Fender Design

FENDER DESIGN

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.

OBJECTIVE:

In this project we are going to design the mounts for the Front fender such as drip, sill, bumper, A-pillar, cowl and baffle for this we are going to design mounts.

FEATURES/TOOL USED:

• SKETCH
• OFFSET IN FACE
• CURVE ON SURFACE
• BRIDGE CURVE
• EMBOSS
• TRIM SHEET
• LAW EXTENSION
• FACE BLEND
• EDGE BLEND
• DART
• THICKEN

DESCRIPTION:

In this project as we said we are going to design the front fender mounts.

There are two types of of fenders
1. Full Bumper Type.
2. Half Bumper Type.

Full Bumper type
This type of fender is used in olden days, it is no more in use due to its heavyweight of the structure and consumes more raw material in manufacturing.

Half Bumper Type
Half Bumper Type fenders are widely used now, due to its mini size and the scrap or wastage is less compared to the full bumper type.

Manufacturing process

The manufacturing of the fender majorly involves these operations.

1.Embossing
2.Bending
3.Cutting and Blanking

Embossing

Embossing is a metal forming process for producing raised or sunken designs or relief in sheet material using matched male and female roller dies, theoretically with no change in metal thickness, or by passing sheet or a strip of metal between rolls of the desired pattern.

Bending

Metal bending is a process by which metal can be deformed when applying force to the subject, which causes it to bend at an angle and form the anticipated shape, which often results in it being in a ‘V’ or a ‘U’ shape. This is done through the application of force on a workpiece. The force on the work piece can be mechanical, pneumatic or hydraulic.

Cutting and Blanking

Cutting processes are those in which a piece of sheet metal is separated by applying a great enough shearing force to cause the material to fail.

Blanking is a steel manufacturing process in which a flat, geometric shape is created by feeding a coil of sheet metal into a press and die. In this process, the blank is punched out from the large metal sheet.

Drip mount

As you can see in the above images we have created some emboss and mounting holes for the fasteners we have created flat surface and have given the minimum 5mm flat area around the mounting holes.

And we have also provided darts to it to increase the strength of the mount.

Sill mount

Like drip mount we have created the sill mount too and we made sure that we didn’t have any sharp corners and we provided relief to it.

We did this by using bridge curve and trim sheet.

Bumper mount

As you can see we have created the bumper mount using emboss, dart and bridge curve to cut out the sharp corners.

A-PILLAR Mount

While creating this mount was tricky one as we have create a emboss on curved surface so for that we have used datum plane and according to that we have created the sketch.

BAFFLE Mount

For baffle mounting we didn’t made any kind of emboss we have created the mounting holes for it and we have created the baffle flange on which the holes are there.

After creating the mounts we finally thicken it which gives thickness to the sheet metal.

So the above image is the final fender part.

Conclusion
The Fender is designed with the necessary mounting points considering the design parameters.