Challenge

Fender Design

VVijay Prasath8 Dec 2022

AIM

To design various mounting points on the fender, according to the design parameters.

INTRODUCTION

A fender is the part of a car, truck, motorcycle, or other vehicles that frames or covers a wheel well. Its main purpose is to prevent debris, rocks, mud, liquids, sand, and other road debris from getting thrown in the air while the tires rotate.

The “fender” typically refers to the front panel that covers the front wheels, and the “quarter panel” typically refers to the rear panel that covers the wheel that also includes the roof pillar. The “bumper” is the front and rear ends of a motor vehicle to absorb impact in a minor collision.

FENDER

The fender car part is the body kit or body part installed on the left and right sides of the vehicle. Manufacturers usually attach fenders to the wheel arches. There are different reasons why they are a requirement in vehicles. One obvious reason is to improve the aesthetics of the vehicle.Fenders also enhance the car’s aerodynamics. They also prevent mud, sand, rocks, liquid, and all sorts of debris from being thrown in the air while you’re driving your car.

TYPES OF FENDERS

There are two types of fenders , they are

1) full bumper type

2) half bumber type

Presently we are using the half bumper type , the reason for choosing the half bumper type is that when we choose the full bumper type the blank used for creating it is very large and also has the lot of wastage , but in the case of the half bumper type we have the possibility to reduce the scrap . This is what we called as scrap management

In half bumper type we reduce the usage of the steel material and uses the lots of plastic on the bumper which in term decreases the cars weight and increases the performance

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.

DIFFERENT TYPES OF MOUNTS

Fender is mounted basically on 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 the fender gets attached to the engine housing through fasteners. It is the major mounting for the fender. Mountings at the drip area are designed leaving a clearance of 200mm from the back of the fender for the cowl setup. And clearance of 150mm from the front of the fender for a headlamp housing unit.

A PILLAR MOUNTING AREA

This Mounting region is located near the cowl of the vehicle where the fender is fastened with the bottom edge of the windshield. This mounting is covered with the side rear-view mirror.

SILL MOUNTING AREA

The area at which the 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 the installation of the bumper. After fixing the fender with fasteners the bumper will cover the bumper mounting.