Box Design

Objective-

To design a Box with lid with Open Hem Joint using NX Siemens sheet metal workbench.

Introduction-

To design a Box with Lid with Open Hem Joint using Nx Siemens sheet metal workbench which can be used for storing small equipment and materials. The Box is designed with press technology that provides strength even if sheet metal of 1mm thickness. The Box can be Prepared by one single sheet bending.

Design methodology-

The tutorial pdf is analysed thoroughly. The topology of the model is checked and all the features and specifics are noted.

1. Sketch ( Base)
2. Tab ( solid sheet extrusion)
3. Flange (Box Wall)
4. Flange (Box Wall)
5. Flange (Box Wall)
6. Closed Corners ( Box Corner)
7. Closed Corners ( Box Corner)
8. Flange (Box Side Joint)
9. Flange (Box Side Joint)
10. Mirror Feature
11. Dimple
12. Mirror Feature
13. Dimple
14. Unbend
15. Bend
16. Sketch (Bead)
17. Beads
18. Mirror Bead
19. Mirror Both Bead
20. Closed Hem Joint ( Box Upper Edge)
21. Design Of Lid Sketch
22. Tab
23. Flange (Lid flange)
24. Sketch (Box Side Joint Hem)
25. Tab
26. Flange
27. Hem Open type
28. Unbend
29. Normal Cutout
30. Rebend
31. Mirror Feature
32. Repeat the step 24 to 31 with parent plane as the top side of Lid Tab.

Description-

1. Sketch ( Base) – The casing base sketch is produced using the sketch tools like rectangle. All dimensipons are provided to get a fully defined sketch. The sketch parameter are so defined that future modification in sketch can update the complete model.
2. Tab (solid sheet extrusion) – It is feature used to produce the sheet metal. We can use the command to create a base feature or a tab by extruding a sketch along a vector by a specified thickness value. We can also use this command to create a secondary tab if the work part includes existing sheet metal features.
3. Cutout – We can use the Cutout command to create openings in sheet metal tabs. The cutout feature only require a position and a sketch. Unlike extrude cut this feature still keeps the sheet metal parameters that can be accessed during the Bend and Rebend commands.
4. Bend – We can use the Bend command to modify the model by bending material on one side of a sketch line or adding a bend between the two sides. We can create a bend on a planar face of a sheet metal body these particular bends can be flatten for manufacturing and can be rebend again as it aslo retain its bend parameters. If the part has multiple sheet metal bodies, we can specify the target face on which you want to create the bend. We can create a bend across existing Bead, Dimple, or Drawn Cutout features. When we create such bends, the bend line must pass completely through the deform features.
5. Flanges- We can use the Flange command to create a single flange instance or multiple instances by selecting a single or multiple base edges. A flange consists of a bend region and a web. We can add a web at an angle to a planar face and add a bend between the two.
6. Breaking Corners- It is a feature used to provide a fillet or chamfer at the end corners for stress relief. The Break Corner option flattens out the corner to be cut. The amount by which it is flattened depends on the value we input. This distance represents the distance from the corner of the modelled workpiece to the actual cut.
7. Unbend – We use the Unbend command to unbend a portion of the part to construct cutout features, hole features, or deform features across a bend. You can later reform the bend to represent the true formed state of the model. We can flatten non-uniform thickness bends that are created when we apply blends or chamfers, tapered holes in the bend region. After the unbend operation, NX retains the features that we apply or create in the bend region.
8. Dimple- We use the Dimple command to lift an area of the model inside a sketch that simulates a stamping tool. We can create an indentation in a sheet metal part using a sketched section as the dimple outline. Like the Drawn Cutout command, the Dimple command makes an indentation in the sheet metal part, using a sketched section as its outline. The difference between the two is that a Dimple feature has a bottom face whereas a Drawn Cutout feature does not.
9. Beads - We use the Bead command to lift material along the contour of a sketch that simulates a stamping tool. The main purpose of Beads is to stiffen sheet metal parts. We can create beads on bends in the folded or flattened state. A bead created on a bend in the folded state cannot traverse the bend. We can also create beads on deform features in sheet metal parts.
10. Rebend - We use the Rebend command to reverse an unbend operation so that the feature that was unbent can returns to its previous bent state. Any features added after the unbend operation are properly repositioned during the rebend operation.We can optionally specify a face or an edge that remains stationary during the rebend operation, and control the positioning of the resultant body. If we do not specify a stationary face or edge, the selected unbend feature reverts to its original position before the unbend operation.

11. Hem Flange – we use the Hem Flange command to modify an edge of a sheet metal part by folding it onto itself for the purpose of safe handling or to increase edge stiffness. The hem flange is always created as a secondary feature on a base part. We are specifically using a Open loop type hem flange for our joint of the box.

Views-

Isometric View

Front View

Side View

Top View

Unbend Flatten View

Rendered View

Conclusion-

Thus the Complete Box with lid is designed and constructed.