Fender Design Challenge

Question:

Follow the given Master section to create the Drip Area

For the Sill, Bumper, Baffle(Splash), and A-Pillar mount create your own design according to the Engineering standard that you learned.

Prepare a report with all the relevant images included for the mounting points created.

Solution:

Introduction to Fender:

• Fender is the part of the bedy of vehicle which covers the wheel and the engine compartment.
• The fender is provided in such a way that it will protect the padestrians from the high impact from the engine comapartment.
• The fender is also the cover made in such a way that the customer won't see the internal ugly areas of the engine compartment.
• It is made up of pastic or softer material so that the impact of the fender on the pedestrians is less.
• The Fender part is of two types:
  • Full Bumper Type
  • Half Bumper Type
    
• Generally full bumper type fenders were used but to reduce the waste material half type fenders are used in most of the cars.
• There are 5 areas of mouting:
  
  1. A-Pillar Mounting
  2. Body Mounting
  3. Sill Mounting
  4. Bumper Mounting
  5. Drip Mounting

Design Methodology:

Master Section to create the Drip Area Mounting

1. Mounting on The Drip Area
   
   • It is the important mounting uni of the fender. It is connected with the engine compartment, therefore the lot of design constraints are to be followed while designing the fender
   • While designing the drip area we have to initially leave 200-300 mm for cowl top
   • For placing the headlamp we have to leave at least 150 mm at the front while designing the fender.
   • Cowl top part consists PF wiper motor and its instruments.
   • Two darts are added on the longer side of the drip area in order to provide the stiffness and adds strength to the part . This helps the fender to not to vibrate and impact the forces outside of the fender during motion of the vehicle.
   • Embossing are provided on the mounting to strengthen them during fastening.
2. Mounting on the Sill Area
   • Sill is the panel directly below the bottom of the door supporting the floor and may be used to combine the floor and the body . The bottom end of the fender is mounted on the sill body for reinforcement of the fender panel , thus the sill mounting position is designed with holes and emboss . M5 fasteners are used to fix the fenders on the sill body.
     
     
     
3. Mounting on the Bumper Area
   Bumper mounting area is used to fix the plastic bumper to the fender with the help of the fasteners.
   

4. DESIGN OF A-PILLAR MOUNTING AREA :
   The A-Pillar is the structural pillar that combines the body to the roof. This make the sides of the windshield rest. Front fenders are fastened to the A-Pillar to form a robust structure.
   
   
   

5. DESIGN OF BAFFLE MOUNTING AREA :

   • Baffle mounting or mudguard are clip fit type of mounting on the inner side of the fender arch over the Tyre.

   • It protects the car engine compartment and pedestrians from causing injuries from chip out debris on the road when the car is in motion.

   • They are mounted on the fender using a special type of locking clips which are made up of plastics.
     

APPLYING OF THICKNESS TO THE SURFACE .

The thickness of 0.75 mm inward on the final sewed surface of the fender to the sheet metal parameters.

CONCLUSION :

Finally design of fender is done with the help of NX-CAD software by following the master section.