Fender Design

FENDER DESIGN

INTRODUCTION :

Fender is the american english term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well. Its primary propose is to prevent sand, rocks, mud, liquids, and other road spray from being thrown into the air by the rotating tire. Fender are typically rigid and can be damaged by contact with the road surface.Sticly materials, such as mud, may adhere to the smooth outer tire surface, while smooth loose objects, such as stones, can be become temporarily embedded in the tread grooves as the tire rolls over the ground. These materials can be ejected from the surface of the tire at high velocity as the tire imparts kinetic energy to the attached objects. For a vehicle moving forward, the top of the trie is rotating upward and forward, and can throw objects into the air at other vehicle or pedestrians in front of the vehicle. 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.

FENDER

It is an aesthetic component/part of a car that frames the wheels. Prevention of sand,  mud particles, and other road contaminants from being thrown into the engine compartment and also to the pedestrians by the rotating tires are the main purpose served by the fenders.

The front fenders are separate components whereas the rear fenders are integrated with the body sides.

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

1. FULL BUMPER TYPE: These types of fenders were used in earlier models of vehicles. They contribute to the major increment of the steel weight by just covering the front headlights with respect to the bumper region. The problem associated with this kind of fender is there is a lot of wastage in the blank and every inch of a material is a cost to the industry.

2. HALF BUMPER TYPE: These fenders are mainly used for serving the purpose of cost-cutting and reducing enough proportions of the steel wait resulting in a reduction of the weight of the vehicle slightly. They can be economically manufactured, i.e by slightly increasing the blank size, we can produce two fenders at a time.

 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

Manufacturing process

The manufacturing of the fender majorly involves these operations.

1.Embossing
2.Bending
3.Cutting and Blanking

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 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

• 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.  It should have enough strength to hold the bumper steadily.

                                                           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  .
• The mounting has to be created by taking the reference from the A-pillar of the vehicle.
• Enough clearance should be given for the easy mounting of the wiper equipment.

  

                                               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 FENDER :