Challenge

Fender Design Challenge

KKarthick C7 Aug 2022

Fender Design

Objective:

To Develope the Front Fender given skin data using NX CAD following Parameters.

Introuduction:

A fender is the part of a car that protects and frames its wheels and keeps mud from splashing it. Most modern vehicles have fenders on their front wheels. When you get into a minor car accident, you can call it a "fender bender," and it's possible that your fenders did get slightly dented.

Design Parameters

The front fender is manufactured as a separate part , this is then mounted to the body of car , for this the front fender basically has 5 mounting points, but this mounting points can differ from OEm to another OEM .below is the points

1.Drip Area

2.A pillar Area

3.Bumper Area

4.Side Sill Area

5.Baffle Mounting

Design Procedure.

Given Outer Skin of the Front Fender taken as Input Shown in Below

Front Fender Skin Data Drip Area Given Parameter

1.Drip Area

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

Drip Area

The height of drip area mounting should be less than 40mm so that it reduces the springback effect during manufacturing .
The edge of the mounting part should be atleast 10mm away from the nearby components in the engine .
It should be distanced atleast 150mm from the front side ande 200m from the rear side .
Ribs should be provided in order to increase the strength of the mounting part .
Bead is provided at the outeredge to increase the rigidity of part .

2.A Pillar

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.

A Pillar Mounting

3.Bumper Area

For improvement of NVH in car, usually a baffle is mounted on the fender of the car . it is mounted on the wheel arch area.

Bumper Area Mounting

4.Side Sill

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.

Side Sill Mounting

5.Baffle Mounting

In this section holes are created which allow the baffle to be fitted with good tolerances
Baffle mounting are clip type of mounting on the inner side of the fender arch over the tyre.
It protect the car engine components and pedestrians from causing injuries. They are mounted on the fender using a special type of locking clip which are made up of plastics.