Challenge

Fender Design Challenge

RRahul Raj9 May 2022

AIM-

The aim of these project is to design fender and the main design requirements for Drip, Bumper, A pillar and Sill mounting areas.

Fender

Fender is the American English term for 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.

Sticky materials, such as mud, may adhere to the smooth outer tire surface, while smooth loose objects, such as stones, can become temporarily embedded in the tread grooves as the tire rolls over the ground. These materials can be ejected from the surface of the tire at high velocity as the tire imparts kinetic energy to the attached objects. For a vehicle moving forward, the top of the tire is rotating upward and forward, and can throw objects into the air at other vehicles or pedestrians in front of the vehicle.

Types of fender:

Full Bumper Type.
half Bumper type

Full Bumper type:

It is not used now a days because they requires bigger size blank to produce the part and the large scrap is also

produced.

Half Bumper Type:

Half bumper types are used in present and future also because the blank size is less and the wastage or scrap is less comparing to full bumper type fenders.

Uses of car Fenders:

Car Fender limit the exposure of your car's body and engase to external elements that are harmful. Fender flares are attached to ensure that both the body and engine have minimal contact with corrosive elements.

Car Fenders provides safety to the driver and the passengers at the time of accidents or collisions. They are manufactured in a way to provide bend during front and side collisions.

Car Fenders are designed to avoid wind resistance and make your car more aerodynamic.

Car Fender enhance the overall look of your cars. Fender flares are available in distinctive designs in the market. Mostly you find universal Fender flares, but you can get customized cars Fenders to fit your car wheels.

Areas to be considered while designing a fender:

1. Drip area

2. Bumper mounting area

3. Sill mounting area

4. Body mounting area

DRIP AREA

The drip area is the connection of the fender with the engine compartment.

It is the area through which the Fender is attached to engine housing through fasteners. Then shold be some consideration followed to design the drip area, from back side of the fender there should be 200mm clearence for cowl mounting area and from the front there should be 150mm clearence for the head lamp housing unit.

Considering the above design constrains we have to design the drip area. Embosses are provided to increase strength, corners of the flanges are smoothen to ease of the production. Uniform wall thickness of 0.75mm.

Design Consideration for drip area are150mm distance from front end of the fender and the gap is filled with headlamp200mm distance from rear end of the fender and the gap is filled with wiper motor assembly.

Initially 3-degree angle and 9mm length is given while credating a drip area because the engine component should not be visible from outside.

The depth of the drift should be between 40 to 60mm. If the depth exceeds from 60mm then forming is not feasible due to spring back and wrinkles.Embosses and ribs are given to drip area to give strength. Embosses dimensions are depth 3.5mm and 15 degree of angle for all three embosses.

A PILLER AREA

A Piller is on the cars either side of the front windshield which is the reason the windshield in the place. It is Mounted on the A Pillar by means of fasteners and these are covered by outer side view mirrors. Here, the proper embossing are provided along with holes for fasteners.

1. Law extension dimensions are 42mm length and 90 degree of angle.Offsetting the law extension face 5mm.Creating a sketch and law extension feature is used 6mm length and 95 degree of angle.Trim sheet to create a hole of 5mm diameter.Edge blend and face blend are 2mm.

SIL MOUNT AREA

The Sill Mounting area is in the bottom of the fender.

It is mostely gets connected with the door region of the car.

Here, proper embossing and holes for the fasteners are provided.

The ribs are provided to improve the strength.

1. Extend sheet to 15mm to make the sheet length 30mm.Giving relief by manual like creating a sketch and trim the sheet both sides.Emboss dimensions are depth 3.5mm and 15 degree of angle.Edge blend is 3mm. Trim sheet is used to create a 6mm hole on sheet.

BUMPER MOUNTING AREA

In this Mounting, the Fender connects with the bumper.

The Bumper Mounting region must be rigid in order to withstand the force acting upon it during collision. So, the Mounting space can be larger.

1. Law extension length 20mm and 75 degree of angle.Skew to join the two surfaces.Dart angle 45 degrees, depth 4mm and radius 3.75mm. Create two darts in existing spaces as shown in figure 7.Trim sheet is used to create a hole of dia 5mm.For skew use 3mm edge blend and for dart and embosses 2mm edge blend.

BAFFLE AREA: