Fender Design Challenge

Fender Design Challenge

AIM

Design Drip area from given master section for fender and create design for Sill, Bumper, Baffle and A-Pillar mount.

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 air by the rotating tire. Fenders are typically rigid and can be damaged by contact with the road.

Fenders protects pedestrain from the wheel when in motion. It also provides better look when provided with smooth finish. Some cars has fenders covered wheel area from side to reduce the drag over the open wheels.

There are mainly two types of fender.

1. Full bumper type
2. Half bumper type
   

• Full bumper type fenders are old designs. These are big in sizes, so used to produce more scrap in blank as it can fit only one fender per blank.
• To reduce scrap percentage, improve producivity and manufacturing some changes were made in design and half bumper type is came into production.
• Half bumper is smaller in size. It can fit two fenders per blank, hence reduction in scrap percentage. These are comparatively easy to manufacture, assemble and handle.

Fender Mountings

In general front fender has Drip area, Sill, Bumper, A-pillar and Baffle mounts. All these mounts are created in this project out which Drip area mount is provided with master section.

1. Drip area mount
   It is the critical mounting area located inside the engine component. It is designed according to the master section provided and optimal opening angle is maintained to make it look well assembled from outside. It is mounted to engine component by weld nuts.
   
2. Sill Mount
   Bottom of the fender is mounted on the sill area. Where sill area is at bottom of the door supporting the floor. To join fender with sill panel and give reinforcement sill mount is created at the bottom side of the fender with holes to join by bolting.
   
3. Bumper Mount
   To fix the fender with the bumper by fastners, a bumper mount is created. Ribs are provided to increase the strength
   
4. A-pillar mount
   A pillar mount is created to fasten fender and A-pillar together. A-pillar is a structural pillar which joins body to roof and gives support to windshield. A-pillar mpunt design is depends on on other body parts design.
   
5. Baffle mounts
   It is located on the inner side of the fender to attach wheel arch over the tyre with fender.
   
   
   

Procedure

1. As per master section, to locate drip mount area, first A-pillar mount needs to be define.
2. Using curve on the face, trim and law extension A-pillar mount is created. Emboss with hole is created for fastening.
3. Next, as per master section, all the sketch marking are created for drip mount area. Using law extention all the surface with required angles are created.
4. emboss are created for mounting such that there is 10mm flat space around the hole. Ribs are created using dart command for strengthening.
5. Then sill mounting is created on extended surfece with emboss.
6. In similar manner, all other mounting are created with emboss for fastening and ribs are provided whwrever required.
7. All the sharp cornes are removed or relief is provided.
8. Drip area mount has edge blends as per master section and all other has radius of 2 or 3 mm.
9. After all the operations 0.75mm thickness is provided

Manufacturing processes:

As per the design complexity, Fender has to undergo many manufacturing process to get the final desired look. Bending and trimming and stamping process.

• Trimming- presses a part through cutting die to remove excess material
• Bending- a process in which punch die is used to give desired angle and shape to the sheet.
• Punching- removal of scrap from the sheet or to create holes
• Deep drawing- a forming process in which sheet metal blank is radially drawn into a forming die by the mechanical action of a punch
• Embossing- a stamping process for producing raised or sunken designs or relief in sheet metal

Output Images

Conclusion

Using the design parameters given in master sketch, all the mountings are created on the given Fender Skin.