Fender Design

Objective:

Design the fender in proper design standard and using above mater section with mountings of A Pillar, sill, cowl, body and drip area

Fender

Fenser purpose is to prevent sand , mud, stucks , liquids and other road spray from being thrown into the air by the roating tire.

There are two types of fenders,

• Full bumper type (High scrap waste,difficult to manufacturing)

It is not used now a days because they requires bigger size blank to produce the part and the large scrap is also produced

• Half bumper type

Half bumper types are used in present and future also because the blank size is less and the wastage or scrap is less comparing to full bumper type fenders

Fender Mountings

Fender attached 5 sub-assembly parts.so it had main 5 mountings

1. Body
2. A Pillar
3. Sill
4. Cowl
5. Drip
6. Bumper
7. Wheel arch (Buffle)

Fender Design Process.

• Intial Class A surface wee need to study and check the Wheel arch gap for regulation standard.
• The fender skin must satisfy the regulation standard.
• If skin okay we will start the design.
• Fender has 5 main mountings. 5 parts assembled in fender.
• There are Drip, A Pillar, Sill, Bumper and Wheel arch (Buffle)
• Sheetmetal Thickness 0.75 mm
• Emboss height 3.5 mm & 2.5 mm
• Weld bold or faster hole diameter is 5mm.
• 

1.Drip Mounting

• Drip mounting area is top side of the fender position.
• Drip area mounting is the important part in the fender .
• This mounting is attached to the engine compartment of the car .
• Fender drip area is mounted via weldnuts to the engine compartment .
• A min of 150mm distance is kept from the front side and a distance 300mm or less can be kept on the rear side .
• The total length of drip area from the top of fender should be less than 40mm , this is to avoid the springback during the manufacturing .
• The edge of the mounting should atleast 10mm away from any nearby component in the engine .
• A rigidity bead is provided at the end to increase the strength of the mounting .
• This mounting have lot of design standard compare to other mountings.
• We consider to design spring back effect, assembly tool clearnace.
• Below image shown the design standards.

• Two Darts add to aviod strength or reduce spring back effect.
• The following design standards is followed to designed the Drip area mountings.

2.A Pillar Mountings

3.Sill Mounting

4.Bumper Mounting

• Head lamp mounting is assembly here.
• Bumper also included

5. Wheel Arch (Baffle) Mountings

• Baffle locking purpose designed 3 mountings.
• These mounting points are created for attaching plastic components i.e baffle which prevents chipping inside the engine compartment.
• 

Fender Design Images

Manufacturing Process

• Sheetmetal is inserted to the mold die.
• Compression force used to press the sheetmetal and desired shape is achived.
• After the Hemming and mastic stealing process done.
• Finaly Primer and Painting