Fender Design Challenge

Fender Design Challenge

Introduction

In this project we have to design the fender as per European standard. We have to take care of pedestrian safety, precaution of sand and chips scratch, mounting points, assembly and manufacturability.

What is fender?

Fender is the American English term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well. Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown into the air by the rotating tire.

Input for Fender design

Class A surface from styling team

Design Consideration

Mounting points in Fender:-

• Body mount.
• A pillar mount.
• Sill mount.
• Cowl mount.
• Drip mount.

Ribs for Flange strength.

Master sections for Fender design.

Fender Design in Catia.

Drip Area mount.

Bumper mount

Sill Mount

A pillar Mount

Splash Cover mount

Manufacturing Process for Fender

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.