Fender Design

NOTE - there is an error while uploading photos of fender mountings , so i have attached a report as a document . please consider it  

AIM - From the given CLASS A surface of the FENDER we have to develop the model with mountings that are DRIP, SILL, BUMPER, A PILLAR, and BAFFEL.

FENDER - It is a part of the vehicle that frames the wheel. The primary purpose of the fender is to prevent sand, mud, rock etc. from being thrown away into the air by rotating tire and to prevent any injuries to pedestrians. Fender can be of two types, full bumper type and half bumper type. Nowadays half bumper type fender is typically used. The cost of sheet metal blank is reduced as we can produce two half bumper type fender in single blank. This also leads to reduction of scrap.

MOUNTINGS -

DRIP -It is the important mounting of the fender. It I connected to engine compartment, therefore a lot of design constraints are to be followed while designing the fender. While designing the drip area we have to initially leave 200mm for the cowl top which consists of a wiper motor and its instruments. For placing the headlamp we have to leave at least 150mm at the front while designing the fender. Using the given master section, drip mounting is designed.

SILL - The 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.

 A PILLAR - The A-pillar is the structural pillar that combines the body with the roof. This makes the sides of the windshield rest. Front fenders are fastened to the A-pillar to form a robust structure.

BAFFLES - Baffle mounting or mudguard are clip-fit types of mounting on the inner side of the fender arch over the Tire. 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.

BUMPER - The bumper mounting area is used to fix the plastic bumper to the fender with the help of the fasteners<!--[endif]-->

SOLID BODY – 0.75mm thickness is given to fender and its mountings to have a closed solid body.

 MANUFACTURING PROCESS – majorly manufacturing of fender involves these operations,

EMBOSSING - It 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 - It is a process by which metal can be deformed when applying force to the work piece, which causes it to bend at an angle and form the required shape, which often results in it being in a 'V' or a 'U' shape. The force on the work piece can be mechanical, pneumatic or hydraulic.

BLANKING - 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.