Flange of the Bumper mounting is external, where the necessary embosses are provided for mounting.

• SILL MOUNTING

The Sill Mounting region comes at the bottom position of the fender, near to Door Side area.

The Mounting Supports to the Floor of the Car chassis/body to make the Fender firmly attached and is aligned in line with the mounting holes provided near door side area.

The Flanges for the Sill Mounting are internal and embosses are provided followed by creation of hole to align with the hole provided in car body for fasteners to accommodate.

• DOOR SIDE MOUNTING

The Door Side Mounting is the Mounting provided near the Door area of the car body.

The Flanges for the Door Side Mounting is provided internal to the fender. The Fastening of the Fender with respect to the internal flange provided is done along with the door area of the car body.

CONCLUSION

The FENDER DESIGN is completed by providing suitable mountings and thickness of 0.75 mm is provided to the FENDER MODEL.