Fender Design

FENDER DESIGN

Fender is the part that covering the side part of the car. They have a main contribution in the pedestrian safety on the roads. There are many parameters to be followed while designing the fender depending on the regulation on the country. Fenders are design in a way the impact are minimum on the pedestrian when the got hit.

There are two types of fenders in the (full bumper type , half bumper type). The full bumper type is the earlry stage of fender that cover the whole wheel arc then they are repalced with the half bumper type which has the advantage of having less wastage while manufacturing and providing large space for bumper that increase safety. This save lot of money and materials while manufacturing the fender.

The fenders are mounted in various places of the car body. They are

1. Body mount
2. Sill mount
3. Bumper mount
4. Wheel arc mount
5. A-piller mount 
6. Drip mount

All this mounts are fastend with help of the bolts and nuts as they are not visblie outside. Among all this mounts the drip mount is the important one and have a master section to be followed while designing. Thaving a specific master section for the drip area is because of following reasons:

• This angle helps to cutt of the visibility of the component in the engine compartment when seen from outside and giving the car a clean look.
• The depth of the drip area must be less then 40mm. This is maintaind in order to avoid the spring back effect on the fender that helps to lower the NVH.
• There must be atlest 10mm of gap between the end of the drip to any of the components in the engine compartment.
• The drip must be placed 150mm from the head light and 200m From the cowl area.

Beside the drip area there are several things should be followed while designing the fender:

• Additional darts can be added to provide strength in the drip area.
• Reinforcements should made in the place of the mountings and around 5mm of gap should be maintained between the mounting holes and the walls off the emboss in to provide space for the head of the bolt to be seated.
• Relif cutts should be provide in the place of tight bends of the mounts.

Manufacturing process involved:

Drawing------> Laser cutting ------> Flanging 1 -------> Flanging 2 

• Deep Drawing:
  Deep drawing is the process where the flat sheet metal are deformed to desired shape. The sheet metal is placed between the two dies in fender shape then pressed with tones of froces that deforms the shaped of the sheet metal.

• Laser cutting:
  The excess part of the fender is Cutted using the high power laser for pricision cutts.

• Flanging:
  Flanging is process of bending of the sheet meetal to desird angle. The mounts of the fender are bend to desired angle using flanging process.

• Fanging 2:
  Flanging is done over and over again as the drip are have several bends.

• Drat:
  If the dart are made punchings is done with special die in the desierd place.