Challenge

Fender Design Challenge

NNobal Nagar28 May 2022

FENDER DESIGN

Fender- Fender is a front outer side member of a car which covers the wheel side .fender purpose is to prevent sand , mud, rocks, liquids and other particles .

Fender is closure component,closing the engine compartment and other compartments.The major role of the fender is to avoid the chipping inside the engine compartment. During the motion the wheel picks a sand mud and small stone particles and throws it inside the car and these fenders will be helpful in preventing them by hitting inside the engine compartment and car body .These fenders will have a plastic part which lies on wheel arch area.The fender plays a major role to avoid problems for pedestrian also. fender are typically rigid and can be damaged by contact with the road surface .It is often also called as Mudgaurd.

Types of fender :-

Full Bumper Type
Half Bumper Type

Full bumper Type:- If the fender covers the tire , the wheel well surrounding the tire,and it is not directly visible from above the car body.It increases the weight and scrap of the component.it is not used now a days because they requires bigger size blank to produce the part.

Half Bumper type:- It Reduces the weight and scrap it creates only half of what the full front fender does the other part is created with the bumper part.It used in present and future also because the blank size is less and the wastage or scrap is less comparing to full bumper type fender.

USES OF CAR FENDERS

car fender limit the exposure of your cars body and engine to elements that are harmful.
fender flares are attched to ensure that both the body and engine have minimal contact with corrosive elements.
car fender are designed to avoid wind resistance and make your car more aerodynamic.
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 fender enhance the overall look of your cars . Fender flares are available in distinctive designs in the market place .Mostly you find universal fender flares , but you can get customised cars fenders to fit your car wheels .

AREAS TO BE CONSIDERED WHILE DESIGNING A FENDER

Drip area
Bumper Mounting area
Sill mounting area
Body mounting area

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

DRIP AREA :-

It is area through which the fender is attcached to engine housing through fasteners.There shold be some consideration follewed to design the drip area ,from back side of the fender there should be 200mm clearance for cowl mounting area and from the front there should be 150mm clearance 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 off 0.75mm.

Design Consideration for drip area area 150mm distance from front end of the fender and the gap is filled with headlamp 200mm 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 creating 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. Exeeds from 60MM, then the forming is not feasible due to spring back and the wrinkles. Embosses and ribs are given to drip area to give strength.Embosses dimensions are depth 3.5mm and the 15 degree of angle for all three embosses.

A PILLAR AREA:-

A pillaris on the cars either side of the front windshiled which is the reason the windshield in the piace.

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 wu=ith holes for fasteners.

Law extension dimentions are 42mm length and 90 degree of angle Offsetting the law extension face 5mm . Creating a sketch and llaw extion 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 3mm.

SILL MOUNT AREA :-

The sill mounting area is in the bottom of the fender.

It is mostly gets conected with the door region of the car.
Here ,proper embossing and holes for the fastners are provided.

The ribs are provided to improve the strength.

Extend sheet to 20mm to make sheet length 35mm .Giving relief by manual like creating a sketch and trim the sheet both sides .Emboss dimension are depth 3.5mm and 15 degree of angle .Edge blend is 3mm .Trimsheet is used to create a 6mm hole on sheet.

BUMPER MOUNTING AREA:-