Fender Design Challenge
INTROUCTION:
Fender is the American english term for the part of an automobile,motorcycle or other vehicle body that frames a wheel well(the fender underside0.its primary purbose is to prevent the sand,mud,rocks,liquids,and other road spray from being thrown into the air by the rotating tire.Fender are typically rigid and can be damaged by contact with the road surface.
OBJECTIVE:
In this project we are going to design the mounts for the front fender such as drip,sill,bumper,A-piller and baffle for this we are going to design mounts.
TYPES OF FENDER:
- Full bumper type.
- Half pumper type.
FULL BUMPER TYPE:
It is not used now a days because they requires bigger size blank to produce the part and the large scrap is also produced.
HALF BUMPER SIZE:
Half bumber types are used in present and future also because the blank size is less and the wastage or scrap is less comparing to full bumper type fenders.
USES OF CAR FENDERS:
Car fender limit the exposure of your car's body and engine to external elements that are harmful.
Fender flares are attached to ensure that both the body and engine have minimal contact with corrosive elements.
Car fenders provides saftey to the driver and the passengers at the time of accidents or collisions.They manaufactured in a way to provide bend during front and side collisions.
AREAS TO BE CONSIDERED WHILE DESIGNING A FENDER.
- Drip area
- Bumper mounting area
- Sill mounting area
- Body mounting area
FEATURE/TOOL USED:
- Sketch
- Offset in face
- Curve on surface
- Bridge curve
- Emboss
- Trim sheet
- Law extension
- Face blend
DRIP AREA:
It is the area through which the fender is attached to engine housing through fasteners.There should be some consideration followed to design the drip area,from back side of the fender there should be 200mm clearance for cowl mounting area and from the front there should be 150mm clearance for the head lamp housing unit.
Considering the above design constraints we have to design the drip area.Embosses are provided to increase strength,corners of the flanges are smoothen to ease of the production.Uniform wall thickness of 0.75mm.
Design consideration for drip area are 150mm distance from front end of the fender and the gap is filled with headlamp 200mm distance from rear end of the fender and the gap is filled with wiper motor assembly.
Initially 3 - degree angle and 9mm length is given while creating a drip area because the engine component should be visible from outside.
The depth of the drift should be between 40 to 60mm.If the depth exceeds from 60mm then forming is not feasible due to spring back and wrinkle effect.Embosses and rips are given to drip area to give strength.Embossed dimensions are depth 3.5mm and 15degree of angle for all three embosses.
A PILLER AREA:
A piller is on the cars either side of the front windshield which is the reason the windshield in the place.
It is mounted on the A pillar by means of fasteners and these are covered by outer side view mirrors.
Here,the proper embossing are provided along with holes for fasteners.
Law extension dimension are 42mm length and 90 degree of angle.Offseting the law extension face 5mm.Creating the sketch and law extension feature is used 6mm length and 95 degree of angle.Trim sheet to craete a hole of 5mm diameter.Edge blend and face blend are 2mm.
SIL MOUNT AREA:
The Sill mounting area is in the bottom of the fender.
It is mostly gets connect with the door region of the car.
Here,proper embossing and holes for the fasteners are provided.
The rips are provided to improve the strength.
Extend sheet to 15mm to make the sheet length 30mm.giving relief by manual like creating a sketch and trim the sheet both sides.Embosses dimensions are depth 3.5mm and 15 degree of angle.Edge blend is 3mm.Trim sheet used to create a 6mm hole on sheet.
BUMPER MOUNT AREA:
In this mounting,the fender connects with the bumper.
The bumper mounting region must be rigid in order to withstand the force acting upon it during collision.So,the mounting space can be larger.
The bumper mounting is placed at the mating head light position.
This is also has a flange with holes for mountings.
BAFFLE MOUNTING AREA:
For baffle mounting we didn't made any kind of emboss we have created the mounting holes for it and we have created the baffle flange on which the holes are there.
After creating the mounts we finally thicken it which gives thickness to the sheet metal.
MANUFACTURING PROCESS OF CAR FENDER:
The invention discloses a manufacturing process for a car 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.
CONCLUSION:
Developed the drip,Bumper,sill A piller and baffle mounting areas by design requirements of the fender design.