Challenge

Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

GGowtham V3 Sept 2022

Write a detailed report on Sheet Metal Component with a good explanation of Sheet Metal modeling tools applied throughout the modeling. Also, attach the Final model Images (Min. 4 images) of the Sheet Metal Box Assembly.

TITLE OF THE PROJECT: Advanced sheet metal design using Siemens NX cad - Box Assembly.

OBJECTIVE:

To design a box assembly and create a draft of it using Siemens NX Sheet metal application

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 sheets are made from different kinds of metals such as aluminum, brass, copper, steel, tin, nickel, and titanium. The sheet’s thickness depends on the material needed for a project. Thicknesses can vary from 0.15 -6.00 mm significantly; extremely thin sheets are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate steel or “structural steel.”

Cutting: – Sheet steel is cut by a shearing method that was used a lot before being replaced by faster and more precise methods. A punch press is used to punch and die sets to cut the metal. It is effective for cutting simple parts which are then cut with a laser or a water jet.

It operates at hundreds of strokes per minute; a punch press makes suitable parts quickly. Punching is used to make holes or other cutouts in parts. The creation of a complex flat pattern with size-limited stamped features is done through laser cutting and combining punch.

Bending: – Some metals can be bent along a straight axis using a variety of presses. Bends shape can be varied from gentle curves to vertical axis of steel used to sharpen the corners at an angle above, below, or right at 90 degrees. Press brakes are used to create these sharp bends. Open or closed single-axis curves can be produced by the rolling and forming method in a bending operation.

Hemming: – It is the rolling edge of a metal shape that provides a smoother, stronger edge that are open, leaving an air space with a bend or closing the folded metal that is pressed tightly against itself.

Barrel hem is the curling that produces a rounded edge to a piece of metal. It is used to eliminate the sharp edges or serve an operational function in the case of a door hinge that holds the pin around the hinge rotates.

DESIGN METHODOLOGY

The design methodology is explained by the flow chart as follows;

creating sketch and tab normal to XY axis

creating flange normal to xz axis length of 70 on both I sides

using a command called closed corner on both sides

flange with bend radius is created on both is in a different direction

extended the flange length to given MM and heming is down to join the sheet metal

mirror option is used to create a surface on another side

a dimple or used on both surfaces to increase the strength of the material

a dimple or used on bottom surfaces to increase the strength of the material

unbend is performed for this sheet metal to check whether the design will be manufactural or not

the bead is used in this design of the bottom four corner

the hem is performed at the top edge

the sketch is created on the top most part for designing the lid

the tab is created for the led

hinge is created for led and the closed surface

hinge is aligned together has shown

Description:

Features Used:

Sketch: It is a basic command to draw 2d models

Tab: This command is used to create a base feature by extruding a sketch along a vector by a thickness value or by adding material to existing faces and bend regions of the sheet metal parts.

Flange: This command is used to add a flat flange at an angle to the planar face and add a bend between the two. A flange consists of a bend region and a web.

Closed Corner: This command is used to modify two flanges in one operation and to close the corner where the two flanges meet.

Hem Flange: This command is used to modify an edge of a sheetmetal part by folding it onto itself for the purpose of safe handling or to increase edge stiffness.

Mirror Body: This command is used to mirror the part w.r.t the required axis.

Unite: This command is used to combine the two parts into one part.

Dimple: This command is used to lift an area of the model inside the sketch that stimulates a stamping tool.

Mirror Feature: This command is used to mirror the required sketch to other side with reference to the axis.

Unbend: This command is used to fatten the 3D model by selecting one stationary face.

Rebend: This command is used to rebend the flattened sheet material.

Bead: This command is used to lift material along the contour of a sketch that stimulates a stamping tool. Beads can also be created to stiffen sheet material.

Datum Plane: This feature is used to project the plane at a certain distance by giving the distance.

Normal Cutout: This command is used to remove the unwanted material w.r.t to the sketch.

Break Corner: This command is used to round or chamfer sharp corners of a tab or flange.

PART NAGVITAR