Fender Design

FENDER :

The main purpose of the fender is to prevent sand,mud, rocks,liquids and another road spray from being thrown into the air  by the rotating tire .

TYPES OF FENDERS :

There are two types of fenders , they are 

1) full bumper type 

2) half bumber type 

• Presently we are using the half bumper type , the reason for choosing the half bumper type is that when we choose the full bumper type the blank used for creating it is very large  and also has the lot  of wastage , but in the case of the half bumper type we have the possibility to reduce the scrap . This is what we called as scrap management
• In half bumper type we reduce the usage of the steel material and uses the lots of plastic on the bumper which in term decreases the cars weight and  increases the performance

 FENDER WHEEL ARCH :

• Fender wheel arch is having some standard specifications , for example if you see the car from the front, if you see the wheel outside  fender it does more chipping and it causes lots of damage to the pedestrians and  also to the car
• In order to maintain the pedestrians safety we have to position the tire wheel inside the fender
• For the European  requirement the clearance between the wheel and the fender outer most skin is 5mm
• This requirements changes from country to country based up on the  road conditions.

MOUNTING REGIONS ON FENDER :

There are  5 mounting regions on the  fender , they are

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

DESIGN METHODOLOGY  :

 GIVEN DATA :

                                                          MASTER SECTION

DESIGN 0F DRIP AREA MOUNTING :

• It  is the important mounting uni of the fender  . it is connected with the engine compartment , therefore the 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 cowl top
• For placing the headlamp we have to leave  at least 150 mm at the front while designing the fender
• Cowl top part  consists pf wiper motor and its instruments  

                                                                   DRIP AREA

• Two darts are added on the longer side of the drip area in order to provide the stiffness and adds strength to the part . This helps the fender to not to vibrate and impact the  forces outside of the fender during motion of the vehicle.
• Embossing are provided on the mounting to strengthen them during fastening

DESIGN OF SILL MOUNTING AREA :

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.

                                                              SILL MOUNTING

 DESIGN OF BUMPER MOUNTING AREA :

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

                                                           BUMPER MOUNTING

DESIGN OF A-PILLAR MOUNTING AREA :

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

                                               A-PILLAR MOUNTING

DESIGN OF BAFFLE MOUNTING AREA :

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 .

APPLYING OF THICKNESS TO THE SURFACE .

The thickness of 0.75 mm inward on the final sewed surface  of the fender to the sheet metal parameters

Different views of the fender