Fender Design Challenge

Purpose:

To design the Drip Area, Sillmount area, bumper mount region and A-pillar mount Region.

THEORY:

FENDER :

Fender covers a wheel, traditionally to prevent water and mud spray, but now also for aerodynamic purposes. Bumper protects the body from small impacts to the front or rear of the vehicle 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.

Fender Design :

• Primary purpose of fender is to avoid sand, mud rock, liquid & other particles to be thrown in air due to rotation of the wheel

• Fender avoids motion of the rocks which can be hit to the pedestrians.

• It also avoids hitting of mud or rock to the inside of the engine compartment

• Front fender are indivisually designed whereas rear fender accomodated in body side structure.

MASTER SECTION OF FENDER:

Requirements to be considered while designing front fender:

• Drip area.
• Wheel arch.
• Front crashal safety requirements.
• Gap and flushness requirements.

Types of fender :

Above fig shows types of fender

• Full bumper type is not used nowadays bescause they requires bigger size blank to produce the pat & the large scrap is also produced.
• In half bumper type the scrap quantity is reduced & we can produce two parts at same time by slightly increasing the size of the blank.
• In half bumper type we can use plastic parts at front which reduces weight of the part.

Fender mainly have 5 points of attachments :

1. A Pillar:

2. SILL:

3. BODY:

4. BAFFEL MOUNTING:

5. DRIP AREA:

Design considerations for drip area :

1.150mm Distance from front end is kept for the headlamps in bumper.

2. 200mm Distance from rear end is kept for the wiper motor assembly

3. Engine components should not be visible from outside. For this purpose initially 3 degree of angle & 9mm length is given

4.40 to 60mm depth is given if the depth increase from 60mm the springback effect will also increase.

5. Embosses are given to the drip area to increase the strength.