Fender Design Challenge

                                                                                                                FINDER

AIM :

         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.

PURPOSE OF FENDER :

• Fender is the US English term for the part of an automobile (Vehicle body) that frames a wheel well (the fender underside).
• Its primary purpose is to prevent sand, mud, rocks, liquids and other road spray from being thrown into the air by the rotating tire.
• When vehicle is moving tires pickup 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.
• Most passenger automobiles have four fenders, one over each wheel. For vehicles with a narrow car body that exposes the tire, the fender is an exposed curve over the top of the tire. For wide body vehicles that cover the tire, the fender forms the wheel well surrounding the tire, and is not directly visible from above the car body.
• Wheel wells tend to be much larger than the diameter of the tire, because they do not move with the tire suspension without touching the interior of the wheel well.
• More elaborate designs include fender skirts for enclosing the outside edge of the wheel well, and stylized pontoon fenders for exposed fenders.

                                                              

                                                                                        FRONT FENDER 

TYPES OF FENDER :

1. Full Bumper Type :

         The full bumper type fender was used in old cars, it covers the full area until the front lighting. But it has a lot of sheet metal material which is unnecessary and increases the weight of the fender. This type of fenders is no longer used in automobiles.

                                                                      

                                                                                            FULL BUMPER TYPE 

    2. HAIF BUMPER TYPE :

•  Mainly now a days half bumper type is used in automobiles. It is basically related to scrap management. Half bumper type leads to less wastage of the blank.  
•  We are changed from full bumper type to half bumper type to reduce the scrap rate per blank. In the full bumper, we can only produce one Fender per blank, whereas as a half bumper type we can produce  2 fenders per blank.

                                                                                  

                                                                                                      HAIF BUMPER TYPE

FENDER AND ITS MOUNTING

       There are five mounting points in a fender.

1. drip area
2. cowl.
3. sill.
4. A piller.
5. Body.

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 weld nuts 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 spring back during the manufacturing. The edge of the mounting should 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.

                                                                        

                                                                                                                                             FENDER DRIP AREA

MASTERING SECTION IN CREATE DRIP AREA:

                                                         

                                                                                                                    FENDER MASTER SECTION

DESIGNING DRIP AREA:

   

                                                                   

Using this parameter to design a drip area:

1. provide law of extension for 40 degrees in 5mm.
2. then using law of extension for 8mm for downward for 5 degrees.
3. 25 mm flat surface creating using law of extension.
4. creating 45-degree upward 3mm then flat surface then 2mm downward for 15 degrees.
5. providing for dart for using collision and stability for the drip.
6. then using to create face and edge blends for edges using input design dimensions.
7. create three side face blends to finish the drip area designing.

COWL AREA (BAFFLE):

                Sometimes fender is also provided with the cowl area mounting. For improvemnet of NVH in car , usually a baffle is mounted on the fender of the car. it is mounted on the Wheeel arch area .

                                                                                                                     

                                                                                                                        COWL (BAFFLE) MOUNTING AREA

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.

                                                                           

                                                                                                        SILL AND ITS RELIFE SIDE

A-pillar :

        Th e 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 PILLER MOUNTING

Body

           A  structure attached to or integrated on front and rear to absorb impact in collision there reducing maintenance cost . this are designed in such a way that they mitgate injary to pedestrain legs through use of soft materails like foam ,crushable plastics etc Fender wiil be attached to bumper through bummper mountings.

                                                                                                            

                                                                                                                     BODY or BUMPER MOUNTING AREA