Fender Design

FENDER DESIGN CHALLENGE

 

AIM:

To Design various mounting points on fender using design parameters.

 

FENDER:

Fender’s purpose is to prevent the rock, mud, sand and liquids from being thrown into the air or on the pedestrians by a rotating wheel. Fender is made aerodynamic in shape to reduce the air drag.

 

There are 2 types of fenders:

• Full Bumper Type
• Half Bumper Type

 

 

Full Bumper Type:

This type of fenders used in olden days. It is no more use due to its heavy weight of the structure an consumes more raw materials in manufacturing.

Half Bumper Type:

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

Manufacturing process:

The manufacturing of fender majorly involves these operations.

1. EMBOSSING
2. BENDING
3. CUTTING AND BLANKING

EMBOSING:

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

BENDING:

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

CUTTING AND BLANKING:

Cutting process are those in which piece of sheet metal is separated by applying a greate enough shearing force to cause the mechanical to fail.

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

 

Fender is mounted basically 5 important regions. They are

1. Drip Area
2. A-Pillar Mounting area
3. Sill Mounting Area
4. Bumper Mounting Area
5. Baffle Mounting Area

Drip Area:

The area at which fender gets attached to the engine housing through fasteners. It is the major mounting for the fender. Mounting at the drip area are designed leaving a clearence of 200mm from the back of the fender for the cowl setup and clearance of 150mm from the front of the fender for the headlamp housing unit.

 

Darts are provided at the bends to stiffen the sheet metal at the region.

A-Pillar Mounting Area:

This mounting region located near the cowl of the vehicle where the fender fastened with bottom edge of the wind shield. The mounting is covered with the side rear view mirror.

 

Sill Mounting Area:

The area at which bottom of the fender gets connected to the floor near the bottom edge of the door. The embossed sill mounting of the fender is attached with the fasteners.

 

Bumper Mounting Area:

The Bumper mounting region is located beneath the bumper. The fender gets attached before he installation of bumper. After fixing the fender with fasteners the bumper will cover the bumper mounting.

 

Baffle Mounting Area:

In this region, the baffle gets installed to the fender with the help of clips which holds the baffle with the fender along wheel arch.

 

CONCLUTION:

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