Fender Design

FENDER:

Fender is part of an automobile which is assembled to protect the pedestrians and passengers and other parts of the automobile body from muds stones and other debrisis thrown from tire of the car.Fender are two types:

Full Fender:

Full fender is a type of fender where it covers upto the front light.It requires more blank for producing the part and it leads to more scrap.Tooling cost and production time is high.It is used in old cars.

                                  

Half fender:

In half fender type,blank required for producing part is comparatively lower than full fender type.Scrap is much more reduced in half fender type.From The blank required for producing one full fender type,two half fenders can be produced.It laso reduces the weight which gives major advantage in weight reduction in car.

                                  

Parts in Fender design:

Drip area

Sill

Cowl

A-pillar

Bumper

Baffle

Drip area:

In fender design,drip area plays major roll because it gives major support to fender and is placed inside the engine compartment room.Drip area should be designed in such way that it should have 10mm distance from engine compartment area.Drip area shold be placed at minimum distance of 150mm from lighting parts.Depending upon the wiper and motor fixing areas,drip area should be 300 or less mm distance.

                               

Spring back effect:

Springback occurs when the material angularly tries to return to its original shape after being bent. When fabricating on the press brake, an operator will overbend to the bending angle, which is angularly past the required bent angle, compensating for the springback.

To add strength to drip area and reduce spring back ,darts are placed in drip area.

While giving blend radius,the distance 3+thickness should be followed.It reduces the stress concentration in the corners and edges.

Bumper:

Mud Baffle:

In fender,Mud baffle is attached with fender through screws and push clips.

A mudflap or mud guard is used in combination with the vehicle fender to protect the vehicle, passengers, other vehicles, and pedestrians from mud and other flying debris thrown into the air by the rotating tire.

                                                       

                                  

A-pillar and side:

                                  

Bumper:

                                 

Sill Mounting:

                                 

In fender,sill,A-pillar , drip area and bumper mounting areas are attached with sheet metal parts.In those areas, emboss of the mounting areas are placed  in such a way that emboss and holes should be in flat face.

                                

                                

Fender - Wheel Arch:

• Certain gap is maintained between tire and fender which is to prevent debris thrown from tire doesn't affect pedestrians and passengers.
• This gap is called wheel arch gap.
• The gap sholud be maintained which is necessary for suspension system and turning radius.
• Europe,Japan and US has developed standards for maintaining gap between fender and wheel.

                           

                           

Conclusion:

Fender is designed as per given master section and sheet metal bending considerations.