Fender Design

FENDER DESIGN

Fender is the side closing component for the engine compartment. It’s major role is to avoid chipping of sand, small stones and mud particles inside the engine compartment when the wheels rotate. Fender also plays a major role to prevent injuries for the pedestrians.

FENDER TYPES:

Basically we have two types of fender

• half bumper type
• full bumper type.

The difference between the two types is its size. The full bumper type consumes more raw material when compared to the half bumper type. Nowadays we don't use full bumper type fenders.

The raw material usage plays a major role in choosing which one and so half bumper is economical. So we can decrease the funds spent on the fender and also it reduces the weight as plastic is used and it helps in improving the automobile efficiency.

Example for Full Bumper type Fender

Example for Full Bumper type Fender

Mounting areas of fender:

• Sill Mounting
• A pillar Mounting
• Drip area Mounting
• Bumper Mounting
• Splash Cover Mounting

Drip Area Mounting:

Drip area mounting is the part which connects the fender with the engine compartment. We use fasteners for joining the component. Designing the drip area has few constraints that there must be enough space at the front and rear end of the fender. At the rear end there needs to be space for the cowl top mount which carries the cowl top along with the wiper motor arrangement. And this must be 300mm or less.

The front end we know that the headlight arrangement occupies at least 150 mm. So now this must be attached to the engine compartment. This must be designed so that from seeing from outside there should not be any ugly components visible. And this part should be given embosses to avoid spring back effect

Example

DATA USED TO DESIGN DRIP AREA MOUNT

With the given Data i have Designed the Drip area mount. Dart is added to give strength to the mount. Thickness is given 0.75 mm.

Sill Mounting:

Sill Mounting is used to link the fender with the sill. Sill is the under side portion of the door. M5 Fasteners are used to fit the Sill and the fender. So emboss and holes are provided in the sill mounting.

Here is the Design of Sill Mount. Emboss are given with holes for fitting.

Bumper Mounting:

This Mounting connects the fender with the bumper. Bumpers are mostly made up of plastics. It is forms the front end of the car. During collision bumper hits first. Fasteners are used to fit the portions. So we provide holes here.

Here the design of bumper mount is shown.

A Pillar Mounting:

This connects the fender with the A Pillar. A Pillar is the structure that combines body with the roof. This is the reason for windshield is in place. It is fitted with Fasteners and those will be kept out of human vision.

A Pillar Design which i have designed is shown below.

Splash Cover Mounting:

Splash cover protects the car tyre debris entering into the engine compartment. This mounting is given as holes that holds the cover in place. This plastic cover restricts small rocks, sand and mud splashing into the car.

MANUFACTURING PROCESS:

Bumper is made by reaction injection molding (RIM). RIM is a process that conserves raw materials and reduces costs. It is similar to injection molding, But here we use thermosetting polymers. This requires a curing reaction to occur within the mold. Common items made via RIM are automotive bumpers, air spoilers, and fenders

Here comes the Cover mount design

Overall View of the fender with mounting i designed