Fender Design
FRONT FENDER DESIGN
OBJECTIVE : To design the front fender of a car from the given skin data by following the given master section.
FENDER : Fender is the American english term for the part of an automobile that frames a wheel well. The purpose of a fender is to prevent the inner part from dust, stone particle,mud,liquid etc. Fender smooths the car profile due to which we don't get a lot of drag off the uncovered wheels. Some fenders are enclosed on the side for this purpose. Fender is also important part for aesthetic view.
TYPES OF FENDER : Fender can classified by two way as follow :
1) Front Fender and Rear Fender
2) Full Bumper type Fender and Half Bumper Type Fender
Front Fender and Rear Fender :
Front Fender Rear Fender
Full Bumper Type Fender and Half Bumper Type Fender :
Full Bumper Type Fender : These type of fenders were used in earlier models of vehicle. In full bumper type fender there is large increment in weight of steel for covering the front headlight in front bumper region. The main drawback of this type of fender is there is a lot of wastage of material in the blank. There is a large cost in industries for every inch of the material.
Half Bumper Type Fender : Half bumper type fenders are mainly used for the purpose of reducing the material consumption than comparision to full bumper type fender, so that the cost of fender will reduce resulting the cost of vehicle is also reduce . In half bumper type fender the weight of vehicle is reduce ,resulting an increment in performance of vehicle. They can be economically manufactured ,i.e.by slightly increasing the blank size ,we can produce two fenders at a time.
Different Manufacturing Processes Followed For Fender :
1) Blanking : Blanking is a sheet metal operation in which a punch and die combination is used to creat the piece of sheet metal of desired shape and size . In blanking operation the punched out piece of sheet metal is used for further operation and this piece of sheet metal is known as blank. Although blanking process is a quick and cost-effective way to produce a large number of identical pieces ,these punched out pieces may have burrs or cracks on the edges . However ,these drawbacks can be avoided by using high-quality tools,and they can be corrected by post-processing the blanks.
2) Rolling : Rolling is a sheet metal process that reduce the thickness of sheet metal and maintain the uniform thickness. The raw sheet metal is passed through one or more pair of roller ,so that it's thickness is reduced. Rolling is classified according to the temperature of sheet metal to be rolled. If the temperature of metal is above than it's recrystalization temperature then it is known as hot rolling and if the temperature of metal is lower than it's recrystalization temperature then it is known as cold rolling process.
3) Bending : In bending Force is applied to a sheet metal workpiece to produce a curvature of the surface. Bending is generally used to produce simple curved surface rather than complex ones. A mechanically operated press drives a punch againsed sheet metal , forcing it into a simple die with enough pressure to produce a permanent deformation
4) Drawing : In drawing the sheet metal is forced againsed a die that has been cut according to the desired shape . Drawing or deep drawing operation can produce relatively complex shape. If desired shape is not found in a single step then we can repeat the process multiple time with different tool and different stroke length.
5) Stamping : In stamping , a device called a stamping press is used with a series of dies to cut and form metal into various shapes. Stamping process is commonly used to make automotive parts like as hubcaps, fenders etc.
MOUNTING REGIONS ON FENDER :
Given Master Section
There are five mounting regions on the fender, these are as follow :
1) Drip Mounting
2) Bumper Mounting
3) Sill Mounting
4) A-Pillar Mounting
5) Baffle Mounting
1) Drip Mounting :
Drip mounting of a fender is the most important mounting because fender is mount on engine compartment with the help of drip mounting. Design of drip mounting is created on the bases of given master section. While the vehicle (car) running away then vibration will generate in the component near by engine .To reduce the effect of vibration embosses and darts are provided there .
2) Bumper Mounting : By the help of bumper mounting portion the fender mount on the bumper. Bumper is the vehicle body part where the headlight, fog light ,nameplate etc are mounted,air intake also takes place from the bumper for the cooling of radiator and engine. In normal crash the bumper can absorb the crash energy.
In the bumper mounting region two embosses are provided, and two holes of dia. 7mm are provided for assembly purpose. One darts is also provided for strengthing purpose.
3) A-Pillar Mounting :
As we know there are generally three pillar in a car ,these all pillars are the part of chassis .By the help of A-Pillar mounting region the fender mount with A-Pillar . For assembly with the A-Pillar an emboss is provided there and one hole of dia.7 is created.
4) Sill Mounting : In the sill mounting region the fender is fixed with the lower portion of the vehicle , basically those part will be covered under the spoiler or the skirts. This mounting is also fixed to the chassis of the vehicle body. For the strengthing and assembly purpose two embosses are provided and two holes of dia. 7 mm are created.
(5) Baffle Mounting :
Baffle mounting or mudguard are clip fit type of mounting on the inner side of fender arch over the tyre . It protects the car engine compartment and pedestrians from causing injuries from chips out debris on the road when the vehicle is in motion .They are mounted on the fender using a special type of locking clips which are made up of plastics.
Splash Mounting :
Splash mounting is basically designed for the safety of pedestrians. When the vehicle is on motion the roadside debris or drainage water is splashed towards the by road pedestrians or the following vehicle behind . To overcome this problem a plastic component is fixed on splash mounting.
