Fender Design Challenge

Aim : To create mounting points for drip area, sill, bumper, A pillar on fender of an automobile using                the master section provided.

Introduction : Front fender is a part of the vehicle that frames the wheel . the primary purpose of the fender is to prevent sand , mud , rock etc from being thrown away into the air by rotating tyre.

There are two types of fenders

1) Full bumper type 

2) Half bumper type 

 Half bumper type fender is typically used . the cost of sheet metal blank is reduced as we can produce two half bumper type fender in single blank, which leads to reduction of scrap. 

Manufacturing process invovlved in fender are as follows

• Blanking
• Stretch forming
• Punching and Trimming
• Deburring and Grinding
• Polishing

Mounting points of fender

There are 5 mounting points on the fender

• A - pillar mounting
• Baffle mounting
• Sill mounting
• Bumper mounting
• Drip mounting

Drip Area
The area at which the fender gets attached to the engine housing through fasteners. It is the major mounting for the fender. Mountings at the drip area are designed leaving a clearance of 200mm from the back of the fender for the cowl setup. And clearance of 150mm from the front of the fender for a headlamp housing unit. Darts are provided at the bends to strengthen the sheet metal at that region.

A-Pillar Mounting Area
This Mounting region is located near the cowl of the vehicle where the fender is fastened with the bottom edge of the windshield. This mounting is covered with the side rear-view mirror. Front fenders are fastened to the A -pillar to form a robust structure.

Sill Mounting Area
The area at which the bottom of the fender gets connected to the floor near the bottom edge of the door. The Embossed sill mounting of the fender is attached with the fasteners.

Bumper Mounting Area
The bumper mounting region is located beneath the bumper. The fender gets attached before the installation of the bumper. After fixing the fender with fasteners the bumper will cover the bumper mounting.

Baffle Mounting Area
In this region, the baffle gets installed to the fender with the help of clips which holds the baffle with the fender along the wheel arch.