Challenge

Fender Design

A Report On Front Fender Design

Objective: To design a front fender of an automobile vehicle from the given skin data and create different types of mountings on it.

Fender:

Fender is one of the important outer body part of an automobile vehicle whose function is to cover or shield the wheel above the ground.
It's primary function is to prevent mud, small rocks, sand, liquid and other small elements present on the road being thrown in the air by the rotating motion of the tyre.
When the vehicle is in motion, the tyre pick ups the small elements (solid & liquid) present on the road and due to the centrifugal action these elements got thrown outside as well as inside the car and engine compartment. This activity might cause some hazards to the pedestrians, to the vehicle itself and other vehicles around. The fender eleminates this activity in considerable amount and these striking particles by the tyre gets accumulate on the baffle mounted underneath the fender.
The fendre also act as a cosmatic part which hides the BIW components present inside and the ugly regions of the vehicle.

Types of Fenders :

The full bumper type fender covers the area all the way from head lamps till the A-piller of the car.
The full body type fenders were use in some old cars before but as the time has pass, engineers realised this type of fender cause more scrap, large blank size and hence cause more manufacturing cost. Therefore this fashion of fender has got stop due to these reasons.

2. Half bumper type

In half bumper type fender, the frontal portion is reduced till which the head lamp ends. This cause considerable amount scrap reduction and blank size as well. Also if the blank size will be increase little bit so that it could accomodate the other side fender, the process could monufactured both the fenders at the same time.
Therefore the manufacturing process becomes more cost effective and time saving in case of the half bumper type fender.

Manufacturing processes to produce mountings on the fender :

To produce mountings on the fender the manufacturing process used is deep drawing and stamping. All the dimensional values are set to produce the mountings must be convenient for the manufacturing process. Therefore the master section has preseted dimensional values.

Types Of Mountings :

1. Drip Area And Drip Mounting :

1) Preparing drip area

As per the master section, from head lamp side there is 150mm clearance and from A-Piller mounting side there is a 200mm gap has left so that the head lamp and cowl could be mounted properly.
So within this distance the drip mounting is going to get form.

2) Master section to produce the flange by deep drawing:

fig(1) fig(2)

From fig(1) the drip mount starts from Line B which has 3* inclination for proper deep drawing operation. This perticular flange is already been provided with the given master section. From point A to point C it is 9mm(assumed). So up to this distance it has been cutted using offset curve and trim sheet.
The next line D has 40* inclination from horizontal and it is 8mm from piont C to point E. This dimension is again set for proper deep drawing operation and to hide the inner portion of the engine compartment that could be seen through the small gap between hood and fender. This section is form by Law Extension with given dimensions.
Line F has 5* inclination from vertical and it's vertical dimension is maintain such that the distance between point A & point H shouldn't be exceed than 40mm.
Then there is a horizontal line G of 25mm length.
The profile before line G is for strenghten the end of the flange and it's dimensions is been calculated from trigonometric relations.
line K = 4.3mm, line L = 1.5mm, line N = 2mm. All the angles are given in the master section.
The edge blends are given to all the sharp edges as per master section fig(2).

2. Sill Mounting :

3. A Piller Mounting :

4. Bumper Mounting :

5. Baffle Mountings :

Ship work like this
in your own course.