Fender Design

FENDER DESIGN

AIM: To design a front fender of a car by following the given master section as per the design considerations of OEM.

FENDER

It is an aesthetic component/part of a car that frames the wheels. Prevention of sand, mud particles, and other road contaminants from being thrown into the engine compartment and also to the pedestrians by the rotating tires are the main purpose served by the fenders.

The front fenders are separate components whereas the rear fenders are integrated with the body sides.

FENDER Manufacturing process

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

Manufacturing process The manufacturing of the fender majorly involves these operations.

1.Embossing

2.Bending

3.Cutting and Blanking

Embossing :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.

USES OF FENDER:

• Get other vehicles or pedestrians on the road side dirty
• Hurt pedestrian
• Scratch the bodies of other vehicles
• Cause minor, and even major damage to other vehicle

TYPES OF FENDERS:

FULL BUMPER TYPE: These types of fenders were used in earlier models of vehicles. They contribute to the major increment of the steel weight by just covering the front headlights with respect to the bumper region. The problem associated with this kind of fender is there is a lot of wastage in the blank and every inch of a material is a cost to the industry.

HALF BUMPER TYPE: These fenders are mainly used for serving the purpose of cost-cutting and reducing enough proportions of the steel wait resulting in a reduction of the weight of the vehicle slightly. They can be economically manufactured, i.e by slightly increasing the blank size, we can produce two fenders at a time.

MOUNTING REGIONS ON FENDER:

DESIGN CONSIDERATIONS:

The front fender has basically five mounting positions with respect to the other components. The mounting positions are as follows:

1.Drip Area Mounting

2.A-Pillar Mounting

3.Sill Mounting

4.Bumper Mounting

5.Baffle Mounting

For the creation of the Drip Area Mounting, the given Master Section is followed, and the other mounting points are created by assuming appropriate positions with the respected components.

1. Drip Area Mounting:

• The drip area is the most important mounting in a fender, it is the point where the fender has to be attached to the engine compartment.
• The drip area should be designed in such a way that it should be at least 150mm away from the front end of the fender to have sufficient space for mounting headlamps housing.
• Mostly the drip area starts from 200mm away from the rear end of the fender, to have sufficient space for the cowl which carries the wiper equipment.
• The length of the drip area depends on the length of the fender.

2.A-Pillar Mounting:

This mounting position is created for attaching the fender to A Pillar of the vehicle. The mounting has to be created by taking the reference from the A-pillar of the vehicle. Enough clearance should be given for the easy mounting of the wiper equipment.

3.Mounting: Sill mounting is created on the bottom portion of the fender for attaching to the sill.

4.Bumper Mounting: This mounting point is created for attaching the bumper to the fender. It should have enough strength to hold the bumper steadily.

5. Baffle Mounting: These mounting points are created for attaching plastic components i.e baffle which prevents chipping inside the engine compartment.

6.Final Part:

7.Different Views:

• CONCLUSION -

The front fender is designed according to the given master section and CLASS A Surface as per the OEM Standards.