Fender Design

AIM : From the given CLASS A SURFACE of the FENDER we have to made changes in the design and develop the model with some extra features that are :

Mounting Area

1. Bumper
2. Drip
3. A Pillar
4. Sill
5. Baffel

Introduction:

Fender:

Fender is a part of the vehicle that frames the wheel . The primary purpose of the fender is to prevent sand , mud , rock etc from being thrown away into the air by rotating tire and harm pedestrians

Types of fender :

• Full Bumper Type.
• Half Bumper Type.

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.

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.

Mounting Area

1. Bumper
2. Drip
3. A Pillar
4. Sill
5. Baffel

Bumper

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

Drip

• 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

Sill

The 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.

BAFFLE MOUNTINGS

Baffle mounting or mudguard are clip-fit types 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.

A-PILLER AREA

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.

Manufacturing process The manufacturing of the fender majorly involves these operations.

L.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.

DESIGN PROCEDURE -

Input - we have the outer skin of fender as our input .

MAIN CONSEDARARION

Drip Area :

In out of 5 mounting points drip area is the very critical design.

MASTER SECTION

1) Drip area -

• The height of drip area mounting should be less than 40mm so that it reduces the springback effect during manufacturing .
• The edge of the mounting part should be atleast 10mm away from the nearby components in the engine .
• It should be distanced atleast 150mm from the front side ande 200m from the rear side .
• Ribs should be provided in order to increase the strength of the mounting part .
• Bead is provided at the outeredge to increase the rigidity of part .

2 ) A-pillar -

• Ribs are provided in order to increase the strength of A-pillar mounting point .
• Other factors for the mounting flange will depend upon the A-pillar design of car .

3) Bumper side -

4) Sill area mounting -

5) Baffle mounting -

Output -

CONCLUSION -

We have developed front fender with mounting points following the design parameters and mastersection .