Fender Design Challenge

OBJECTIVE:

To design the drip area,bumper mount region,A pillar mount region and sill mount region from the given fender skin.

FROND FENDER:

Fender is the body part above the front wheels of the car.The fender covers the wheel to prevent damage to the car body due to rocks thrown at the body by tires.The fender is also designed to provide safety to the pedestraian.

TYPES OF FENDER:

1. Full Bumper Fender
2. Half Bumper fender

Half Bumper is widely used in the modern world because of its advantages such as scrap management,light weight when compared to the full Bumper.

Types of mounting in fender:

Fenders are basically mounted on five important regions such as body,A pillar,sill,cowl and drip.The job of mounting is not only to hold the part in place,but to reduce the vibration felt inside the car.The fasteners are used to hold down the mountings.

1. A Pillar mounting
2. Sill mounting
3. Cowl mounting
4. Drip mounting
5. Body mounting

Drip mounting:

• This is the connection of fender with engine compartment.
• Based on the cowl part and front headlamp,drip area is designed and usually has mounting points with suitable forward and rearward clearance from the car line.
• Considering the tool workability factor the depth of the flange is limited within 40mm and the clearance of 10mm is ensured for engine room.
• The flange length should be minium of 9mm inorder to avoid the visibility of the engine compartment.
• The flange should be in such a length that it avoids spring back effect.
• From the back side of the front fender,there will be 200mm clearance for the cowl for accomodating the wiper motor.
• From the front side of the front fender there will be 150mm clearance for the headlamp housing unit

A Piller mounting:

A piller mounting is used to connect the fender with the A piller with the help of fastners.

Sill mounting:

Sill mounting is used to connect fender with the sill.

Bumper Mounting:

Bumper mounting is used to connect the front fender and the bumper of the cars

Baffle Mounting:

Baffle mounting is used to connect the fender and the baffle.Baffle is present above the wheel.

Dart:

The dart tool is used to incerease the strength of the flange.By making contact between two adjcent flanges.

Emboss:

Emboss is used to strengthen the sheet metal.

Corner relief:

Corner relief helps to control sheet metal material behaviour and to prevent unwanted deformation during unbending operation.

Manufacturing process:

• As per the design plan for tools to make ready the part for assembly.
• Snipping or blanking operation should be done for taking the piece of a sheet from rolled one
• Bending and striking are performed to get the desire shape
• Trimming is performed to trim the unwanted section from working sheet
• Piercing should be performed to make the required holes on the sheet
• Embosses are creared by doing the deep drawing by considering the good draft angle
• Burring is the process of clearing the burrs and edges like sharp corner after operation.

Conclusion:

Thus the dip Area,Bumper Mount Region,A piller mount region and sill mount area are designed for the fender from the styling surface.