Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

TITLE : Sheet metal box assembly

Obtective : To design a Box assembly using NX cad sheet metal workbench.

Intoduction :

sheet metal is a metal forming process used in industries to process thin,flat picess in to products.

Here i have created a sheet metal Box assembly of various thickend parts .

Box assembly contains 3 parts

1. BOX(base part)
2. BOX LID
3. HINGES

To design this parts in nx sheet metal workbench. I have used this methodology described below.

Design Methodology :

Description :

Step by step of creating cad model of Box assembly descriped here.

Tools used to design Cad model is here

Box assembly has 3 parts

1. Box
2. Box lid
3. Hinges

1) Box

1.Sketch

cerate a 2d sketch in xy plane of 200mm x 150mm rectangle

2.Tab

base of box by selecting the 2d curve from sketch create a tab of 1mm thickness

3.Side Flanges

side wall are created by selecting the edges of tab using flange feature

4. closed corner

this feature is used to porvide smooth corners by removing intersections and fineshed edges of flanges

5. hem flange

in hem flange use close loop feature to close the gap between the ends of the side flanges

6. Mirror body

using mirror body feature complet the box body.

7.Unite

after mirroring the the body use unite feature to unite 2 saperate bodies

8. Dimple

emboss is created on the body of box to give additional strength to the box using dimple feature.

9.Mirror feature

To create emboss on the other side of the box by using mirror feature tool by selecting the emboss created before on the other side of box

10. Dimple

Again using dimple feature created a dimple at the bottom of the box by sketching a rectangle on bottom face of box

11. bead

A bead is created at the bottom of box by creating a circle

12. mirror feature

Again using mirror feature 4 beads are created at the bottom of the box

13. hem flange

By selecting the top ends of box hem flange is created to give clean and smooth edges

2) Box lid

1) Datum plane

a datum plane created w.r.t xy plane at an distance of 203mm

2) Sketch

by selecting new datum plane created at the top of box create a sketch using top of the box edge references for box lid

3) Tab

using tab feature box lid is created

4) flange

flange is added at the edge of lid to complete the box lid

3) Hinges

here hinges are in 2 parts

1. box part

2. box lid part

1) tab

selecting the side face of box a tab is created on side wall of the box

2) Break corner

corner is blended with 10mm radius

3) 2 additional flanges create on the base tab

4) Hem flange

open loop hem flange is created

5) unbend,normal cut,rebend

flattened hinge portion to perform normal cut and rebend to get hinge in its original position

6) mirror body

using mirror body feature hinge part is completed on box

2) Box lid part

1) Tab

a rectangular tab is created on the to edge of the lid using tab tool of 2mm thickness

2) break corner

corners are blended with 10mm radius

3) Flange

a flange is added at the tab end using flange tool

4) Hem flamge

open loop hem flange is created

5) unbend,normal cut,rebend

same process is followed while creating box part hinge to create lid part hinges

top view

front view

isometric view

side view

bottom view

Conclusion :

by doing this project i have learned some new NX cad sheet metal tools like hem flamge, closed corners.