Fender Design - Wheel Arch Challenge
Fender: Normally rear fender has integrated with body whereas front fender is separated assembly component. This front fender is one of the side closest components to the engine compartment. The major function of this front fender is to avoid the chipping inside the engine compartment. in general during motion of the vehicle the wheels or tyres pick up some sand, mud particles. so the front fender helps to prevent these types of road particles throwing into the engine compartment which lies on the fender arch area, that plastic component is protecting the engine compartment. This fender plays a major role in case of pedestrain safety when they are attacked. While rotating, the mud particles on tyre may tend to clip outside and hit the pedestrains. So this anti chipping of fender will help to avoid such type of attacks. So while designing the fender commodity we should remember and implement these types of mandatory safety requirements.
TYPES OF FENDERS:
In now a days fenders are divided into two types they are
1.Full bumper type:
The full bumper type fender are mainly used in old cars.
2.Half bumper type:
Now a days all automoblies are runs with half bumper type fenders. because it is basically related to scrap management. Half bumper type leads to less wastage of the bank.
FENDER DESIGN:
CLASS A:
The class A surface is provided by the styling team. We have to creat the fender mounting for the given class A.
FENDER MOUNTINGS:
1.DRIP AREA:
Master section for drip area:
It is the most important mounting unit of a fender. it is connected with the engine compartment and therefore a lot of design constraints are to be followed while desiging the deip area.
It should have sufficient clearance from the front and rear end of the fender to accommodate the cowl mounting region and the headlamp housing unit respectively as shown in figure.
The master sketch provides the liner and regular measurements for angular measurements for desigining the drip mount after taking into consideration varies factors like hood opening, Tool workability, aesthetics(since fender is a styling surface),spring back effect due to exceeded length etc the given model is created.
2.BUMPER AREA:
The bumper mounting area is created at the place where fender is fitted to the bumper.
3.SPLASH OR BAFFLE AREA:
The baffle is the black coloured part over the tyre. It is press fitted.
4.PILLAR AREA:
A pillar area is mounted to the A-pillar frame of the chasis so that it is rigidly attached to the body of the car.
5.SKIL AREA:
The area is the area where the fender is mounted to floor rails by bolts.
MANUFACTURING PROCESS:
Generally the manufacturing of sheet metal are involved following steps
1.Process planning:The purpose of process planning of automotive panels is to identify the number of operations, the tasks in each operation,and the content of each task. This reseaeching process an automatic reasoning procedure based on expert experirnce and the laws of physics.
2.Blank size calculation.
3.Trimming task: The trimming task is separated into two parts.
4.Restriking task: The restriking task is necessary when surface deform because of springback after drawing and trimming, or accuracy requirement is high beacuse a surface of another panel during assembly. to over come spring back of sheet metal restriking is required.
5. Piercing task: Each hole feature requires a piercing task. Hole features can be classified as basic holes, lock holes, and enlarge holes based on their different functions during assembly. A basic hole is for locking panels.
6.Burring task: Removing the sharp edges and harmfull burns from the component.
Steps involved in manufacturing process:
1.DRAWING
2.TRIMMING
3.RESTRIKING AND FLANGING
4.PIERCING
5.BURRING
If some groups cannot be shaped while drawing. undercuts exit in the drawing directing. When a group cannot be draw or trimmed successfully and modeling is complex, the group is shaped by two forming tasks. A flanging task is first used to bend the die face into a transitional shape and the restriking task is then form the transitional shape to product shape.
Fender requires five operations in the result of processes planning. First two operations are for drawing and trimming, and suitable standard cams are chosen or the size of homemade cams is reasoned based on features.
CONCLUSION:
Fender mountings i.e, Drip area, Bumper area, A pillar area, Sill area, Baffle areas are created for the given fender class A by following all design rules and master section references.