Design of Box Assembly

ADVANCED SHEET METAL DESIGN USING NX CAD IN BOX ASSEMBLY

OBJECTIVE:

Main objective of the project is to create a Box assembly Sheetmetal design in NX cad Sheetmetal workbench, and learn about the some Sheetmetal feature to create a box assembly.

SOFTWARE USED: NX 12.0

• To design the Sheetmetal Box assembly in NX by using some basic feature.
• NX Software is a flexible and powerful integrated solution that helps you deliver the products faster and efficiently.
• NX Cad software is widely used automotive, aerospace, thermal power station. Because of it is containing modelling, drafting and manufacturing platform.

INTRODUCTION:

1. Let’s get started how NX Cad software performing in Sheetmetal application. Sheetmetal fabrication is the process of forming metal sheets to the desired shape of the components using different types of manufacturing application.
2. Sheetmetal fabrication is the process of forming parts from a metal sheet by punching, cutting, stamping, and bending.
3. 3D files are converted to machine codes to control the machine movement to create the desired shape of the component.
4. There are different types of material are used in this fabrication process, such as ALUMINIUM, BRASS, COPPER, STEEL, TIN.
5. Sheet metal parts are known for their durability, which makes them great for durability, which makes them great for end use applications.
6. Parts are used for low volume prototypes high volume production runs are most cost-effective due to large initial setup and material costs
7. Because parts are formed from a single sheet of metal, designs must maintain a uniform thickness.
8. Be sure to follow the design requirements and tolerances to ensure parts fall closer to design intent and cutting sheets of metal.

DESIGN METHOLOGY: (BOX ASSEMBLY)

DESCRIPTION:

The sheet metal Box assembly creating to help of above mentioned featured. While designing the Box assembly model in Sheetmetal workbench there are multiple features are used to Create them.

SKETCH:

Sketch is used for creating the model by specify shape and dimensions.

SKETCH EXPLANATION:

• In this model we want to create a tab, so that why we are creating the sketch option.
• Rectangle shape is using in this tab feature.

TAB:

Tab is the first feature used for creating Sheetmetal designing process. All other features of the Sheetmetal components are based on the base feature or tab. The tab feature is always parent feature of the other Sheetmetal feature in the NX cad platform.

TAB FEATURE EXPLANTION:

• We select the XY plane for Creating to the sketch.
• Then create Rectangle shape in dimension of (200mm,150mm) sketch in XY plane.
• After that select the tab feature and add thickness to 1mm.

FLANGE:

This tool is used to create the bend structure of the edges of the Sheetmetal.

FLANGE FEATURE EXPLANATION:

• It is widely used feature in Sheetmetal option.
• Click which edges you want bend. And This model you want to create four edges of flange operation.
• So, Add the dimension edges of flange feature

Flange 1& 2:

Width – Full,

Length – 200mm,

Angel – 90,

Length references – Inside,

Inset – Material inside,

Bend radius – 10mm.

Flange 3&4:

Width – Full,

Length – 70mm,

Angle – 90,

Length reference – Inside,

Inset – Material inside,

Bend radius – 10mm.

CLOSED CORNER:

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

CLOSED CORNER FEATURE EXPLANATION:

• In this box assembly Sheetmetal model in corner feature option is used to close the corner by which type of closes you want it is create them.
• Click close & relief option and treatment (Closed), Overlap (Closed).

FLANGE:

This tool is used to create the bend structure of the edges of the Sheetmetal.

FLANGE FEATURE EXPLANATION:

• Now we are using the flange feature for create to hem flange that why we add the flange feature.
• Click which edges you want bend. And This time you want to create four edges of flange operation.
• So, Add the dimension edges of flange feature

Flange 5:

Width – Full,

Length – 0.02mm,

Angel – 90,

Length references – Web,

Inset – Material inside,

Bend radius – 0mm.

Flange 6:

Width – Full,

Length – 6.5mm,

Angle – 90,

Length reference – Inside,

Inset – Bend outside,

Bend radius – 0.5mm.

Flange 7:

Width – Full,

Length – 0.01mm,

Angle – 90,

Length reference – Outside,

Inset – Material inside,

Bend radius – 0mm.

Flange 8:

Width – Full,

Length – 6.5mm,

Angle – 90,

Length reference – Web,

Inset – Bend outside,

Bend radius – 0.4mm.

HEM FLANGE:

Modifies the model by folding the edges of the Sheetmetal flange over onto itself for the purpose of safe handling or the purpose of increase the edge stiffness.

HEM FLANGE FEATURE EXPLANATION:

• In this Sheetmetal design hem flange is use for safe handling. So, click the which edges you want to create hem flange.

