Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly

Objective

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

Introduction

Sheet Metal Fabrication is the process of forming parts from a metal sheet by punching, cutting, stamping, and bending. Parts are formed from a single sheet of metal, designs must maintain a uniform thickness. Parts used for low volume prototypes, and high volume production runs are most cost-effective due to large initial setup and material costs. Sheet metal parts are known for their durability, which makes them great for end use applications (e.g. chassis). They are used in different machineries, automobiles, and aerospace sectors.

Sheet metal components can be created in NX under sheet metal module. From a sketch it can create both simple and complex components using different features such as Tab, Bend, Flange, Hem, Jog, Bead, Dimple, Cutout, Louver, Punch, Unbend etc. Then it is converted in flat pattern for manufacturing purpose. In this project, A Box Assembly is created in NX using few of the previously mentioned operations.

Design methodology

Description

• Tab- Creates a base feature by extruding a sketch along a vectior by thickness value or add material to a planer face.
  
• Flange- Adds a flat flange at an angle to a planer face and adds a bend between the two.
  
• Closed Corner- Closes a corner where two adjacent flanges meet by extending the bends and flanges.
  
• Hem Flange- Modifies the model by folding the edge of sheet metal flange over onto itself for the purpose of safe handling or to increase edge stiffnes. Closed and open loop hem types are used in this assembly.
  
  
• Mirror Body- Copies a body and mirrors it across a plane
  
• Unite- Combines the volume of two more solid bodies into a single body
  
• Dimple- Lifts an area of the model inside a sketch that simulates a stamping tool.
  
• Bead- Lifts material along the contour of a sketch that simulates a stamping tool
  
• Mirror feature- Copies a feature and mirrors it across a plane
• Unbend- Flattens a bend and the material adjacent to the bend.
  
• Rebend- Restores an unbend feature to its previous bent state, along with any features added after the unbend feature.
  
• Normal Cutout-Cuts material by projecting a sketch onto the model and then cutting perpendicular to the faces intersected by the projection.
  
• Assembly Constraints- Positions components in relation to other components in the assembly by specifying constraint relationships.
  

Output

Front	Side
Top	Isometric

Conclusion

A Sheet metal Box Assembly is created as per the given design in NX by using features such as Tab, Flange, Dimple, Bead, Normal cutout, Unbend, Rebend, Mirror etc to create components seperately. And later assembled together by giving geometrical constraints.