Challenge

Fender Design Challenge

NNumit Sharma22 Aug 2022

FENDER DESIGN

OBJECTIVE

The main objective of this project is to design the BIW(Body in white) of the front fender using the fender skin data and the master section as the data by using NX CAD.

Introduction of Fender

Fender is the American English term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel nicely. its primary purpose is to prevent sand, rocks, mud liquids, and another road spray from being thrown into the air by the rotating tire. The fender is typically rigid and can be damaged by contact with the road surface.

Sticky materials, such as mud may adhere to the smooth outer tire surface, while smooth loose objects, such as stones can become temporarily embedded in the tread grooves as the tire rolls over the ground. these materials can be ejected from the surface of the tire at high velocity as the tire imparts kinetic energy to the attached objects. For a vehicle moving forward the top of the trie is rotating upward and forward and can throw objects into the air at other vehicles or pedestrians in front of the vehicle. The fender is a front outer side member of a car that covers the wheel side It has so many small features with ups and downs.

Type of Fender

There are two types of Fender

Full Body Type
Half Body Type

Full Body Type

This type of bumper or Fender is not commonly used because this design produces more scrap during manufacturing. The blank sheet or aluminum used to create this type has more wastage. This type is not economically suitable to manufacture. Full body type Fender increases the weight of the vehicle.

Half Body Type

This type of fender is most commonly used. The cons of full bumper type are satisfied in this design and the blank area of wastage while producing the part is drastically reduced by scrap management. half body type fender is having less weight as comper the full body type fender so they also help to reduce the weight of the vehicle.

Purpose of Fender

Cleanliness - Protect the car occupants and passers-by from items water, mud, ice, thrown off the tires when driving a vehicle
Safety - Protects pedestrians from the wheel,e.g.its better to be it by a laterally moving fender than a rolling tire, keeps loose streaming items from being wrapped up in a rolling wheel.
Aerodynamics - Smooths the car profile so you don't get a lot of drag off the uncovered wheels. Some fenders are enclosed on the side for this
General Appearance- Looks better with fender, gives a finished look looks more streamlined.

MOUNTING REGIONS ON FENDER

There are 5 mounting regions on the fender, they are

A- pillar mounting
Body mounting
Sill mounting
Bumper mounting
Drip mounting

DESIGN METHODOLOGY

MASTER SECTION

DESIGN 0F DRIP AREA MOUNTING

It is the important mounting uni of the fender. it is connected with the engine compartment, therefore a 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 the cowl top
For placing the headlamp we have to leave at least 150 mm at the front while designing the fender
The cowl top part consists of a wiper motor and its instruments

Two darts are added on the longer side of the drip area in order to provide stiffness and add strength to the part. This helps the fender not to vibrate and impact the forces outside of the fender during the motion of the vehicle.
Embossing is provided on the mounting to strengthen them during fastening.

DESIGN OF SILL MOUNTING AREA

The 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.

DESIGN OF BUMPER MOUNTING AREA

The bumper mounting area is used to fix the plastic bumper to the fender with the help of the fasteners

DESIGN OF A-PILLAR MOUNTING AREA

The A-pillar is the structural pillar that combines the body with the roof. this makes the sides of the windshield rest. front fenders are fastened to the A-pillar to form a robust structure.

DESIGN OF BAFFLE MOUNTING AREA

Baffle mounting or mudguard are clip-fit types 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.