Fender Design Challenge

                                                                                                                              FENDER DESIGN

PURPOSE OF FENDER

1. Fender is an automobile part that frame a wheel well and also for the pedestrain safety requirement.
2. It Primary purpose to prevent sand , mud, rocks, liquids & other road spray from being enter into air by the rotating tire.
3. While the tires are rotating the stones enter into the fender they hurl them in all directions these damages can be prevented by fender. Fenders are  basically present to prevent any injuries and contain the motion of these particles. 
4. It also covers the engine compartment area to have a stylish outlook.
5. Fender form the Wheel well area above the wheel and  its not directly visible from top. Whell well is larger than the wheel diameter to allow the full range of suspension of the wheel without touching the interior of the wheel well.

MAJOR AREAS TO DESIGN A FENDER ARE:

1. Design Requirements .
2. Functional Requirements.
3. Drip Area .
4. Wheel Arch Area.
5. Baffle & ORVM(OUTSIDE REAR VIEW MOUNTING) Mount Area.
6. FRONTAL CRUSH.
7. GAP AND FLUSHNESS Requirements.

TYPES OF FENDERS 

• FULL BUMPER TYPE

• HALF BUMPER TYPE

• It is developed to reduce the Scrap and material usage.

FENDER MOUNTING REGIONS

• BODY 
• A PILLAR AREA
• SILL 
• DRIP

DESIGN OF DRIP AREA 

On all mounting region Fender Drip Area is the most critical part. It as some standard dimensions to  follow while designing the Drip Area.

• To design a drip area , there should be some gap of distance tobe naintained in the front and rear end of the fender. Minimum 200mm of distance or not more than 300mm from the rear end of the fender to have the sufficient space for the cowl mounting. Cowl parts are carrying the viper motor and its components. 
• Front End of the fender to have 150mm of distance for the Head Lamp mounting.

MASTER SECTION OF DRIP AREA DESIGN

• The Drip area is opened with an angle of 3 degree and length of 9mm . The 3 degree is used for the production purposes and again opened with the 5 degree flange to prevent the visibility of the engine compartment area from the outside of the hood. 
• Then Extend downwards of 40 degree depth of 40mm to 55mm to avoid the spring back effect, more the depth more the spring back will create in the drip area. Have a width of minimum 25 to 30mm to have space for the tools to tightens the fastners while the Hood in open condition.

• And also have max 0f 200mm distance between the drip area and the hood in open condition for mountning the weld nuts using fastners.

FENDER AND PEDESTRAIN SAFETY

• There show be minimum 10mm gap between the drip area and the Engine area to avoid the damages to the engine components while assembling the fender. 
• From the side reference lane the distance between the end point of the fender to the tip should not be more than 50mm. If the value is higher than the standard value correction to be made in fender or hood design.
• The L shaped 10mm bracket is used to join the fender with engine compartment.

BUMPER MOUNTING AREA

For Bumper mounting area, remove the extra portion material using the curve on surface feature and create an emboss using datum plane for flat surface. There is no design constraint for this area.

Baffle Mounting

• Baffle mounting is used is some vehicles to get the better of NVH Section.

A-PILLAR MOUNTING AREA

• The Region is created by trim sheet command remove the unwanted material using offset curve option and curve on face. A Pillar is used as a support for the roof of windshield. It is mounted on the rear end of the Fender.

SILL MOUNTING AREA

• Sill mounting is at bottom of the fender, this mounting design differs from car to car and some of the vehicle doesnt need the sill mounting region.

DART COMMAND

Dart is used to add the more strength to the area for the flat surface mounting area. Before applying Dart the sheet metals are to be sewed , Dart can be used only in the joined surface.

THICKEN

The value of thickness given to the sheet metal parts is 0.75mm.

Differntial Views of Fender

Conclusion

Hence , the Fender is deigned according to master section dimensions to the industry standard.