Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

SHEET METAL BOX ASSEMBLY

OBJECTIVE:- Sheet metal box assembly using Sheet Metal features in NX CAD.

INTRODUCTION:- NX Sheet Metal provides a set of tools within the NX design environment that allows for simple and fast design of sheet metal parts, dependent on their material and manufacturing process, the most common of which is straight brake sheet metal forming.

DESIGN METHODOLOGY:- There are some step ot stages follows as shown as....

• Create a new sheet metal model as .prt file.
• Changing the parameters preferences accordingly.
• Create a sketch on certain plane.
• Use Tab tool for creating sheet metal of certain thickness.
• Add a flat flange at an angle to a planar face by using Flange command.
• Modify corner use Closed Corner tool, Closes a corner where two adjacent flanges meet by extanding the bends and flanges.
• Use Hem Flange tool, Modify the model by folding the edge flange over onto itself for the purpose of safe handling or to increase edge stiffness.
• Copy a metal part and mirror it across the plane by using Mirror Body tool.
• Combines the volume of two or more bodies into a single body by using Unite tool.
• Lift an area of the model inside the sketch that simulates the stamping tool by using Dimple command.
• Copy a mirror feature and mirror it across the plane by using Mirror Feature tool.
• Flatten the bend and the material adjacent to the bend face by using Unbend command.
• Lift material along the contour of the sketch that simulates the stamping tool by using Bead command.
• Create a datum plane used to construct the other feature by using Datum Plane tool.
• Use Normal cutout Tool for making a rectanglar hole in the sheet accoding to the sketch.
• Modify the model by bending material on one side of a sketch line by using Bend command.
• Round or chamfer a sharp corner of a tab and flange face by using Break Corner command.
• Rebend command using to restores an unbend features to its previous bent state, along with any features addad after the unbend features.
• Drafting

Descrption:-

1. Sketch:Creat a sketch in XY plane and draw a rectangle centred at the origin with an certain dimesions.
2. Adding a Solid Sheet:Exit the sketch mode, use the tab button for creating first rectanglar metal sheet of 1mm.
3. Flange: Click the flange button, use a length of certain value and apply the flanges normal to plane on the edge of the metal sheet as correponding symmetrical egde.
4. Adding Another Flange: Click the flange button, use a length of certain value and apply the flanges normal to flanges plane on the edge of the metal sheet as correponding symmetrical egde.
5. Closed Corner: Click the closed corner button, select the type "Close and Relief" and then Select the adjacent bend face where required.
6. Flange With bend radius 0 and length 0.02mm: Click the flange button, use a length of certain value and apply the flanges normal to plane on the edge of the metal sheet as correponding symmetrical egde.
7. Flange With bend radius 0.5 and length 6.0mm: Click the flange button, use a length of certain value and apply the flanges normal to plane on the edge of the metal sheet as correponding symmetrical egde.
8. Repeat the step 6 and 7 respectively on other flanges creation.
9. Creating Open Hem Flanges:- Click on the hem flanges button for open hem flanges accordingly safe handling or the edge stiffness.
10. Adjusting the Hem Flanges length: adjust the length reference and insert type of previous flanges.
11. Mirror Body: Click on the mirror body button for complete the box body symmetrically.
12. Unite: Click on the Unite button for convert into a single body.
13. Adding Dimple: Firstly sketch on that where dimple features required, draw a sketch on plane with certain sketch tooling and exit sketch mode and then click on the dimple button for dimple properties with validate parameter.
14. Mirror Feature: Click on the Mirror Feature button for creation of the same previous feature on other face by using existing mirror plane.
15. Again Adding Dimple on Bottom Face: Firstly sketch on that where dimple features required, draw a sketch on plane with certain sketch tooling and exit sketch mode and then click on the dimple button for dimple properties with validate parameter.
16. Unbending the Face: click the unbend button, select as stationary face of the metal sheet for bending face one of its adjacent faces.
17. Rebend: Click on the rebend button select the bend faces respectively to restores an unbend features to its previous bent state, along with any features addad after the unbend features.
18. Adding bead: Click on the bead button, select the curve using sketch feature and select the bead propeerties along with validate parameter.
19. Again Using Mirror Feature: Click on the Mirror Feature button for creation of the same previous feature on other face by using existing mirror plane.
20. Adding Closed Hem Flanges:- Click on the hem flanges button for open hem flanges accordingly safe handling or the edge stiffness.
21. Craeting a Datum plane for lid design.
22. Designing the Lid: sketch on the new plane respectively box design.
23. Adding a Solid Sheet for lid:Exit the sketch mode, use the tap button for creating first rectanglar metal sheet of certain value.
24. Flange on lid sheet: Click the flange button, use a length of certain value and apply the flanges normal to plane on the edge of the metal sheet as correponding symmetrical egde.
25. Adding a Solid Sheet for hook joint between lid and box:Exit the sketch mode, use the tab button for creating first rectanglar metal sheet of certain value.
26. Breaking Corner for previous design: click the break corner button and create the round corner on edges where required.
27. Flange: Click the flange button, use a length of certain value and apply the flanges at an angle 40 degree to plane on the edge of the metal sheet as correponding symmetrical egde.
28. Adding open loop Hem flange: Click on the hem flange button of open loop type select the validate parameter.
29. Unbending the Face: click the unbend button, select as stationary face of the metal sheet for bending face one of its adjacent faces.
30. Normal Cutout: In that sketch, draw a rectangle symmetrical with respect to the x-axis which is coincide with the left edge of the rectangular sheet of certain dimesions for making rectangular hole.
31. Re-Bending: Again draw a sketch in the plane consisting in two symmetrical horizontal lines w.r.t. the y-axis from the upper egde of the sheet. and Exit the sketch mode and click the bend button.
32. Mirror Body: Click on the mirror body button for complete the box body symmetrically.
33. Again Adding a Solid Sheet for hook joint between lid and box:Exit the sketch mode, use the tab button for creating first rectanglar metal sheet of certain value.
34. Breaking Corner for previous process: click the break corner button and create the round corner on edges where required.
35. Flange: Click the flange button, use a length of certain value and apply the flanges at an angle 39 degree to plane on the edge of the metal sheet as correponding symmetrical egde.
36. Adding open loop Hem flange: Click on the hem flange button of open loop type select the validate parameter, adjust the parameter with respect to last open loop hem flanges.
37. Normal cutout after unbend: In that sketch, draw a rectangle symmetrical with respect to the y-axis which is coincide with the left edge of the rectangular sheet of certain dimesions for making rectangular hole.
38. Rebending

SCREENSHOT OF VIEWS of MODEL

• Front View

• Left View

• Right View

• Top View

• Isometric View

CONCLUSION:-NX sheet metal design software incorporates material and process information in sheet metalspecific modeling features: bends, flanges, tabs, cutouts, beads, dimples, louvers, corner and edge treatments, patterns and other formable features. You can also quickly convert solid models to sheet metal components, and create sheet metal parts that enclose other components.