Challenge

Fender Design Challenge

AAmandeep Rohilla28 Jun 2022

AIM :To design the car fender according to the given design parameters related to industry standards.

INTRODUCTION-

FENDER :

Front fender is a part of the vehicle that frames the wheel . the primary purpose of the fender is to prevent sand , mud , rock etc frombeing thrown away into the air by rotating tire . fender can be of two types , full bumper type and half bumper type . nowadays halfbumper type fender is typically used . the cost of sheet metal blank is reduced as we can produce two half bumper type fender insingle blank . this also leads to reduction of scrap

Although nowadays the fender/wing covering the wheel is very much part of the overall car body, in the early days of car design thewheels were more remote from the chassis, and so to stop all manner of grubby bits flicking up at high speed from the wheels intoother road users (and all over your own gleaming coachwork) there needed to be some kind of extra guard.

DESIGN PARAMETERS

The front fender is manufactured as a separate part , this is then mounted to the body of car , for this the front fender basically has 5mounting points, but this mounting points can differ from OEm to another OEM .below is the points -

Drip area-

Drip area mounting is the important part in the fender . this mounting is attached to the engine compartment of the car . fender driparea is mounted via weldnuts to the engine compartment .a min of 150mm distance is kept from the front side and a distance300mm or less can be kept on the rear side . the total length of drip area from the top of fender should be less than 40mm , this is toavoid the springback during the manufacturing . the edge of the mounting should atleast 10mm away from any nearby component inthe engine . a rigidity bead is provided at the end to increase the strength of the mounting .

A-pillar area -
The A-pillar area mounting depends upon the A-pillar of the car . the mounting can also be provided with ribs to strengthen the part .this mounting is critical in design as it has to be mounted on A-pillar properly .
Body side area-
Another mounting point is created for the body side on the fender . this mounting is created such that it can be mounted on the bodyof he car . it may consist of one or two bolting holes .
Sill area -
Sill area mounting is also an important mounting part .this mounting point is basically on the bottom of the fender . the mounting partshould be created such that the fender is firmly attached to the sill .
Cowl area -
Sometimes fender is also provided with the cowl area mounting . this mounting is on the top side of the fender .

DESIGN

1)Drip area-

The height of drip area mounting should be less than 40mm so that it reduces the springback effect during manufacturing .
The edge of the mounting part should be atleast 10mm away from the nearby components in the engine .
It should be distanced atleast 150mm from the front side ande 200m from the rear side .
Ribs should be provided in order to increase the strength of the mounting part .
Bead is provided at the outeredge to increase the rigidity of part .