Objective:

To design a front fender from the given skin data and the master section provided with Drip mounting, A-pillar, Sill, Bumper and Baffle (splash) Mounts.

Introduction:

Fender is the sheet metal part which is mounted above the wheel. Its main function is to prevent sand, mud, pebbles etc. from being spread via moving wheels. There are two types of fender:

• Full bumper type
• Half bumper type

Half Bumper type Fender

In this project we are working on Half bumper type fender. It normally used in most of the cars because it reduces the amount of sheet metal used and increased the use of plastic; resulting in weight reduction of the car and cost reduction in the production.

Design Methodology:

Fender design on NX-CAD was done with the help of Given master section and skin Data:

Master Section

Skin Data

There are five Mounting area of the fender which are to be created on the design:

• Drip Mouning
• A-Pillar Mounting
• Sill Mounting
• Baffle mounting
• Bumper mounting

Different Mounting Areas

Drip Area Mounting:

It serves as the fender's crucial mounting unit. It is attached to the engine compartment, so there are many design constraints that must be adhered to when constructing the fender.

Two Darts are provided in this area. These darts reinforce the design and provides extra stiffness. Basically, it dampens the vibration in this are while the movement of vehicle.

Also, Embossings are provided to increase the strength during fastening.

Drip Area

Sill Mounting Area:

It is the bottom area of the car which supports the door and the floor of the car along with the fender. Here also we have provided embosses to strengthen the design during fastnening.

Sill Area Mounting

Bumper Mounting Area:

It is the area where the Fender is attached to the bumper of the vehicle.

Bumper Area Mounting

A-Pillar Mounting:

The structural pillar connecting the body to the roof is known as the A-pillar. The side of the windshield rests on it. A -pillar and front fenders are connected to make a solid framework.

A-Pillar Mounting

Baffle Mounting Area:

Baffle mounting, also known as mud-guard ensures safety of pedestrians and also protect engine compartment.

Baffle Area Mounting

Thickness:

After finishing the design, a thickness of 0.75mm was provided to the surface in inward direction.

The final Design:

The Front View

Side View

Top View

Isometric View

Conclusion:

Thus, the fender was designed based on the given skin data and master section with ass the mountings, embosses, Darts etc.