Fender Design

Fender

Fender is a front outer side member of a car which covers the wheel side. Fender purpose is to prevent sand, mud, rocks, liquids and other particles. Fender is a closure component, closing the engine compartment and other compartments. The major role of the fender is to avoid the chipping inside the engine compartment. During the motion the wheel picks a sand mud and small stone particles and throws it inside the car and these fenders will be helpful in preventing them by hitting inside the engine compartment and car body. These fenders will have a plastic part which lies on wheel arch area. The fender plays a major role to avoid problems for pedestrian also.Fender are typically rigid and can be damaged by contact with the road surface. It is often also called as Mudguard.Fender is the US English term for the part of a vehicle body that frames a wheel inside it. Its primary function is to prevent sand, mud, liquid, and other materials from being thrown into the air by rotating tires. Fenders are typically rigid and can be damaged by contact with the road surface. Sticky materials, such as mud, may adhere to the smooth outer tire surface, while smooth loose objects, such as stones, can become temporarily embedded in the tread grooves as the tire rolls over the ground. These materials can be ejected from the surface of the tire at high velocity as the tire imparts kinetic energy to the attached objects. For a vehicle moving forward, the top of the tire is rotating upward and forward and can throw objects into the air at other vehicles or pedestrians in front of the vehicle.

Types of fender

1.Full Bumper type

It is not used now a days because they requires bigger size blank to produce the part and the large scrap is also produced.They contribute to the major increment of the steel weight by just covering the front headlights with respect to the bumper region.

2.Half bumper type

Half bumper types are used in present and future also because the blank size is less and the wastage or scrap is less comparing to full bumper type fenders.They can be economically manufactured, i.e by slightly increasing the blank size, we can produce two fenders at a time.

There are 5 mounting regions on the fender , they are

• A- pillar mounting
• Body mounting
• Sill mounting
• Bumper mounting
• Drip mounting

1. DRIP MOUNTING

• It is the important mounting uni of the fender . it is connected with the engine compartment, therefore a lot of design constraints are to be followed while designing the fender
• While designing the drip area we have to initially leave 200-300 mm for the cowl top
• For placing the headlamp we have to leave at least 150 mm at the front while designing the fender
• The cowl top part consists of a wiper motor and its instruments

2.A-PILLAR MOUNTING

The A-pillar is the structural pillar that combines the body with the roof . this makes the sides of the windshield rest, front fenders are fastened to the A-pillar to form a robust structure.

3.BUMPER MOUNTING

Bumper mounting area is used to fix the plastic bumper to the fender with the help of the fasteners.

4. SILL MOUNTING

Sill is the panel directly below the bottom of the door supporting the floor and may be used to combine the floor and the body . The bottom end of the fender is mounted on the sill body for reinforcement of the fender panel , thus the sill mounting position is designed with holes and emboss. M5 fasteners are used to fix the fenders on the sill body.

5.BODY/BUFFLE MOUNTING

Baffle mounting or mudguard are clip fit type of mounting on the inner side of the fender arch over the Tyre. it protects the car engine compartment and pedestrians from causing injuries from chip out debris on the road when the car is in motion . they are mounted on the fender using a special type of locking clips which are made up of plastics

Overall view:

Purpose of Fender :

• Cleanliness : Protect the car, occupants and passers by from items, water, mud, snow, ice, thrown off the tires as you drive.

• Safety : Protects pedestrain from the wheel, e.g. its better to be it by a laterally moving fender than a rolling tire, keeps loose, streaming items from being wrapped up in a rolling wheel.

• Aerodynamics : Smooths the car profile so you don't get a lot of drag off the uncovered wheels. Some fenders are enclosed on the side for this.

• General Appearance : Looks better with fender, gives a finished look, looks more streamlined.

FENDER Manfacturing process

Fender's purpose is to prevent rocks, mud, sand, liquids from being thrown into the air or on to the pedestrians by a rotating wheel Fender is made aerodynamic in shape to reduce the air drag.

The manufacturing of the fender majorly involves these operations.

1.Embossing

2.Bending

3.Cutting and Blanking

• Embossing

Embossing Embossing is a metal forming process for producing raised or sunken designs or relief in sheet material using matched male and female roller dies, theoretically with no change in metal thickness, or by passing sheet or a strip of metal between rolls of the desired pattern.

• Bending

Metal bending is a process by which metal can be deformed when applying force to the subject, which causes it to bend at an angle and form the anticipated shape, which often results in it being in a 'V' or a 'U' shape. This is done through the application of force on a workpiece. The force on the work piece can be mechanical, pneumatic or hydraulic.

• Cutting and Blanking

Cutting processes are those in which a piece of sheet metal is separated by applying a great enough shearing force to cause the material to fail. Blanking is a steel manufacturing process in which a flat, geometric shape is created by feeding a coil of sheet metal into a press and die in this process, the blank is punched out from the large metal sheet.