Fender Design Challenge

FENDER:-

The fender is the car body part that frames the wheel. Its purpose is to prevent sand, dirt, rocks, and other roads spray from being thrown into the air by the rotating tire and close the engine component. When a vehicle is moving, tires pick up stones and others and hurl them in all directions. Fenders are basically present to prevent any injuries to pedestrians and contain the motion of these particles. A pair of front and rear fenders can be found on each side of a vehicle.

Fender is the US English term for the part of an automobile (vehicle body) that frames a wheel well (the fender underside).

Aside from keeping your vehicle clean, car fenders protect vital components from minor collisions. They also help define the car's overall style and design. They provide classy contours that give your car a classy, edgy look, especially when your vehicle is viewed from the side. They also help improve your car's aerodynamics, so your car is not only cleaner but also faster.

Curved steel was predominantly used in the fabrication of fender panels when they were first introduced in the late 1800s. Today, automakers use non-ferrous sheet metals and other materials to avoid corrosion damage caused by exposure to water and the elements. You can find modern car fenders made from steel, aluminum, thermoplastic, and fiberglass.

Types of car fenders:

• Full Bumper type
• Half Bumper type

Either a single full bumper type or two half bumper type fenders can be produced from a single blank. Half bumper type is widely used because of less wastage of material, which in turn reflects the car's overall price.

Fenders based on location:

Front Fenders or Front Quarter Panels:

Front fender panels are located on the sides of each front wheel. These panels typically cover the sides of the headlights to the hinge of the driver and passenger doors on the A-pillar. A car front fender runs vertically from the hood to the wheel well.

Rear Fenders or Rear Quarter Panels:

Rear fender panels are located on the sides of each rear wheel. They extend from the edge of the rear doors on the C-pillar all the way towards the edge of the taillights. Rear fenders also usually feature a fuel hole with a gas cap. These features can be found on either the driver or passenger rear panels, depending on the year and model of the vehicle.

Mounting points on a fender:

• Drip Area
• Bumper Mounting Region
• Sill mounting Region
• A-Pillar Mounting Region
• Wheel Arc Mounting Region

Drip Area: It is the critical mounting area located inside the engine component. Designed according to the master section provided, an optimal opening angle is maintained to make it look well assembled from the outside. Minimum clearance from headlamp and cowl part is maintained. The vertical distance of the drip mounting is maintained at less than 60mm to avoid the spring-back effect. The drip area is mounted to the engine compartment by weld nuts.

Master section to create drip area:

Modeling:

Drip and Sill Regions:

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.

Considering the above design constrains we have to design the drip area. Embosses are provided to increase strength, corners of the flanges are smoothen to ease of the production. Uniform wall thickness of 0.75mm.

• Design Consideration for drip area are150mm distance from front end of the fender and the gap is filled with headlamp200mm distance from rear end of the fender and the gap is filled with wiper motor assembly.
• 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.

Bumper and A-pillar mountings:

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.

Here, the proper embossing are provided along with holes for fasteners.

1. Law extension dimensions are 42mm length and 90 degree of angle.Offsetting the law extension face 5mm.Creating a sketch and law extension feature is used 6mm length and 95 degree of angle.Trim sheet to create a hole of 5mm diameter.Edge blend and face blend are 2mm.

Splash/Baffle Mountings:

VIEW OF FENDER:

TRIMETRIC VIEW:

TOP VIEW:

ISOMETRIC VIEW:

LEFTSIDE VIEW:

FRONT VIEW:

RIGHTSIDE VIEW:

BACK VIEW:

BOTTOM VIEW:

CONCLUSION :

Thus, all moounting areas for the fender designed from skin data and master section is done by following all design rules .

Part file and STEP (.stp) format are attached below.