Challenge

Fender Design

YYash Gupta27 Feb 2023

FENDER

Fender is the part of car, truck, motorcycle or other vehicle that cover or frames the wheel well (the wheel underside). Main purpose of fender is to prevent the debris, sand, mud, rock, stone and other road spray from being throw in air by rotating wheel.

'Fender' refer to the front panel that cover the front wheel and 'Quarter panel' refer to the rear panel that cover rear wheel.

Fender should have made up of firm and rigid material such as steel.

TYPES OF FENDER

1. Full Bumper Type : This type of fender found in old model vehicles, now it is no more in use due to its heavyweight structure and consume more raw material in manufatcuring, while producing a large amount of wastage.

2. Half Bumper Type : Now a days this type of fender used widely as its give advantage of less raw material consumption in manufacturing and produce less scrap. Also, making structure lightweight and reducing the weight of vehicles.

MOUNTING OF FENDER

Drip Area
A-Pillar Mount
Sill Mount
Bumper Mount
Baffle (Splash) Mount

1. Drip Area : Drip area is used to mount the fender with engine compartment through fastner. Mouting at the dip area of fender designed in such a way that leaving a clearance of 200mm from the back of fender for the cowl setup and 150mm from the front of fender for headlamp housing unit. It also prevent to look inside the enginer compatment while hood is closed.

2. A-Pillar Mount : A-pillar mount is used to connect the fender with A-pillar while fender is installed on vehicle. The mounting region is situated near the cowl of vehicle.

3. Sill Mount : The Region at which the bottom of fender fastened with the floor near the bottom edge of door.

4. Bumper Mount : Bumper mounting region is used to mount the bumper with fender through fastner afte installation of fender on the vehicles. It is located beneath the bumper.

5. Baffle (Splash) Mount : Baffle mounting area is used to installed the baffle on the fender with help of clips and surround the wheel. it prevent splashing of road spray in air while car driving and prevent engine compartment from stone, mud and other road spray. Baffle usually made up of plastic material.

MANUFACTURING PROCESS

Embossing : Embossing is a metal forming process used to create a raised surface on a material by applying a pressure on the material. Machine press the material against the die to impart a raised surface onto the material. Embossing add dimension to the surafce and enhance its look. it also protect material from wear and tear.

Bending : Bending is the process by which a material is plastically deformed into many shapes by applying a pressure. The material is stress beyond the yield strength but below the ultimate tensile strength. The surface area of material do not change much while the shape of the material being changed.

Drilling : Drilling is a cutting process used to cut the material in a circular cross-section using a drill bit. The drill bit is usually a rotary cutting tool that rotate at rotation of hundred to thousand of revolution per minute and force against the workpiece to cut out the circular cross-section in the material.

Blanking or Piercing : Blanking or piercing is a shearing process in which punch and die used to produce a parts from coil or sheet stock. Blanking creates the outside feature of the component, while piercing also know as 'punching' make a internal holes or shapes.

DESIGN CONSIDERATION FOR THE FENDER

Drip area mouting is designed at a distance of 150mm from the front of fender for headlamp housing unit.
Drip area mounting cleareance is to be keep of 200mm from the rear of fender for wiper assembly, it varies depend upon car.

Engine compartement should not be visible while looking from outside when hood is closed. For this purpose initially 3° angle and suitable height probvided to drip area..
To prevent spring back effect the depth of drip should be less than 40mm.
Gap between engine compartment and drip area should be minimum 10mm for easy access of tools.