Advanced Sheet Metal Design Using NX Cad Challenge_1_Casing Design

Tittle of the project: Designing the sheet metal Casing Using Siemens NX.

Objective: Creating the Sheetmetal casing using Siemens NX with 1mm thickness.

Introduction: Creating sheet metal models are not like modelling components. In sheet metal component creation, we have to follow certain guideline like minimum bend radius according to thickness of the sheet and always should be greater than or equal to the sheet thickness. There will be standard procedure like which operation is first and which operation is last also need to follow and some operations are need to be done before folding in practical procedure. But in CAD procedure there are some operations to be done by unbending part.

Design Methodology:

The basic methodology is followed to create the above casing by the following flow chart:

Description:

Sketch: For any sheet metal creation first step is creation of base sketch (blank shape). This sketch is created by taking any one plane as reference. The following sketch is created.

Tab (Base): Tab is the first parent feature in sheet metal designing using Siemens NX tool. All the other feature are usually based on tab. In this casing design, the sketch is used to create tab with our preferences of Sheetmetal with 1mm thickness.

NORMAL CUTOUT:

After creation of tab create the sketch of 40*5mm symmetry with X-axis and cut the portion of tab using normal cutout option in NX to make hole on sheetmetal.

BEND:

After cutting the tab to create the bend draw sketch which is consist of 2lines parallel to X-axis & 10mm far from the edges of Sheetmetal. Using the bend option in NX select the bending line as curve and select the face which you want to bend. The same process to be one more time to bend other side also.

FLANGES:

After bending operation flanges are added to the part using Flange command in NX. After creation of flanges the component looks as follows: the circled portions are added to the component using flange button.

BREAK CORNER:

After adding flanges, the sharp edges of component are removed by using the break corner button. Removing the sharp edges provides stress relief and wear& tear relief. The result of the Sheetmetal part looks as follows:

UNBEND:

After creation above operation to create holes and to do some dimple, bead operation component. This unbend operation will not be there in practical approach. After done unbend operation the component becomes like flat sheet and as follows:

HOLES:

To create holes we need to create sketch or create the points on the surface to position the holes. In this case we create the sketch and the gap maintained between bending portion to the hole center. after creation of holes the component looks as follows:

DIMPLE & BEAD CREATION:

For creation of dimple we need to create the skectch. In this case I have created the sketch and made to rotate 45degrees with respective of sketch origin and exit the sketch. Here we need to follow the design rules otherwise the material get distructed and causes loss of component. By using dimple button in punch tool bar selected the sketch and provided the direction of punch and the component as follows:

After creation of dimple we need to create one more sketch for bead operation the component as follows:

After creation of one bead by using mirror features with respective to datum planes 3more beads are created as follows:

REBEND:

After completion of punching and other operations the component again bend as per our requirements and the final component is looks as follows:

FLAT PATTERN:

After completion of all operations to make 2d drawing & to calculate the blank size we go for flat pattern option.

The flat pattern as follows:

DRAFTING:

After designing 3-d model for further process of manufacturing we have to convert the entire sheet metal component into 2D form for easy interpretation. For this project of casing design a drawing is created out of the flat pattern in 2:1 scale in A3 sheet.

CONCLUSION:

Casing is created with help of NX sheetmetal with 1mm Thicknes as per given considerations.