Fender Design Challenge

DESIGN OF FRONT FENDER

What is Fender? :

A fender is the part of a car, truck, motorcycle, or other vehicle that frames or covers a wheel well. Its main purpose is to prevent debris, rocks, mud, liquids, sand, and other road debris from getting thrown in the air while the tires rotate.

The “fender” typically refers to the front panel that covers the front wheels, and the “quarter panel” typically refers to the rear panel that covers the wheel that also includes the roof pillar. The “bumper” is the front and rear ends of a motor vehicle to absorb impact in a minor collision.

Mountings:

1) Bumper

2) Drip

3) A-pillar

4) Sill

5) cowl

Types of Fender

1) Full Bumper Type

2) Half Bumper Type

The Fender types are based upon the area covered i.e., "Full fender" and "half fender".

Full fender type :

The full fender type is the traditional type of fender where more material consumption is observed. This type is used in old designs of automobiles where it increases the overall weight and thus reduces performance. The maintenance is more due to more surface

Half fender type :

The half fender type is a modern design where less material consumption is observed, so productivity increases by reducing the size of the blank and thus providing more performance. The maintenance is also relatively low compared to the full bumper type

Below is given MasterSection Data To Make the Mounting Area as listed below.

Drip Mounting :

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 of the fender. From the backside of the front fender, there will be 200mm clearance for the

cowl(wiper motor) mounting area. From the front side of the front fender, there will be 150mm clearance for the headlamp

housing unit. The remaining area we can use to design a drip area.

Drip mounting Area Created as per the Engineering Standard, with proper support of the weakness Area. Equally Distributed the Mounting Distance with respective Embosses and removed the sharp edges with Edge blend commands.

Bumper Mounting :

It is the front portion of the fender where the bumper is mounted with the help of brackets

The front fender and Front Bumper joint are together by liner joint so we have to Create the Bumper Mounting Area on the Fender. with respective mounting holes and support in the Week Area.

A-Pillar Mounting :

This Mounting takes Place between the fender and A-Pillars front right and left. so we have to create the Mounting Area on the Fender with the respective mounting holes and support in the mounting Area.

Sill Mounting :

Sill mounting is "the bottom side mounting of the fender, where the mounting is done at the sill of the car".

Baffle Mounting :

Baffle mounting is a clip type of mounting on the inner side of the fender arch over the tire. It protects the car engine components and pedestrians from causing injuries. They are mounted on the fender using a special type of locking clip which is made up of plastics.

I have designed equally distributed Baffle Mounting places with respective holes Roughly

some images of smooth surfaces:

Achievements :

All the mounting areas are designed as per the manufacturing requirement and considered all the factors for crash analysis emboss and ribs are provided to strengthen the component and provide stiffness. Also, a thickness of 0.75 mm is provided for the component.