Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly
Aim - Design of sheet metal box assemby & detail explanation about the tools.
OBJECTIVE - The main objective of this challange is to design tge box assembly it us like a storage box like the inverters & electronic instruments etc.which the upper panel can be open & closed because it is connected with the hinge like structure. The designed model is shown below as images.
INTRODUCTION-
Sheet Metal is a type of material that is flattened into thin sheets. Sheet metal is made by taking a large cast in and rolling it into a long ribbon of the thickness it wants. This flat metal is rolled into a coil and sent directly or cut the metal into sheets before being sent to a machine shop.
The most common sheet meta; used in automotive to make bodies is mild steel.it ia reasonabily cheap & easy to press in to desired shape. the next is aluminium it is lighter in weight but much harder to bend in to tight shapes without cracking.it is also hard to weld in mass production.
DESIGN METHADOLOGY
TOOLS USED TO DESIGN THE SHEET METAL BOX ASSEMBLY
TAB- this tab is used to generate the base sheet to start the required body to be modled.by sketching the required shape as per our design rectangle is drawn on the xy plane of 200mmx direction &150mm in y direction.
FLANGES-this is used to make the walls like structure by taking the support of the edges at desired length by adding the fillets of 10 mm.
CLOSED CORNER- to make the open sheet at corners where the two adjacent faces are joining to geather me make them join them by fill the gap space by selecting the adjacent faces as target.
FLANGE- select the xz direction flange edges & change the dimension of length & bend radius to 0mm & create the round flange at both side edges as required. & create the another flange of length 6.5mm& 0.5mm radius.
HEM- select the 70mm flange created at the xz direction change the dimension of the bend radius of0.5mm & flange length of 5mmcreate the hem at both required sides.
MIRROR BOBY-select the complete designed body & select the yz plane & make the body to be both sides as to be complete closed body.
UNITE- this feature is used to make the various bodies into a single body.select the designed body & mirrored body & click ok so the now it is a single body.
DIMPEL- create the sketch on the face where the dimple is to be done & given the depth of 2mm. & mirror the dimple & sketch on the opposite side by selecting the plane.
BRAKE CORNERS-Breake corners feature is used to make the sharp edges rounded by cutting the unwanted materail by default. bend is nothing but (FILLET)
UNBEND- Unbend feature is used to make the shhet metal shape part in to flat to analyse the part is perfectly aligned with the features & a;lso to add the required features lke holes,dimples,beads etc,
BEADS- create the sketch on the bottom phase of12mm dia & make the bead of 2mm depth.& mirror it as all the 4 sides.
HEM-select the upper corners egdes as create the close hem of 2mm lenth.
CREATE THE NEW DATUM PLANE OF DISTANCE 203MM Y DIRECTION- create the sketch of outer edges so that the body to be closed completly this sketch is to make the bottom box covering gate by the tab feature.
FLANGES- select the required egdes & give the radius of 0.5mm
HINGES LIKE STRUCTURE THIS IS USED TO MAKE THE TOP BODY TO ACT AS THE DOOR TO THAT BOX. TO CREATE THAT DRAW THE SKETCHS ON THE DESIRED FACES & MAKE THE FLANGES & HEM BY GIVING THE RADIUS THAN CUT THE UNWANTED SHEET METAL BY MAKING THE SKETCH ON THAT FACES.
DRAFTING- This feature is used to make th drawing of the designed sheet metal part into a drawing sheeet representing the pre model of how the model to be like 2d sketch on a paper model.it consists of dimensions sctional views like isometric,front,side,etc.
ISOMETRIC VIEW OF BOX ASSEMBLY.
RIGHT SIDE VIEW
FRONT VIEW
BOTTOM VIEW
UNBEND VIEW OF COMPLETE BOX ASSEMBLY
DRAWING SHEET (drafting)-
CONCLUSION DESIGN OF THE SHEET METAL BOX ASSEMBLY & DETAILED EXPLANATION OF THE TOOLS USED TO DESIGN IS DONE.& RELATED IMAGES & FILES ARE ATTACHED IN THE ANSWER BOX.