Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

TITLE: Box Assembly using NX Cad "SheetMetal".

OBJECTIVE: Write a detailed report on Sheet Metal components with a good explanation of Sheet Metal modelling tools applied throughout the modelling. Also, attach the 'Final model Images'.

INTRODUCTION: Siemens NX Cad is designing software for advanced and complicated product design with ease. Straight and simple tools are available for drafting 2D and 3D models. Where different designing software needs different parameters and constraints to set up but here we are really free to design as a real-life product with advanced methodology. One of the tools of this software gives the knowledge in Sheetmetal operation from basics to advanced format. From designing a simple tab to contour flange, with various modelling features like three bend corner, dimple, flat pattern, etc.

In this project, we will look and play with some amazing tools of 'SheetMetal' like Flange, Hem Flange, Break Corner, etc. with varieties of techniques to implement them.

DESIGN METHODOLOGY:

DESCRIPTION: Brief description about tools and techniques used to create 'Box Assembly':-

• The base of the box is designed with appropriate dimensions.
• Next, all of the four sides are created with the help of 'Flanges'.
• The small side sheets are attached with help of 'Hem Flange - Open'.
• Above 3 steps create half body only. Full body is created with help of the 'Mirror' tool.
• To make them a single unit 'Unite' command is used.
• On both long sides of the box, 'Dimple' is created with the appropriate sketch as required. And is mirrored to the opposite side of the box too.
• At the bottom side of the box, 'Dimple' & 'Bead' is created with desired parameters.
• 'Unbend' & 'Rebend' is done to check the correctness of the designed part.
• To avoid sharpness of the created box 'Closed - Hem Flange' is created on three sides of the box.
• To create a 'Lid' we defined a CSYS for that concerning the Datum CSYS and created a sketch with the required parameters of 'Tab'.
• And 'Web' flange is created on all those three sides of the box where 'Hem flange' is created on the main "Box Assembly".
• According to project guidelines the last thing is to create "Hinges" which is done in the following manner {Tab is created, corners are curved by 'Break corner', two flanges are created followed by 'Hem flange', unbending, 'Normal cutout' for meshing two hinges and at last rebending.

Additionally, I have created two more features in a project for making it more real-world basis and these are:-

1. Connecting rod for the "Hinges".
2. The flange & curved corner at the opening side of 'Lid' to avoid sharp edges.

Explanation of Tools used for creating "Box Assembly":-

• TAB: A flat sheet metal sheet is obtained here by default parameters(global parameters) and selection of sketch. A 'tab' is a cut-out from the raw material to further process as a final product with different operations on it.
• FLANGE: An extended part of the existed component with various width options to be modified with the desired angle, bend radius, relief, length by selecting any edge of the component. 'Flanges' are the external or internal by-products that serve either to increase strength or for attachment with any other object.
• CLOSED CORNER: By a name, this suggests that a corner is created with zero gap tolerance. The same happens here also, with required gap tolerance we can create a corner of various structures and treatments.
• HEM FLANGE: Hem flange is used to joining two sheets into different geometry like closed, open, loop etc. with appropriate bend radius and various other parameters as desired.
• NORMAL CUTOUT: A sketch is drawn to be cut out from the sheet. In 'Normal cut-out' the cut is always perpendicular to the cutting surface or only tangent propagation cut occurs on the surface.
• UNITE: This operation is having a very simple phenomenon to join two sheet metal bodies together aligned in the same plane.
• MIRROR: Mirror is also an easy and simplistic tool to create a mirrored reflection of an object about a particular plane or axis.
• DIMPLE: 'Dimple' is a part of 'Sheetmetal forming operation' where it is done either to make the product look good or to increase its efficiency. A sketch is required for creating a dimple and then dimple properties & parameters are set.
• BEAD: 'Bead'can be of different cross-sections like circular, v-shaped & u-shaped along with parameters like depth, radius, die radius, end condition and tool clearance.
• UNBEND: Used to make straight or flat the sheet metal from a twisted or bent position to get it in a relaxed position for further modifications. Once the flat face is selected (to be fixed), then bent corners are selected to unbend.
• REBEND: This is a similar operation technique as of 'Unbend'. But here instead of creating a straight or flat product we change the flat product to the original shaped product but in reverse order, as done to 'unbend' the component.
• FLAT PATTERN: 'Flat Pattern' operation is used to create a 2D pattern of the final component with all centrelines, bending curvature lines, flanges line, holes & their centres with detailed specifications.

DETAILED PART NAVIGATOR:

DIFFERENT MODEL VIEWS:

Front view

Top view

Left Side view

Right Side view

Bottom view

Isometric view 1

Isometric view 2

DRAWING SHEET:

CONCLUSION:

In this project, I have learnt other new "Feature's" of the 'Sheet Metal' to design 'Box Assembly'. All these features provide a vast knowledge of drafting and modelling techniques. Different new tools are used here for drafting & modelling. The tools used in this project to create 'Box Assembly' are tab, bend, normal cut-out, mirror, break-corner, bead, dimple, unite, hem flange, closed-corner, unbend, rebend, flat pattern, drawing sheet. After this modelling & drafting of 'Box Assembly' is completed, an A4 drawing sheet is created with as required parameters for designing.