Fender Design

Fender Design

Challenge:

Follow the given Master section to create the Drip Area.

For the Sill, Bumper, Baffle (Splash), and A-Pillar mount create your own design according to the Engineering standard that you learned.

Prepare a report with all the relevant images included for the mounting points created.

Fender:

Fender is a curved panel over the wheels made up of plastic, metal or rubber material on the side of a car. The important function of fender is to prevent the dirt, mud, debris and liquid particles thrown outside due to the wheel rotation. While during this rotation, chipped out particles from the tyre may affect the pedestrians or it may affect underside of the car and engine chambers. To prevent this fender should be installed in a car.

Fenders are of two types:

1. Full bumper types are conventional bumper types consumes more material and these types of fenders are not in used nowadays. These full bumper type vehicles will have less performance when compared to half bumper type.
   
2. Half bumper types are modern bumper types which consumes nearly half of the material than the full bumper type. Due to this reason, performance of the vehicle increases and cost also get reduces.
   
   

Fender design and its mounts:

Fender should be designed for major five types of mounts. Those five types of mounts are

1. Body mounting
2. A-pillar mounting
3. Sill mounting
4. Bumper mounting
5. Drip mounting

1. Body mounting:

The part of the fender which gets mounted to the chassis of the body is for body mounting.

 

2. A-Pillar mounting:

The part of the fender which gets mounted to the windshield frame and door window.

3. Sill mounting:

The part of the fender which gets mounted to the platform of the door frame is known as sill mounting region.

 

4. Bumper mounting:

The part of the fender which gets mounted to the headlight area or to the bumper area is known as bumper mounting region.

5. Drip mounting:

The part of the fender which gets mounted to the engine compartment area is known as drip mounting region.

Baffle or Splash region:

The place where the water or dust particle might enter from wheel is known as baffle or splash region or it can be defined as the mountings used to mount the baffles to prevent water or dust particles to enter inside car.

 

Fender Design Procedure and Design Parameters:

• Outer curve to be offset using Offset in face tool.
• Now by using Curve on Surface, Trim Sheet and Law Extension tools to create 5 mounting parts.
• Now use data plane, sketch, trim sheet and emboss tools to create mountings.
• Now use two face blend, edge blend and bridge curve and trim sheet tools to remove sharp edges.
• Drip area to be designed using master section provided in the input by using two-face blend, three-face blend and dart for increased stiffness.

Manufacturing Process:

Most of the fenders are made up of steel or thermoplastics. The following procedures or manufacturing process will take place to produce the desired output.

• The flat sheet metal to be cut into desired shape of flat pattern for the desired output.
• Then the sheet metal to be blanked for the hole.
• Then the sheet metal is bended to flange and desired shape using press brake tool.
• Then trimming process to be done to remove sharp edges.
• Then the product to be immersed into galvanised for galvanising process.
• The fender product to be painted completely as per standard procedure to prevent corrosion.

Conclusion:

The desired output can be achieved using above procedures and by above manufacturing process. Indicator cut-out also done for indicators light mountings.