Fender Design Challenge

OBJECTIVE :

Fender design start with wheel arc calculation as per the standards like Japan, European, American standard and then it's move on to designing satge with include the mounting features on it. Design the fender with mounting features for mount fender with other parts in car.

INTRODUCTION :

Design of any product starts from an requirement . The design engineer sketches the product based on the the requirement . Then the 2D sketch with the proper dimensions is converted into the 3D model using the advanced CAD software's . The another important thing in the design is that , every product that is designed should be able to manufactured . so the role of the design engineer is to design the product that can be easily manufactured and with less cost effective . This is the place where the Design for manufacturing [DFM] and Design of assembly [DFA] takes a role while developing any product . The process of development of design carries on until the design satisfies the customer needs .Here in this project the product that we are going to develop is a car fender

FENDER :

The main purpose of the fender is to prevent sand,mud, rocks,liquids and another road spray from being thrown into the air by the rotating tire .

TYPES OF FENDERS :

1) full bumper type

2) half bumber type

• Presently we are using the half bumper type , the reason for choosing the half bumper type is that when we choose the full bumper type the blank used for creating it is very large and also has the lot of wastage , but in the case of the half bumper type we have the possibility to reduce the scrap . This is what we called as scrap management
• In half bumper type we reduce the usage of the steel material and uses the lots of plastic on the bumper which in term decreases the cars weight and increases the performance

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

MASTER SECTION :

DRIP AREA MOUNTING

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 .

A PILLER AREA MOUNTING

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.

BUMPER AREA MOUNTING

Another mounting is for bumper area mounting of car front side. Which has two holes for mount on bumper and the one drip creataed for strengthen the mount.

SILL AREA MOUNTING

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.

BAFFLE AREA MOUNTING

Which is created for attach the wheel arc attachment on fender. This protect the engine and inner parts from sand, mud, stone hit and creates chip on it.