Fender Design

FENDER:

BAFFLE MOUNTS:

'A' Pillar:

BUMPER:

SILL:

DRIP:

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Fender Report:

Purpose: Fender restricts the debris enter the engine compartment.

-> It plays key role in aesthetics.

-> It also helps for mounting bumper and baffle.

Design Parameters:

-> Design has many parameters in consideration

-> First one would be ensuring the space between engine components and fender, it shoudn't come in close with the compartments.

-> Taking aerodynamics into consideration is also parameter for designing fender.

-> There are many standard dimension formulas/standards should be taken into account.

Mounting points:

Baffle:

It is the mounting point for baffle which helps in shielding the splash and debris entering underbody and the engine bay.

A pillar:

It is the main mounting point for holding the fender itself.

Bumper:

It is the point for mounting bumper onto the vehicle which also accommodates headlights and other such parts.

Sill:

It is mounting point connected to sill, which is part in chassis.

Drip:

It helps the mounting of drip area which is basically collects the water from wiper washers and rainwater collected on wind shield.

Manufacturing process:

Material Selection

-> Fender is mostly aluminium, Plastic composites/metal composites.

-> Should be corrosive resistant and environmental degradation resistant.

-> Finally, should withstand minor impacts and collisions.

Manufacturing:

A design is made according to aesthetics, dimensions and aerodynamics in CAD software.

Tools and Dies are created for the Stamping and molding processes.

Main process-

FOR METAL:

Blanking, Stamping, Piercing, Welding, Surface Treatment.

FOR PLASTICS:

Injection Molding, Trimming, Surface Treatment.

=> Blanking is process where a large sheet of metal is cut into smaller pieces.

=> Stamping is shaping of fender according to the design, It includes DEEP DRAWING, TRIMMING, FLANGING.

=> Piercing is making required holes.

=> Welding as known is welding joints if necessary.

=> Surface Treatment includes some colour treatment, corrosive protection layer.

=> Injection moulding is basically piping molten plastic into a mold and cooling down at a certain temperature.

=> Trimming is the process of removing flashes formed in injection molding.