Fender Design Challenge

AIM:

To design the car fender using the given master section considering all the design parameters.

INTRODUCTION:

Fender is the American English term for the part of an automobile, motorcycle or other 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. Fenders are 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 tire is rotating upward and forward, and can throw objects into the air at other vehicles or pedestrians in front of the vehicle.

There are two types of fenders,

• Full Bumper
• Half Bumper

Mounting:

There are major 5 mounting points in the fender.

• Body
• A Piller
• Sill
• Cowl
• Drip

Drip Area:

This region is mounted below the hood inner panel which needs to be in flush when the hood is in closed condition and also there should be very less gaps. The drip area is either spot welded or in some cases bolted down via self-tapping screws.It is the critical mounting area located inside the engine component. Designed according to the master section provided and optimal opening angle is maintained to make it look well assembled from outside.Minimum clearance from head lamp and cowl part is maintained. Vertical distance of the drip mounting is maintained less than 60mm to avoid the spring back effect.

Design considerations for drip area-

1. 150mm Distance from front end is kept for the headlamps in bumper.
2. 200mm Distance from rear end is kept for the wiper assembly, some time it may excide and less also.
3. Engine components should not be visible from outside. For this purpose initially 3 degree of angle & 9mm length is given.
4. Embosses are given to the drip area to increase the strength.
5. The gap between drip area and the engine compartment not less than by 10 mm.
6. To avoid the springback effect drip depth should maximum 40 mm.
7. Relief is provided so that maintenance low cost production

A-pillar Mount

A Pillar where the fender is connected by fasteners with the body of car and also A-Pillar provide car some strength.

Sill Mount

Sill mount area is near the door downside part where the fender and body is connected with fasteners and provides proper support.

Baffle mount

It allow to hold the fender uniformly and provides proper balance to the fender.

Bumper Mount

Final Model:

Conclusion

Thus Front Fender of car is developed by providing proper mounting structures as per the design parameters.