Advanced Sheet Metal Design Using NX Cad Challenge_1_Casing Design

Aim :

Write a detailed report on Sheet Metal Component with good explanation on Sheet Metal modelling tools applied throughout the modelling. Also attach the Final model Images (Min. 4 images) of Sheet Metal Casing.

Solution:

 First we will define a few terms related to sheet metal :

1.Bend Radius:

It is the inner radius of the sheet metal after bending .

2.K Factor :

The K-factor is the ratio of the neutral axis to the material thickness. When a piece of metal is being formed, the inner portion of the bend compresses while the outer portion expands . The neutral axis is the area of transition between compression and expansion, where no change in the material occurs—except that it moves from its original location at 50 percent of the material thickness toward the inside surface of the bend. The neutral axis does not change its length but instead relocates; this causes elongation to occur during bending. How far the neutral axis shifts depends on a given material’s physical properties, its thickness, inside bend radius, and the method of forming.

 Now we make the following sheet metal part :

We will first create the base sketch of a rectangle as shown below :

 Now we set the sheet metal parameters as shown below :

We have used the tab and cut out feature to create the following :

Now we will  bend using the following sketch :

 We get the following as output :

Now we will add flanges to it as shown :

After adding fillets we get :

Now we will unbend as shown :

 Now we will add holes :

We have added beads to it as shown below :

We have used rebend to get the following:

1

We have created the flat pattern and drafted it as shown :

Hence we have created the part as shown :