Fender Design Challenge

Aim:

The main aim is to design the fender model with the necessary mounts using the class-A surface.

Mounts:

1. Bumper
2. A-Pillar
3. Sill
4. Cowl
5. Drip

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. or

Fender is a 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 Mudguard.

Types of fender:

• Full Bumper Type.
• Half Bumper Type.

Full Bumper type:

The use of full Bumper type is stopped now a days because they requires bigger size blank to produce the part and there will be a large amount of scrape so to reduce the wastage of material and in order to reducing the cost we shifted to half Bumper type

Half Bumper Type:

Half bumper types are used in present and future also because the blank size is less and the wastage or scrap is less comparing to full bumper type fenders with increasing the size of Blank size slightly we can produce 2 fenders at same time and save material and cost.

Uses of car Fenders:

• Car Fender limit the exposure of your car's body and engine to external elements that are harmful.
• Fender flares are attached to ensure that both the body and engine have minimal contact with corrosive elements
• 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 Fenders are designed to avoid wind resistance and make your car more aerodynamic.
• Car Fender enhance the overall look of your cars. Fender flares are available in distinctive designs in the market. Mostly you find universal Fender flares, but you can get customized cars Fenders to fit your car wheels.

Key Points to remember while designing the fender mounting points

• To have sufficient mounting space for the Cowl top we need 200mm space
• If cowl top become smaller then the conventional cowl top we can reduce the 200 mm space else no
• For Head lamp housing unit to have sufficient space to place we provide atleast 150 mm space
• A parting shall be provided within a range of 47.5 mm from SRL if there is no problem in terms of styling

Areas to be considered while designing a fender:

1. Drip area
2. Bumper mounting area
3. Sill mounting area
4. Body mounting area

Drip Area

The drip area is the connection of the fender with the engine compartment. It is the area through which the Fender is attached to engine housing through fasteners. There shold be some consideration followed to design the drip area, from back side of the fender there should be 200mm clearence for cowl mounting area and from the front there should be 150mm clearence for the head lamp housing unit

point to remember for this area are

• 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 exceeds from 60mm then forming is not feasible due to spring back and wrinkles.Embosses and ribs are given to drip area to give strength. Embosses dimensions are depth 3.5mm and 15 degree of angle for all three embosses.
• To have sufficient mounting space for the Cowl top we need 200mm space
• For Head lamp housing unit to have sufficient space to place we provide atleast 150 mm space

A Piller

A Piller is on the cars either side of the front windshield which is the reason the windshield in the place.It is Mounted on the A Pillar by means of fasteners and these are covered by outer side view mirrors.

SIL MOUNT AREA

It is mostely gets connected with the door region of the car.

BUMPER MOUNTING AREA

The Bumper Mounting region must be rigid in order to withstand the force acting upon it during collision. So, the Mounting space can be larger.

BAFFLE AREA

To attach the baffle simple holes are provided because it will be connected by the plastic fastners