BiW Design of front fender of a car

Fender Design:

• Design Considerations:

• Drip area
• Sil Mount
• Bumper Mount
• A pillar Mount
• Baffle Mount

• Functional Requirements:

The function of the fender is to enclose the Engine compartment and prevent the exposure of engine to any foreign matter particles. The Fender is to be designed to the given skin data from styling team including all the design considerations.

Various views of the final design are shown below.

Figure 1: Front view

Figure 2: Back view

Figure 3: Fender side view

• Mounting Designs:

Figure 4: Drip area

The drip area has been designed according to the given draft and two mounting regions have been dedicated to bolt the fender to the engine compartment. A nominal hole diameter of 8mm (M8) has been designed considering a 7mm hole drilling and tapping. Fillets have been given as reliefs according to the drafts’ specification. Circular emboss is imparted in the design to prevent fillet overlapping owing to the small drip area.

A clearance of 150mm at the front region and 200mm at the rear is given for the accommodation of headlight mount and wiper motor respectively.

The vertical height of al the flanges of the drip area is less than 60m to avoid spring back effect.

Figure 5: A pillar Mount

Figure 6: Bumper Mount

Figure 7: Sil Mount

The Bumper, Sil and A pillar mount shown above each have 2 M8 bolt regions with rectangular embosses of 3mm drawing depth each and fillet reliefs at sharp corners to avoid stress concentration. All the flanges are of 25mm length from the skin data.

The Bumper mount tab has a rib at the center of the arc to impart strength to the face. It is of 45degrees and 3mm deep.

Figure 8: Baffle Mount

Three mounting flanges have been specified along the wheel arch curve and each has two mounting holes spaced 25mm apart.

• Manufacturing:

All the holes are perpendicular to the Global Datum Plane and Co ordinates for ease of machining.

Embosses are drawn to an angle of 23degrees to a depth of 3mm and all edges have been blended with a fillet radius of 2mm and 3mm.

Half bumper type is preferred, to reduce scrap (material wastage) as 2 fenders are manufactured from one big plank.

Note: This report does not contain information regarding the wheel arch. It has been attached as a separate report in a different challenge.