Fender Design Challenge

AIM:

The aim of these projects is to design fenders and the main design requirements for the Drip area, Bumper, A-pillar and Sill mounting areas.

FENDER DESIGN:

Fender

The fender is a front outer side member of a car which covers the wheel side. Fender's purpose is to prevent sand, mud, rocks, liquids and other particles. or

The fender is a closure component, closing the engine compartment and other compartments. The major role of the fender is to avoid chipping inside the engine compartment. During the motion, the wheel picks sand mud and small stone particles and throws it inside the car and these fenders will be helpful in preventing them from hitting inside the engine compartment and car body. These fenders will have a plastic part which lies on the wheel arch area. The fender plays a major role to avoid problems for pedestrians also. The fender is typically rigid and can be damaged by contact with the road surface. It is often also called a Mudguard.

Types of fender:

• Full Bumper Type.
• Half Bumper Type.

Full Bumper type:

It is not used nowadays because they require a bigger size blank to produce the part and the large scrap is also produced.

Drip area:

Drip area mounting is an important part of the fender. this mounting is attached to the engine compartment of the car. The fender drip area is mounted via weld nuts to the engine compartment. a min of 150mm distance is kept from the front side and a distance of 300mm or less can be kept on the rear side. the total length of the drip area from the top of the fender should be less than 40mm, this is to avoid the springing back during the manufacturing. the edge of the mounting should be at least 10mm away from any nearby component in the engine. a rigidity bead is provided at the end to increase the strength of the mounting.

Bumper mounting area:

Sometimes fender is also provided with the cowl area mounting. this mounting is on the top side of the fender.

A-pillar mounting area :

The A-pillar area mounting depends upon the A-pillar of the car. the mounting can also be provided with ribs to strengthen the part. this mounting is critical in design as it has to be mounted on A-pillar properly.

Sill mounting area :

Sill area mounting is also an important mounting part .this mounting point is basically on the bottom of the fender. the mounting part should be created such that the fender is firmly attached to the sill.

GIVEN FENDER SURFACE:

Let's cut the fender mounting surface used to create flanges in the drip area, sill mounting, A-Pillar, bumper and wheel arch area.

Features used

Boundary

Parallel curve

Points

Spline

Join

Split

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 should be some consideration followed to design the drip area, from the back side of the fender there should be 200mm clearance for the cowl mounting area and from the front, there should be 150mm clearance for the head lamp housing unit.

MASTER SECTION FOR DRIP AREA:

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

• Design Consideration for drip area are150mm distance from the front end of the fender and the gap is filled with headlamp 200mm distance from the rear end of the fender and the gap is filled with wiper motor assembly.
• Initially, a 3-degree angle and 9mm length is given while creating a drip area because the engine component should not be visible from the outside.

The depth of the drift should be between 40 to 60mm. If the depth exceeds 60mm then forming is not feasible due to spring back and wrinkles.

Embosses and ribs are given to the drip area to give strength. Embosses dimensions are depth of 5 mm and 10 degrees of angle for all three embosses.

Creat hole along with embosses for mounting with engine compartment using fasteners.

A PILLAR AREA:

A-Pillar is on the car on either side of the front windshield which is the reason the windshield is in 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 is provided along with holes for fasteners.

Sweep from the split edges in the A-pillar area for dimensions 42mm in length and 90 degrees of angle. Creating a sketch and extrude should intersect with sweep face and split it. again sweep in split edges used 6mm length and 80 degrees of angle. Offsetting the sweep face 5mm. Trim sheet to create a hole of 5mm diameter.Edge fillet and surface fillet are 2mm.

SIL MOUNT AREA:

The Sill Mounting area is at the bottom of the fender. It mostly gets connected with the door region of the car. Here, proper embossing and holes for the fasteners are provided.

Sweep from the edges of the sill mount area for 42mm length and 90 degrees of angle. Creating a sketch and extrude should intersect with sweep face and split it. again sweep in split edges used 6mm length and 80 degrees of angle reference with surface. Offsetting the sweep face 5mm. Trim sheet to create a hole of 5mm diameter.Edge fillet and surface fillet are 2mm.

BUMPER MOUNTING AREA:

In this Mounting, the Fender connects with the bumper.

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

Sweep from the edges of the bumper mounting area for 50mm length and 90 degrees of angle. Creating a sketch and extrude should intersect with sweep face and split it. again sweep in split edges used 6mm length and 80 degrees of angle reference with surface. Offsetting the sweep face 5mm. Trim sheet to create a hole of 5mm diameter.Edge fillet and surface fillet are 3mm.

BAFFLE AREA:

Creating holes for baffles(wheel arch).

create holes of 5mm in the split face in the wheel arch area.

FINAL FENDER SOLID COMPONENT:

MULTI VIEWS OF FRONT FENDER:

FINAL FENDER SOLID: