Fender Design

                         A

              Project Report

                       Of

             Fender Design 

                       On

                   NX Cad

By: Manish Kumar

Objective

To design a fender of thickness 0.75mm, with the mountings for connecting with different regions.

Introduction

Body In White

These are components of the automotive which is made up of steel. These parts include hood panel, fender, roof, body side panel.

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Fender

A car 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 main function of car fenders is to protect tires and braking systems from mud or other impurities so that they are safer and more efficient. It is one of the side closing components of the engine compartment.

Types of fenders

On the basis of location

Front Fender

Front fenders are located at the front of the car, covering the front wheels. They are designed to protect the car's body from damage caused by rocks, dirt, and other debris that may be kicked up by the front wheels. Front fenders are usually made of metal, plastic, fiberglass, rubber, or a combination of these materials.

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Rear Fender

Rear fenders, also known as quarter panels, are located at the back of the car, covering the rear wheels. They are designed to protect the car's body from damage caused by rocks, dirt, and other debris that may be kicked up by the rear wheels. Rear fenders are usually made of metal, plastic, fiberglass, rubber, or a combination of these materials.

On the basis of body cover

Full bumper type

It is used early in the cars. It is not in use due to manufacturing of full bumper require a big flank and more wastage of material.

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Half bumper types

It is used in modern day cars. It is easily manufactured compared to full bumper type fender. It requires a small flank and less wastage of material. It increases the strength and reduces weight compared to full bumper type.

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Function of the fender

<!-- [if !supportLists]-->·      <!--[endif]-->Wheel Guard

Fenders are useful as wheel protectors from unexpected things that could happen on the road. This also applies to protecting pedestrians and other road users. The debris that comes from the street can potentially cause discomfort to others. For example, rocks, mud, or other liquids so they don't get thrown into the air. The debris will be stuck when the wheels are moving. As a result, driving becomes more comfortable and does not disturb other road users.

 

 

 

<!-- [if !supportLists]-->·      <!--[endif]-->Protector of Scratch

The function of this one actually comes from the fender cover. This one part is the front cloth which is located on the right and left side of the fender. Its function is to protect the car when it is being serviced or routine check. The service that is carried out will not cause scratches, so that the car parts are maintained. Keys used for this service can cause scratches accidentally, requiring protection.

<!-- [if !supportLists]-->·      <!--[endif]-->Car Fenders is designed to avoid wind resistance and make your car more aerodynamic.

<!-- [if !supportLists]-->·      <!--[endif]-->Avoid chipping inside the engine compartment.

<!-- [if !supportLists]-->·      <!--[endif]-->It helps in avoiding injuries in the pedestrians.

 

 

 

 

 

 

 

 

 

 

 

 

Fender material

Fenders can be made of different materials depending on the make and model of the car. Metallic fenders, fiberglass fenders, and plastic fenders are the most commonly used materials.

Metallic Fenders

Metallic fenders are made of aluminum or steel. They are durable and can withstand a lot of wear and tear. Metallic fenders are commonly used in heavy-duty vehicles such as trucks and SUVs. They are also used in high-end luxury cars such as Mercedes, Audis, and BMWs. Metallic fenders are more expensive than other types of fenders, but they provide better protection against road debris and accidents.

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Fiberglass Fenders

Fiberglass fenders are made of a composite material consisting of glass fibers and resin. They are lightweight and durable, making them a popular choice for sports cars and racing vehicles. Fiberglass fenders are also used in some high-end luxury cars. They are less expensive than metallic fenders, but they are not as strong and can crack or break easily.

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Plastic Fenders

Plastic fenders are the most commonly used fenders in modern cars. They are made of heavy-duty plastic, high-quality plastic, or thermoplastic. Plastic fenders are lightweight, durable, and affordable. They are also easy to replace if they get damaged. Plastic fenders are commonly used in economy cars, mid-range sedans, and some luxury vehicles.

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Mountings area of the fender

These are the regions where fender connects to other parts of the car. The fender is attached with bumper, a pillar, sill, engine compartment, splash region.

Master section of the fender

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Engine Compartment Mounting (Drip Area Mounting)

It is the region where the fender connects with the engine compartment. The design of the drip area required some constrains such as front end of the fender is connected with the bumper where front head light housing is mounted. So minimum 150mm distance is given as the clearance for the drip area design from the front side. For the rear side of the fender minimum 200mm distance is clearance for the cowl top mount which has housing such as wiper motors. At the end of the drip area design an emboss surface for additional strength and avoid spring back effect.

Master section of the drip area

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Procedure for drip area creation

<!-- [if !supportLists]-->·      <!--[endif]-->The drip area surface is created with the help of the law extension command.

<!-- [if !supportLists]-->·      <!--[endif]-->The horizontal surface of the drip area where fasteners are attached  

          has embossed surface which has a flat curvature.

<!-- [if !supportLists]-->·      <!--[endif]-->The flat surface has a hole of 10mm diameter with 5 mm clearance on the emboss surface.

<!-- [if !supportLists]-->·      <!--[endif]-->To avoid sharp corners surface blends are provided using either face blend or edge blend.

<!-- [if !supportLists]-->·      <!--[endif]-->For additional strength dart surface is also created.

 

The drip area mounting

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A pillar mounting

This is the region where fender connects with a pillar. A pillar is the component which connects the roof with the door. The a pillar mounting is covered properly so that no any rough surface is visible.

 

 

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Sill Mountings

It is the region where fender connects with the sill of the vehicle. The sill is situated in the lower end of the vehicle. Embosses are created along the fender to connect with the sill.

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Bumper Mountings

This is the region where fender is connected with a bumper of the vehicle. It is situated in the front end of the car.

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Buffel Area Mounting

Splash cover protects the road debris entering into the engine compartment. This mounting has an extended surface with holes that place the splash cover in place.

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Body Mounting

This is the region where fender is connected to the body of the car. This region has same side where at the top the a pillar is connected.

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Different Views of the fender

 

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Fender Manufacturing Process

 The manufacturing process includes the following steps that firstly, unfolding and shearing are carried out on a plate, wherein a proper cold roll specification is selected at first, a cold roll is unfolded, and then the unfolded cold roll is sheared to an iron plate of the corresponding size according to production material specifications; secondly, oil pressing and punching are carried out, wherein the iron plate is extended at first, then side shearing 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 parts of the fender are machined, wherein first of all, the iron plate is punched to a needed outer contour blank, then the iron plate completing the outer contour blank is further shaped, and the iron plate is punched at last; fourthly, installation and welding of a metal plate are conducted. The manufacturing process for the car fender is simple and high in production efficiency; a body of the fender and the small parts can be separately machined, so waiting time is shortened; working efficiency of production is improved.

 

 

 

 

 

 

 

 

 

Conclusion

The fender design with different mountings.

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