Advanced Sheet Metal Design Using NX Cad Challenge_1_Casing Design

Design of casing using NX-CAD sheetmetal

Objective -

To Design a Sheet Metal Casing using NX CAD

Introduction-

Sheet metal is metal formed by an industrial process into thin, flat pieces. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Countless everyday objects are fabricated from sheet metal. Thicknesses can vary significantly; extremely thin sheets are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate steel or "structural steel".Sheet metal is available in flat pieces or coiled strips. The coils are formed by running a continuous sheet of metal through a roll slitter.In most of the world, sheet metal thickness is consistently specified in millimeters. In the U.S., the thickness of sheet metal is commonly specified by a traditional, non-linear measure known as its gauge. The larger the gauge number, the thinner the metal. Commonly used steel sheet metal ranges from 30 gauge to about 7 gauge. Gauge differs between ferrous (iron-based) metals and nonferrous metals such as aluminum or copper. Copper thickness, for example, is measured in ounces, representing the weight of copper contained in an area of one square foot. Parts manufactured from sheet metal must maintain a uniform thickness for ideal results.There are many different metals that can be made into sheet metal, such as aluminium, brass, copper, steel, tin, nickel and titanium. For decorative uses, some important sheet metals include silver, gold, and platinum (platinum sheet metal is also utilized as a catalyst).Sheet metal is used in automobile and truck (lorry) bodies, airplane fuselages and wings, medical tables, roofs for buildings (architecture), and many other applications. Sheet metal of iron and other materials with high magnetic permeability, also known as laminated steel cores, has applications in transformers and electric machines. Historically, an important use of sheet metal was in plate armor worn by cavalry, and sheet metal continues to have many decorative uses, including in horse tack. Sheet metal workers are also known as "tin bashers" (or "tin knockers"), a name derived from the hammering of panel seams when installing tin roofs.

Approch -

1:Sketch:

2Dsketch command used to create this variious sketches. Sketch is the basic feature to crate any sheet metal design.

2) Tab

Primary base feature of the casing.Tabcommand in NX sheet metal work bench used to creat base of the sheet metal casing.

3) Normal Cutout

It is used to cut the the specific portion of the part. Sketch is needed to perform this operation.

4) Bend

Here, a horizontal line was drawn to bend the face of the part at specific angle.

5)Flange

flange is the secondary feature. It needed base feature to perform this operation. It just needed an edge of the base to createsecondary flanges.

6) Break Corner

Break Corner tool is used to give blend or chamfer with specific radius or distance and angle respectively.

7) Unbend

This operation is performed to flattening all the faces of the sheet metal part to create some complex structure over it, which isnot possible in it's original position where many faces of the sheet metal parts are not colinear with the base. It could be rebendafter compex operation completed.

8) Holes

Holes are created for fitting purpose. Various type and size of screw holes can be created through this tool.

9) Dimple

Dimple is a punch tool used to create emboss oevr sheet metal part. It needed a skecth to perform. we can create sketch overthe plane parallelto the surface of sheet metal where we want to give emboss. This type of structure increase the strength of thepart locally.

10) Bead

Bead is another punch tool useed to create embosses over the sheet metal body w.r.t. the sketch created in the specific plane.

11) Rebend

It's a tool to get the flanges of the sheet metal body into it's original position that flattend with unend tool to create some somecomplex structure on the sheet metal body

Drawing Sheet

Conclusion
by doing this challenge I learned the basics of sheet metal design, using of fatures like tab, flange, bend, punch tools, etc. Ilearned the design approach that should follow to construct this type of sheet metal part.