Fender Design

FENDER

Fender is a US English term for the part of a vehicle body that frames a wheel well.when the vehicle will be moving the wheel tries to pick up stones and mud water and hurl them in all directions,which may cause injuries to the pedestrians on the road.

The main function of the fender is to prevent stones and mud water flying into the air by the rotating wheel.

importance of car fenders

fender protects the pedestrians from the wheel if a car is going to hit sideways by coming in contact earlier than the rolling wheel.

fender also protects the side body of the car from stone pellets and sand hurled into the air and hitting the car surface and outside rear view mirror.

There are two types of Fenders

1.Full bumper type

2.Half bumper type

Full bumper type fenders are sheet metal part covering the sideways of the engine compartment above the wheel well till the front headlamp.Full bumper type fenders are used in the earlier models of cars, due to their large size and adding weight of steel this type of fender is not used in today's models.

Half bumper type fenders are designed in such a way to reduce the weight of the steel and adding the remaining area by the plastic part of the bumper thereby reducing the cost of manufacturing and reducing the weight of the vehicle.

Mounting areas of fender

there are five areas where fender is mounted to the vehicle.

1.To the Body

2.To the engine compartment at Drip area

3.A pillar

4.Bumper

5.Sill

VARIOUS MANUFACTURING PROCESSES INVOLVED

EMBOSSING

Embossing involves the creation of an impression by placing dies in contact with the stock under high pressure, usually with the addition of heat to help the material conform. This process produces a raised, embossed surface.

Embossing can help disperse liquid more effectively, reduce friction and static, bolster metal panel stiffness and rigidity, increase metal surface area for acoustic or heat transfer and improve traction.

Punching

Sheet metal punching is a subtractive fabrication process that cuts metal as it passes through a punch press.The punching tool and die set the shapes and forms custom designs into metal work pieces.A Die consists of male punches and female dies.

Bending

bending is a method used by manufacturers to form metal parts and components to a desired shape. It is a common fabrication process where forces is applied to plastically deform the metal on one of its axes.

Master section of the fender design

Drip area mounting

drip area mounting is the very crucial part in designing the centre because drip area connects to the engine compartment.

in designing the trip area we must consider the offset of 200 mm for the cowl top and 150 mm for the headlamp in the front as shown in the master section.

The vertical height of the drip area mount must be 40 or less as shown in the master section and each vertical face is given an angle of 3° and 5° with the vertical and slant angled surface(line D) is provided to avoid the visual of the inside of the engine compartment.

two beeds are given to the drip area flange to provide additional strength and avoid spring back effect.

Bumper area mounting

The bumper mounting attached to the front side of the bumper.

M6 holes are provided for the fastening process within the emboss

Baffle area mounting

Sill area mounting

Body mounting

After completing all the surface work the fender surface is thickened to 0.75mm.

Final images of Fender