Hem Flange 1:

Option – Open,

Inset – Bend outside,

Bend radius – 0.6mm,

Flange length – 4mm.

Hem Flange 2:

Option – Open,

Inset – Material outside,

Bend radius – 0.9mm,

Flange length – 4mm.

MIRROR BODY:

Mirror body option is used to copies a body and mirrors it across a plane.

MIRROR BODY FEATURE EXPLANATION:

• In this Sheetmetal design, mirror body option used for mirror & copy the box assembly half of the body to parallel plane.
• Click parent part and select respective plane (YZ) for using mirror body option.

UNITE:

Unite option is used for combine the separate two bodies.

UNITE FEATURE EXPLANATION:

• In this model we just combine two bodies to single body.

UNBEND:

Unbend feature is used to unbend the bended region in NX Sheetmetal workbench.

UNBEND FEATURE EXPLANATION:

• Unbend feature is to create the flattens the Casing Sheetmetal.
• If the Unbend feature we are using it will Flattens the Sheetmetal and adjacent to the bend.

DIMPLE:

In this feature is used to lift the Sheetmetal from inside a sketch that stimulates the stamping tool.

DIMPLE FEATURE EXPLANATION:

• Dimple feature is just Lift the material inside the sketch.
• Then create the sketch and specify the Depth(2mm), side angle(0), Depth reference(inside), Side walls(material outside), Punch and corner radius(1mm), Minimum tool clearance(5mm).

MIRROR:

Mirror feature is used to mirror the feature along axis or plane.

MIRROR FEATURE EXPLANATION:

• In this feature we are mirror the Sketch feature help of plane.
• We first select the Sketch feature and mirror the feature with help of XZ plane.
• After mirroring the sketch feature then apply dimple feature for Previous sketch and rectangle sketch.

REBEND:

Rebend option is used to unbend feature to its previous bent state, along with any feature added after the unbend feature.

REBEND FEATURE EXPLANATION:

• It is just Restores an unbend features to its previous bend state.
• And it is including to the any feature added to after the unbend feature.

BEAD & MIRROR FEATURE:

Bead feature is used to lift material along a contour of the sketch that stimulates the stamping tool.

BEAD FEATURE EXPLANATION:

• Bead feature is Lift the material along the contour of the sketch.
• Then specify the Cross section (Circular), Depth and Radius(2mm), End condition (Formed shape), Minimum tool clearance(5mm).

And also add some hem flange feature for top edges of the box assembly Sheetmetal design.

And also add some hem flange feature for top edges of the box assembly Sheetmetal design.

DATUM PLANE:

Datum plane used for creating a new plane for some specific distance to create feature.

DATUM PLANE FEATURE EXPLANATION:

• If you create the sketch for some specific distance in new plane.
• To create a new sketch and add dimension, for tab feature.

Add some flange feature for top of the tab feature for Container cab.

And create tab feature in side wall of the container.

BREAK CORNER:

Round or chamfers a sharp corner of the tab or flange feature.

BREAK CORNER FEATURE EXPLNTION:

• Break corner option just create the round shapes in edges.
• Click the break corner feature and which edges you want to modify the round shape.

Add some flange and hem flange feature for creating the hinge feature.

Unbend the Sheetmetal

NORMAL CUTOUT:

Using the normal cutout option, it is used to remove the material from projecting a sketch onto the intersecting model.

NORMAL CUTOUT FEATURE EXPLANATION:

• In normal cutout option in Sheetmetal platform, first select to top of tab surface in sidewall.
• Then Create Rectangle shape and add dimension.
• After creating a sketch click ok to normal cutout option and specify the depth value at 5mm.

REBEND and Mirror the hinge design.

So, create the tab, flange and break corner feature.

Add the hem flange, normal cutout and unbend.

After all you creation the Sheetmetal design and rebended.

BOX ASSEMBLY VIEWS:

1.FRONT VIEW:

2.TOP VIEW:

3.RIGHT SIDE VIEW:

4.ISOMETRIC VIEW:

DRAFTING:

We can create the 2D Drawing sheet from Casing model in NX Cad software.

DRAWING SHEET:

• Drawing sheet is used to represent the Sheetmetal model in 2D view(A4) help of NX cad platform.
• It is show the which feature you are using in this Box assembly Sheetmetal

DETAILED VIEW:

• Detailed view is nothing but it is just Show the recommended view from the model in single sheet(A4).
• You will see the detail view in A4 size sheet top, right, front, isometric views in detailed view.

CONCLUSION:

• In this project creating the Box assembly Sheetmetal design using NX Cad Siemens 12.0 version platform.
• So, Sheetmetal basic feature and tools are learning in this project.
• Designing the Sheetmetal in NX cad software, it is user friendly interface for working in this project.