Challenge

Fender Design Challenge

Aim:

Objective: The main object 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.

Fender

A fender is a front outer side member of a car which covers the wheel side. Fender's purpose is to prevent sand, mud, rocks, liquids and other particles. or
The fender is a closure component, closing the engine compartment and other compartments. The major role of the fender is to avoid chipping inside the engine compartment. During the motion, the wheel picks sand mud and small stone particles and throws them inside the car and these fenders will help prevent them by hitting inside the engine compartment and car body. These fenders will have a plastic part which lies on the wheel arch area. The fender plays a major role to avoid problems for pedestrians also. The fender is typically rigid and can be damaged by contact with the road surface. It is often also called a Mudguard.

Fender Safety:

The fender is a part of the car, it is also used a protect the side of the engine compartment.
Pedestrian safety is also considered while designing a wheel arch in a fender since the debris in the wheel shouldn't hit them in the motion of the car.
Fender is also reduced pedestrian injury when there is a pedestrian-vehicle crash and prevents the throwing up of debris nearby vehicles.

Types of the fender:

Full Bumper of the fender:

Half Bumper of the fender:

Half Bumper helps reduce the weight of the fender while proving the safety of pedestrian moving motion as shown in the figure.

Uses of car Fenders:

Car Fender limits the exposure of your car's body and engine to harmful external elements.
Fender flares are attached to ensure that both the body and engine have minimal contact with corrosive elements
Car Fenders provide safety to the driver and the passengers at the time of accidents or collisions. They are manufactured in a way to provide bend during front and side collisions.
Car Fenders are designed to avoid wind resistance and make your car more aerodynamic.
Car Fender enhances the overall look of your cars. Fender flares are available in distinctive designs in the market. Mostly you find universal Fender flares, but you can get customized cars Fenders to fit your car wheels.

Areas to be considered while designing a fender:

Data:

Drip area:

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, from the back side of the fender there should be 200mm clearance for the cowl mounting area and from the front, there should be 150mm clearance for the headlamp housing unit.
Considering the above design constraints we have to design the drip area. Embosses are provided to increase strength, and corners of the flanges are smoothened to ease production. Uniform wall thickness of 0.75mm.
Design Consideration for drip area are150mm distance from the front end of the fender and the gap is filled with headlamp200mm distance from the rear end of the fender and the gap is filled with wiper motor assembly.
Initially, a 3-degree angle and 9mm length are given while creating a drip area because the engine component should not be visible from the outside.
The depth of the drift should be between 40 to 60mm. Forming is not feasible if the depth exceeds 60mm due to spring back and wrinkles. Embosses and ribs are given to the drip area to give strength. Embosses' dimensions are depth of 3.5mm and 15 degrees of angle for all three embosses.

A-pillar mounting:

A-Pillar is on the cars on either side of the front windshield, which is why the windshield is in place.
It is Mounted on the A-Pillar using fasteners and these are covered by outer side view mirrors.
Here, the proper embossing is provided along with holes for fasteners.
Law extension dimensions are 42mm in length and 90 degrees of angle. Offsetting the law extension face 5mm. Creating a sketch and law extension feature is used 6mm length and 90 degrees of angle. Trim sheet to create a hole of 5mm diameter. The edge blend and face blend is 2mm.

Bumper Mounting:

The Bumper Mounting region must be rigid to withstand the force acting upon it during a collision. So, the Mounting space can be larger.
Law extension length 20mm and 75 degrees of angle. Skew to join the two surfaces. Dart angle 25 degrees, depth 5mm and radius 3mm. Create two darts in existing spaces as shown. The trim sheet is used to create a hole of dia 5mm. For skew use a 3mm edge blend and dart and embosses a 2mm edge blend.

Sill Area Mounting: