Fender Design

Front Fender Design

Aim: To Design Front Fender and the necessary mountings by following the Master section with the design parameter.

Introduction: Fender is the American English term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other roads spray from being thrown into the air by the rotating tire. Fenders are typically rigid and can be damaged by contact with the road surface. The material used in the fender is Steel or aluminum

Various materials are used to make cars. The main materials used for making cars, parts, and components, along with future trends, are steel, aluminum, magnesium, copper, plastics, and carbon fibers. The prime reason for using steel in the body structure is its inherent capability to absorb impact energy in a crash situation. The use of aluminum can potentially reduce the weight of the vehicle's body. Recent developments have shown that up to 50% weight saving for the body in white can be achieved by the substitution of steel for aluminum.

The fender is a front outer side member of a car, which covers the wheel side. It has so many small features with ups and downs. The binder surface is not a planer one in this case. This is because it reduces the draw depth and it has two rows of draw beads. It seems to be difficult to form due to its small radius fillets. In this analysis, there is a need to find out the forming feasibility of this component, and if not possible in a single stage then we need to modify the die design with the least modification and need to optimize the draw bead profile, and draw the radius in such a way that we can get the good component in a single stage itself. For thin and very big forming dies, we need to do gravity analysis. If our die face is profiled, then we may need to do a binder wrap analysis. The binder wrap analysis results are taken to the forming analysis. After the forming analysis, if trimming is there means just before trimming analysis we have to do mesh coarsening. Then the coarsened mesh and its results are taken for trimming analysis. The results of the trimming analysis are taken to the spring back analysis. From the results of the spring back analysis, further, we can cross-check the spring back of the real component. The analysis results obtained are used in the sheet metal industry for metal forming processes.

In fig.0.1 shows the fender location on the car where it is mounted on the front and rear side.

                                                                                     Fig0.1: Fender location on car

Fig 0.2 shows Fender.

                                                                                     Fig.0.2: Fender

There are 2 types of Front Fender

1. Full Bumper Type 

2. Half Bumper Type

We are changed from full bumper type to half bumper type to reduce scrap rate per blank. In the full bumper, we can only produce one Fender per blank, whereas as a half bumper type we can produce 2 fenders per blank.

Mounting locations: Fender is going to fix on following locations 

1. Drip Area.

2. Bumper Area.

3. Baffle Area.

4. Sill Area.

5. A PillarArea.

Fig 0.3 shows Fender Mounting locations.

                                                         Fig.0.3: Fender Mounting locations.

All areas are connected by using Bolts or Snaps or clips or Screw. in the fig0.4 show an example fender assembly

                                                                                     Fig.0.3: Fender Assembly

 Manufacture of front Fender: Generally the manufacturing of sheet metal are involved the following steps

1. Process planning: The purpose of process planning of automotive panels is to identify the number of operations, the tasks in each operation, and the content of each task. This research proposes an automatic reasoning procedure based on expert experience and the laws of physics.

2. Blank size calculation.

3. Trimming task: The trimming task is separated into two parts. 

4. Restriking task: The restriking task is necessary when surfaces deform because of spring back after drawing and trimming, or the accuracy requirement is high because a surface overlaps another surface of another panel during assembly. To overcome the spring back of sheet metal Restriking is required.

5. Piercing task: Each hole feature requires a piercing task. Hole features can be classified as basic holes, lock holes, and enlarge holes based on their different functions during assembly. A basic hole is for locating the panel, and a lock hole is for locking panels.

6. Burring task: Removing the sharp edges and harmful burs from the component.

If some groups cannot be shaped while drawing. undercuts exist in the drawing direction. When a group cannot be drawn or trimmed successfully and modeling is complex, the group is shaped by two forming tasks. A flanging task is first used to bend the die face into a transitional shape and the restriking task is then used to form the transitional shape to product shape.

fender requires five operations as a result of process planning. The first two operations are for drawing and trimming, and suitable standard cams are chosen or the size of homemade cams is reasoned based on features.

Design requirements for Fender: 

1. Check for Wheel arch area, as per regulation taken for design.

2. Drip Area: The following Design requirements are used to design the drip area

a. Drip Area should be 150 mm from the front side and 200 from the mirror area

b. From the master section, we have optimized values for draft, drawing, and assembly points of view. such as Distance from engine comportment is 10mm, Height of fender, etc.

c

Fender Design Procedure: 

1. Import the file: File > open > browse file and select the given file (Product name. part) shown in fig. 1A.

                                                                                            Fig.1A: Imported File

Given surface is A class and we have Design Fender using given class A with the help of the Given master section shown in fig 1B.

                                                                                      Fig.1B: Master section

First made an offset curve on the surface with 5mm.

then made a curve on the surface that required area to trim.

trimming is done in required areas with curves on the surface.

Then made law excitation for all required areas.

For support required area made a Dart.

Made Datum plane for all required areas.

Then made sketches for emboss and clamping holes.

Trimming and Radius did in all the required areas. And removed all the sharp edges.

After completing all required mountings Thickening has done 0.75mm.

A-Pillar Mounting

Sill Area Mounting

Baffle(Splash) Mounting

Bumper Mounting

Drip Area Mounting