Fender Design Challenge

Objective:- Design of the fender.

Introduction:- The fender car part is the body kit or body part installed on the left and right sides of the vehicle. Manufacturers usually attach fenders to the wheel arches. There are different reasons why they are a requirement in vehicles. One obvious reason is to improve the aesthetics of the vehicle. Fenders also enhance the car’s aerodynamics.

The main purpose of the fender is to prevent sand, mud, rocks, liquids and another road spray from being thrown into the air by the rotating tire.

Material Used:-You can find modern car fenders made from steel, aluminum, thermoplastic, and fiberglass. Steel is the most rigid and abrasion-resistant material used in making fenders. They offer the best protection from large debris and are less likely to dent—making them a popular choice for off-road vehicles.

Types Of Fender:- There are two type of fender-

1. Full Bumper type
2. Half Bumper Type

• Presently, We are using half bumper type, the reason for choosing the half bumper type is that when we choose full bumper type the blank used for creating, it is very large and also has lot of wastage, but in the case of the half bumper type we have the possibility to reduce the scrap. This is what we called as scrap management.
• In half bumper type we reduce the usage of the steel material and uses the lots of plastic on the bumper which in term decrease the cars weight and increase the performance.

Fender Wheel Arch:-

The design of the wheel arch of a fender should be such that it must have sheild wheel and protect both passenger compartment and pedestrians from the projection of water, mud and stons. Wheel arch is the semi- circular part of the fender positioned above the wheel of the vehicle. For the vehicle to has its use permit in different countries the wheel arch of fenders must be compliant with the standard and regulation set by the respective countries.

Different Fender Regulations In world

U.S. Regulation:-The clearances L at all position every 10 degree from -20 degree to 180 degree should greater than 5mm to satisfied U.S. regulation.

European Regulation:-

• All the section have a clearance of 5mm from the tire when viewed from the top.
• The value of L should be more than 5mm at a line 30 degree forward and 50 degree rearward from centre vertical axis of the wheel.

Japanese Regulartion:-

• Clearance L between the outer surface of the tire and fender in three different positions within area K as mentioned in the figure must be greater than 5mm.
• The value of L shall be more than 5mm at line 30 forward and 50 rearward from the central verticle axis to the axis of the wheel.

Note:-We follow the European Regulation.

Mounting Regions on Fender:- There are 5 mounting regions on the fender, they are-

1. A-Pillar Mounting
2. Body Mounting
3. Side Mounting
4. Bumper Mounting
5. Drip Mounting

Design Methodology

Design Of Drip Area

• It is the important mounting unit of the fender. It is connected with the engine compartment, therefore the lot of design constraints are to be follows while designing the fender.
• While designing the drip area we have to initially leave 200-300mm for cowl top.
• For placing the headlamp, we have to leave at least 150mm at the front while designing the fender.
• Cowl to part consists of wiper motor and its instruments.
• Two darts are added on the longer side of the drip area in order to provide the stiffness and adds strenth to the parts. This helps the fender to not to vibrate and impact the forces outside of the fender during motion of the vehicle.
• Embossing are provide on the mounting to strength then during fastening.

Design Of Sill Mounting Area :- Sill is the panel directly below the bottom of the door supporing 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 reinforecement of the fender panel, thus the sill mounting position is designed with hole and emboss. M6 fastners are used to fix the fender on the sill body.

Design Of Bumper Mounting Area:- Bumper mounting are used to fix the plastic bumper to the fender with the help of the fastners.

Design Of A-Piller Mounting Area:- The A-Pillar is the structural pillar that combine the body to the roof. This make the sides of the windshields rest. Front fender are fastnent to the A-pillar to form a robust structure.

Design Of Baffle Mounting Area:- Baffle mounting or mudguard are clip fit type of mounting on the inner side of the fender arch over the tyre.It protects the engine compartment and pedestriant from causing injuries from chip out debris on the road when the car is in motion. They are mounted on the fender using motion. They are mounted on the fender using a special type of locking chips which are made up of plastics.

Applying Of Thickness Of the Surface:-At the end, we apply 0.75mm inward thickness.

Isometric View

Front View

Side View

Top View