Fender Design Challenge
FENDER DESIGN CHALLENGE
FENDER
fender is a metal or plastic enclosure over the wheels of an automobile or other vehicle to protect against splashing mud, etc.
How important is a fender on a car?
Car fenders provide safety to the driver and the passengers at the time of accidents or collisions. They are manufactured in a way to provide bend during front and side collisions. Car fenders are designed to avoid wind resistance and make your car more aerodynamic. Car fenders enhance the overall look of your car.
HALF BUMPER TYPE
Half bumper type is the modern design where less material consumption is observed, so productivity increases by reducing the size of the blank and thus providing more performance. The maintenance also relatively low compared to the full bumper type.
MANUFACTURING PROCESS
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
- Embosses are provided to increase strength.
- The corners of the flanges are smoothened to ease the producibility of part.
- Fillet of 2-3mm is provided to avoid sharp corners and edges.
- Cut outs are provided at certain regions in order to save material as possible.
- Rear clearance of drip area must be 200 mm from the cowl area.
- Frontal clearance of the drip area must be 150mm from the head light room.
- Always maintain 3 degree angle to avoid human eye see the ugly component inside the hood.
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The total drip area length from the vertical must be always maintained below 40 mm to avoid the spring back effecThe total drip area length from the vertical must be always maintained below 40 mm to avoid the spring back effect.
1 . A-pillar mounting.
2 . Sill mounting.
3 . baffle or splash mounting.
4 . bumper mounting.
5 . Drip area mounting.
- This Mounting region is also called as body mounting 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.
SILL MOUNTING
- 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.
BAFFLE OR SPLASH 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.
- The flange provided for the wheel arch is provided with just holes for push pin clips to mount wheel arch.
- The mounting structure can ensure the strength and rigidity of an A post area of the fender, prevent local collapse, avoid abnormal sound produced by resonance due to poor rigidity and improve the NVH performance.
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.
DRIP AREA MOUNTING
- 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.
FRONT VIEW
BOTTOM VIEW
REAR VIEW
TOP VIEW
HENCE THE FENDER HAS BEEN DESIGNED AS MASTER SECTION PROVIDED UNDER FENDER DESIGN CRITERIAS AND SHEET METAL CRITERIAS.