Advanced Sheet Metal Design Using NX Cad Challenge_1_Casing Design
REPORT
DESIGN AND DEVELOP CASING MODEL
OBJECTIVE: The objective of the project is to design and develop the casing model in sheet matel workbench by using NX CAD, and to understand the design methodology of sheet metal, features and commonds.
INTRODDUCTION:
The term “sheet metal” refers to any metal that can be formed into flat pieces of varying thicknesses. Thick metals are called plate. Metals used in the sheet metal industry include cold rolled steel, mild steel, stainless steel, tin, nickel, titanium, aluminum, brass, and copper.
There are six major types of sheet metal material, each with its own unique advantages:
- Alloy steel.
- Stainless steel.
- Carbon steel.
- Tool steel.
- Galvanized steel.
- Aluminum.
MUFACTURING PROCESS:
When making sheet metal, however, companies often use one or more of the following forming processes.
1) Curling:Curling is a sheet metal forming process used to form the edges into a hollow ring. Curling can be performed to eliminate sharp edges and increase the moment of inertia near the curled end. Other parts are curled to perform their primary function, such as door hinges.
2) Bending:Metal bending is a process by which metal can be deformed when applying force to the subject, which causes it to bend at an angle and form the anticipated shape, which often results in it being in a 'V' or a 'U' shape. A press brake is a tool used in order to bend sheet metal and uses a punch and die to do this.
3) Ironing:Ironing can be accomplished during deep drawing or performed separately. The process uses a punch and die, forcing the metal sheet through a clearance that will act to uniformly reduce the entire thickness of the workpiece to a certain value. As with bending, the deformation does not reduce volume.
4) Laser Cutting:Laser cutting fabrication uses a high-power beam of light (laser) to cut out flat and thin sheets of metals. The process is directed by optics and computer numerical control (CNC) technology, which accounts for the high precision of laser cut parts.
5) Hydroforming:Hydroforming (Sheet Hydroforming) is a specialized deep draw process that uses high-pressure rubber to shape and form metal workpieces. In sheet hydroforming, a metal sheet is placed over a die before highly pressurized water forces it down and makes it conform to the shape of the mold.
6) Punching:Metal punching is the process of impressing a form on a surface by pressure or percussion with a steel punch tool. In the metal punching process, the material is removed from a piece of sheet metal by applying a great enough cutting force. The metals that can be punched are different: steel, iron, copper, and aluminum.
DESIGN METHODOLOGY AND APPROACH:
The below flow chat show the methodology or approach for this model:
COMMONDS USED FOR DEVELOPED THIS MODEL:
The following commands using while developing thsi model are listed below-
1) Tap
2) Normal cut
3) Bend
4) Flange
5) Unbend
6) Holes
7) Dimple
8) Bead
9) Corner break
1) Tab Command: Tab command is use to given the thickness of the profile as per the required dimensions.
2) Normal cut: This is the command which help to remove the material as per the sketch profile, it is perpendicular to the sheet and it will follow the sheet metal shap.
3) Bend: This command help to bend the sheet at perticular place with given dimendions.
4) Flange: This command creat the flanged as per required edge at specified dimension. In this also there will be different option to give relief.
5) Unbend: This command helps to the model to bring it in initial stage before bending witout loosing the bending operation, which help to achieved some cuts and holes or some specified patter, which is difficult to achieved in bend position.
6) Hole: This command helps to creat holes as per requirment. In this command variety of operation can be achieved.
7) Dimple: THis is the command which helps to creat a emboss type structure on the sheet by giving specified dimention as per the requirment.
8) Bead:Use the bead command to lift material along the contour of a sketch that simulates a stamping tool. Beads can also be created to stiffen sheet metal part.
9) Corner Break:This command helps to giver the chamfer or fillet at given dimension for the smooth manufacturing operation.
PROCEDURE AND STEPS FOLLOW IN THIS MODEL
1st step:
creating the rectangle profile of 60mm x 50mm dimention and give the thickness of 1 mm using Tap command.
2nd step:
Creat an rectangle of 40mm X 5mm dimension at the end of the sheet and the one line of the rectabgle is aligned with the y-axis. By using normal cut cammand remove the material.
3rd step:
Creat sketch on the surface of the sheet. The distance from the top edge is 10 mm. By using Bend command creat a bend on bothe edge with the reference of sketch.
4th step:
By using flange command created the flange on all four end endges.
5th step:
With the hepl of unbend command we need to bring the sheet in flat shap. Now at all the four corner need to creat the point at specified dimention and creat a simple holes.
6th step:
At the center , need to creat profile with the specified dimension for the dimple operation. By using dimple command we need to creat dimple.
7th step:
We need to creat sketch of a siple circle 8 mm form the edge wit dia 10 mm . By using the Bead command we need to creat bead at four point with similar distance.
8th step:
Then after creating bead we need to bend it again by using bend command agian.
9th step:
creat draft fo the final model. Befor creating drafting for the model we need to do the flat pattern of the model.
DIFFERENT VIEW OF THE MODEL
CONCLUSION:
In this project we learn the commands and proccedure for designing the sheet metal , and learn how to execute the commands. While design of sheet metal model we need to define the proper dimension and need to give proper relief and remove all the sharp edges for smooth operation