Challenge

Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

GGaya Sudan R20 Feb 2022

DESIGN

OBJECTIVE :

To design a Box Assembly using NX CAD tool.

INTRODUCTION :

Sheet metal is a metal formed by an industrial process into thin, flat pieces. sheet metal is on of the fundamental forms used in metal working and it can be cut and bent into a varierty of shapes. countless everyday objects are fabricated from sheet metal.
A sheet metal box assembly was selected for this project to understand the basics of sheet metal application in siemens NX. The box assembly has some important features like flange, dimple, normal cutouts etc. The box is a basic component which can be used as a CPU cover and other electronic components.

DESIGN METHODOLOGY :

DESCRIPTION :

BOX :

STEP 1 : Start NX CAD. Then set the global parameters as per requirements. Menu-->Preferences-->Sheet metal

STEP 2 : Design a base sketch for box and create a base with Tab option. A tab is used to form a base of the model along the planar face with respective thickness. A sketch with single or multiple closed profile can be formed as a base.

STEP 3 : Use Flange option to form the side bodies of the box. The flange feature creates a flat bended profile at an angle to a planar face.

STEP 4 : Then apply closed corner at the adjacent bends for both sides. The corner feature helps to close a corner where two adjacent bends meets.

STEP 5 : After closing the corner, use Hem Flange to create a ‘U’ profile which self-locks the sheet metal after bending. Hem Flange is used to modify the model by folding the edge of the sheet metal flange over onto itself.

STEP 6 : Now mirror the body to form a replicate of the existing body. Mirror feature mirrors the selected face or body across the selected planes or line.

STEP 7 : Now unite the two bodies (Existing body & Mirrored Body). Unite feature used to unite the selected bodies into a single body.

STEP 8 : Now create a sketch and make a dimple on the front & bottom side of the box and mirror it on back side. Dimple is one of the punching process which is used to raise an area of the model perpendicular to the face where contour sketch is drawn.

STEP 9 : After that, create a sketch for creating a beads. Then select bead option with circular cross section and give proper radius and depth and mirror it to make it four beads at the bottom. Beads is used to lift a material along the contour of the sketch.

STEP 10 : Then use hem flange at top edges to create a ‘U’ shaped corners which neglect the sharp edges and create a smooth & safer edge. Hem Flange is used to modify the model by folding the edge of the sheet metal flange over onto itself.

LID:

STEP 11 : Create a datum plane at resp distance. Then design a base sketch for lid and create a base with Tab option.

STEP 12 : Use Flange to create the bends in the lid which seats on the sides of the box.

HINGE :

STEP 13 : Using a right side face of the box as a reference, create a base for the hinge using a Tab option.

STEP 14 : Use break corner option on hinge base to avoid the sharp edge.

STEP 15 : Then using the flange and hem flange, create a circular profile with the dia where the hinge rod get inserted to lock.

STEP 16 : After creating flange, unbend the profile with the use of Unbend option. This feature is simply used to flatten the bended profile.

STEP 17 : Create a sketch that has to be cutout from the profile with Normal Cutout. A cutout profile is used to remove the material from the base.

STEP 18 : Then rebend the model & mirror it to get the bended view of the model with the replication of the existing body. Rebend is used to restore the model to its bended state.

STEP 19 : Repeat the same steps for mating hinge by taking top side of the lid as a reference for creating a tab.

IMAGES :

FRONT VIEW :