Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

DESIGN OF BOX ASSEMBLY IN SHEET METAL USING SIEMENS NXCAD

OBJECTIVE

To design box assembly in sheet metal application under given geometry and measurements using the SIEMENS NXCAD software

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".

DESIGN METHODOLOGY

The design methodology of the box assembly is explained with the help of flow chart for easy and better understanding

FLOWCHART

DESCRIPTION

There are various tools used to design the casing in the sheet metal application in SIEMENS NXCAD they are described as follows,

Features Used

Tab: Creates a base feature by extruding a sketch along a vector by a thickness value, or adds material to a planar face. Additional planar selection can be added to generate bends as parts of the base feature.

Normal cutout: Cuts material by projecting a sketch onto the model and then cutting perpendicular to the faces intersected by the projection

Bending: Modifies the model by bending material on one side of a sketch line, adding a bend between the two sides.

Flanges: Adding a flat flange at an angle to a planar face and adds a bend between the two

Hem Flange: Modifies the model by folding the edge of a sheet metal flange over onto itself for the purpose of safe handling or to increase edge stiffness.

Breaking Corner: Rounds or chamfers a sharp corner of a tab or flange

Closed Corner: Closes a corner where two adjacent flanges meet by extending the bends and flanges.

Mirror Feature: Copies and mirrors it across a plane.

Mirror Body: Creates Associative copies of bodies, faces, curves, points and datums, and associative mirrored copies of bodies, within the same part.

Unite: Combines the volume of two or more solid bodies into a single body.

Unbend: Flattens a bend and the material adjacent to the bend

Hole: Adds a hole to one or more solid bodies in a part or assembly with options for counterbored, countersunk, and threaded.

Dimple: Lifts an area of the model inside a sketch that stimulates a stamping tool.

Beads: Lifts material along the contour of a sketch that stimulates a stamping tool

Datum Plan: Creates a datum plane used to construct other features.

Re-bend: Restores an unbend feature to its previous bent state, along with any features added after the unbend feature.

Flat Pattern: Creates a flat pattern feature from the formed sheet metal part

Drafting: Starts the drafting application, which provides tools to create and maintain drawings of the design model.

PROCEDURE

A tab is created by drawing a sketch on the xy-plane. feature like flanges, closed corner and hem flange are added to the tab and the body is mirrored. The mirrored body is then united. Then a dimple is added and the dimple is mirrored. The model is then un-bend and re-bend. add bead and mirror them and add the hem flange to it. create a datum plane and create a tab and add a flange. Create tab and add features like break corner, flange, hem. Then unbend the model add a normal cutout and then re-bend it. the body is mirrored. Create another tab, add features like break corner, flange, hem to the tab. un-bend the model and add a normal cutout then re-bend the model. Finally flat pattern the model and save it in sheet.

PART IMAGES

Isometric View:

Top View:

Front view:

Right Side View:

Bottom View:

Back View:

Left Side View:

Detailed Drawing Sheet:

CONCLUSION

The box assembly is designed using the Sheetmetal application in the SIEMENS NXCAD.

Link:https://drive.google.com/file/d/1sImu-TPFTkYUUu2V_L43sAtHr-4Nv1WA/view?usp=sharing