Fender Design

                                                                                                                                     REPORT ON FENDER DESIGN 

FENDER

A CAR TIRE FENDER IS A PLASTIC, METAL, OR RUBBER PANEL THAT BENDS OVER THE WHEEL ON THE SIDE OF THE CAR, EXTENDING FROM THE FRONT BUMPER TO THE CAR DOOR

THE FENDER IS A PART OF AUTOMOBILE, MOTORCYCLE OR OTHER VEHICLE BODY THAT FRAMES A WHEEL WELL. ITS PRIMARY PURPOSE IS TO PREVENT SAND, MUD, ROCKS, LIQIUDS AND OTHER ROAD SPRAY FROM BEING THROWN INTO THE AIR BY ROTATING TIRES, THUS PREVENTS THE SAFETY OF PEDESTRIAN.

IN BRITISH ENGLISH THE FENDER IS CALLED AS WING. IN MODERN INDIAN AND SRI LANKAN ENGLISH THE FENDER IS CALLED AS MUDGUARD.

SOME OF THE PURPOSE OF FENDER ARE CLEANLINESS, SAFETY, AERODYNAMICS AND AESTHETIC PROPERTY.

TYPES OF FENDER

CLASSIFIED BASED ON THE AREA COVERED. 

1.FULL BUMPER TYPE

2.HALF BUMPER TYPE

1.FULL BUMPER TYPE-

FULL BUMPER TYPE IS A TRADITIONAL TYPE OF FENDER WHERE MORE MATERIAL IS CONSUMED IN MANUFACTURING. THIS TYPE OF FENDER IS USED IN OLD DESIGN FOR AUTOMOBILES WHERE IT INCREASES THE WEIGHT AND THUS INCREASES THE OVERALL COST OF THE CAR.

2.HALF FENDER TYPE-

HALF BUMPER TYPE IS A MODERN DESIGN WHERE LESS MATERIAL IS CONSUMED IN MANUFACTURING. ITS SIZE IS SMALLER COMPARED TO THE FULL BUMPER TYPE SO THE PRODUCTIVITY IS MORE.

FENDER MOUNTINGS 

IT IS THE MOUNTINGS PROVIDED TO THE FENDER SO AS TO RIGIDLY MOUNT ON TO THE CAR BODY.

INORDER TO MOUNT THE FENDER IT CONSISTS OF 5 AREA WHICH ARE AS FOLLOWS

1.DRIP MOUNTING

2.SILL MOUNTING

3.BAFFLE (SPLASH) MOUNTING

4.A-PILLER MOUNTING 

5.BUMPER MOUNTING

1.DRIP MOUNTING-

THE TOP MOST PART OF THE FENDER IS ATTACHED TO THE CAR BODY THROUGH DRIP MOUNTING. THE MINIMUN OF 10MM GAP SHOULD BE MAINTAINED BETWEEN DRIP MOUNTING AND ENGINE ROOM.

2.SILL MOUNTING-

THE VEHICLE BODY IS SUBJECTED TO VARIOUS FORCES DURING TRANSIT SUCH AS VERTICAL AND LONGITUDNAL BENDS AROUND THE AXIS OF THE VEHICLE BODY SO THE BOOTOM MOST PART OF ANY COMPONENT NEED TO BE RIGIDLY FIXED SO THE FENDER IS MOUNTED ON TO THE SILL OF CAR BODY.

3.BAFFLE (SPLASH) MOUNTING-

THESE MOUNTING ARE PROVIDED SO AS TO MOUNT THE BAFFLE ON TO THE FENDER SO AS TO EXTEND THE FENDER TO PROVIDE PROTECTION FROM DEBRIS SPLASHING OUTWARDS AND TO THE ENGINE COMPARTMENT. IT ALSO INCREASES THE AESTHETIC PROPERTY OF THE FENDER.

4.A-PILLER MOUNTINGS-

THIS MOUNTINGS IS PROVIDED TO THE FENDER TO MOUNT ON TO THE A-PILLER. IT ALSO COVERS THE ATTACHMENTS USED IN MOUNTING OUTSIDE REAR VIEW MIRROR (ORVM).

5.BUMPER MOUNTING-

THESE MOUNTINGS IS PROVIDED SO THAT THE FENDER IS ATTACHED TO THE FRONT BUMPER. IT IS PROVIDED TO SECURELY FIX TO THE BUMPER AND TO PREVENT THE LARGER GAPS BETWEEN THEM.

MANUFACTURING PROCESS OF FENDER

THE MANUFACTURING PROCESS OF FENDER INCLUDES THE FOLLOWING STEPS THAT FIRSTLY, UNFOLDING AND SHEARING ARE CARRIED OUT ON A PLATE, WHEREIN A PROPER COLD ROLL SPECIFICATION IS SELECTED AT FIEST, A COLD ROLL IS UNFOLDED, AND THEN THE UNFOLDED COLD ROLL IS SHEARED TO AN IRON PLATE OF THE CORRESPONDING SIZE ACCORDING TO THE PRODUCTION MATERIAL SPECIFICATION.

SECONDLY OIL PRESSING AND PUNCHING ARE CARRIED OUT, WHEREIN THE IRON PLATE IS EXTENDED AT FIRST, THEN SIDE SHERARING AND PUNCHING ARE CONDUCTED ON THE IRON PLATE, FOLDING AND SHAPING ARE CARRIED OUT ON THE IRON PLATE, AND FINALLY RESHAPING IS CARRIED OUT ON THE IRON PLATE.

THIRDLY SMALL FIRST PART OF THE FENDER ARE MACHINED, WHEREIN FIRST OF ALL, THE IRON PLATE IS PUNCHED TO A NEEDED OUTER COUNTER BLANK, THEN THE IRON PLATE COMPLETEING THE OUTER COUNTER BLANK IS FURTHUR SHAPED, AND THE IRON PLATE IS PUNCHED AT LAST 

FOURTHLY INSTALLATION AND MOUNTING OF METAL PLATES ARE CONDUCTED.

DESIGN PARAMETERS CONSIDERED FOR FENDER DESIGN

1.THE DRIP MOUNTINGS ARE DESIGNED BY FOLLOWING THE MASTER SECTIONS WHICH IS SHOWN IN BELOW IMAGES.

2.THE NECESSARY DRAFT ANGLE IS PROVIDED TO DRIP MOUNTING SURFACES TO OBSTRUCT THE VIEW INSIDE THE ENGINE COMPARTMENTS OF CUSTOMERS.

3.WHEN THE SURFACES ARE DEEP-DRAWN BEYOND 60MM SPRING BACK EFFECT IS OBSERVED, SO WE SHOULD ENSURE THAT THE SURFACES SHOULD NOT EXCEED THE MENTIONED LENGTH. IN CASE THE LENGTH IS NOT SUFFICIENT TO MOUNT THEN SMALL BRACKET IS INTRODUCED IN BETWEEN.

4.MINIMUM OF 5MM FLAT SURFACES NEED TO BE PRESENT AROUND THE CIRCULAR HOLE.

5.ALWAYS THE SHARP EDGES ARE AVOIDED BY PROVIDING RADIUS OR EDGE FILLET.

6.DART OR BEADS ARE PROVIDED TO INCREASE THE STRENGTH OF THE COMPONENT.

ORIENTATION VIEWS

1.ISOMETRIC VIEWS

2.FRONT VIEWS

3.SIDE VIEWS

4.TOP VIEWS