Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly
BOX ASSEMBLY USING NX CAD SHEET METAL APPLICATION
Objective:
The main objective of this project is to create the Box assembly using NX cad sheet Metal Application workbench.
Introduction:
In this challenge, we have created the Box assembly using various basic features like bend, flange, Hem, Break corner, Dimple, Mirror, Unbend and Rebend. The box assembly consists of a box, closure, and the hinges between the closure and box. Hemming operation is done for connecting the two sheetmetal, so that the box have the asthetic looks and the perfect joint. None of the component in our assembly is having the sharp edges which could hurt the end users. Dimple operation is done on the two sides and the bottom of the box to ensure the stiffening and strength of the box. Beading is done on the bottom the box which could act like a bush.
Design Methodology:
Description:
Step 1: Creating the Base sketch
The first step is to create the base sketch for the design and then the base sketch is converted into the base tab which is nothing but providing the thickenss for the sketch, so that we can add more features from the base tab.
Step 2: Adding Flanges to the base Tab
After creating the base tab the falnges are added at the edges of the tab, so that the walls for the box assembly is created. Four flanges were created in the XY and XZ plane with the required length and the Bend radius as 10mm.
Closed corner option is used to close the gap at the bottom of the created flange.
Step 3: Adding supporting flanges for Hemming operation
The supporting flanges were created at the opening of the two flanges, so that we can easily perform the hemming operation to joint the sheetmetal.
Step 4: Hemming operation
Open Hem operation is done at the two supporting flanges to joint the sheet meatal rigidly. This gives the asthetic look for the assembly as well as the perfect joining operation
Step 5: Mirror body and Unite
After the hemming operation, one half of the box assembly is ready. To get the another half we have performed the mirror option so that the same half is reflecting without any error. This mirror opertion is done by selecting the one half of the part and the Mirror plane.
Unite operation is done to combine the volumes of the two bodies and make it as a single one.
Step 6: Dimple and Mirror
Dimple operation is done at the side wall of the box assembly. This provides the extra strength and stiffness for the assembly. And the same feature is mirrored on the opposite wall of the box.
One more dimple is provided at the bottom of the box for the strengthing purpose.
Step 7: Unbend and Rebend
After creating the features, the sheetmetal is unbend and rebend for checking the manufacturing fesability of the added features.
Step 8: Bead and Mirror
Bead is a long, drawn-out impression, which is impressed to increase stiffness in metal sheets or plates. Depending on the workpiece size and material thickness, the ratio of length, width and imprint depth must be adjusted to obtain the maximum strengthening effect.
The same bead is mirrored for the four corners in the box assembly
Step 9: Closed Hem
Closed Hem is provided at the opening end of the box assembly, thus providing the blend edges on the mouth of the box. This is one of the operation for providing saftey for the users to handle the box easily.
Step 10: Box closure
For creating the box closure, new datum plane is created by offsetting upto the height of the box. Then the sketch is drwan for that closure profile and then the Base tab is crated with the thickness of 2mm.
The edges of the closure is added with the flange feature in all the four sides.
Step 11: Flanges for hinges
Flanges were created at the certain angle to make the assembly fo the closure and the box. This flange is then follwed with the Open loop heming operation and the feature is mirrored.
Step 11: Creating hinges with open loop hem
The open loop heming operation is created with the sweep angle of 325deg and bend radius 5mm. Then it is checked for unbend and rebend opeartion.
Step 12: Normal cut out
After unbending the flange then the rectangular profile sketch is drawn. Then Normal cut operation is performed.
Step 13: Hinges in the closure
The same above operation Open hem and Normal cutout is performed for the hinges which is to be created in the closure also.
Step 14: Final Hinge Assembly
Thus the final hinge assembly is done with the above process (flange, open hem, Normal cut out, Unbend and Rebend)
Step 15: Final Box Assembly in Isometric view
Front view:
Side View:
Top view:
Drawing sheet:
Conclusion:
Thus the Box Assembly is completed in the NX Cad Sheet Metal Application Workbench.