Advanced Sheet Metal Design Using NX Cad Challenge_2_Box Assembly
ADVANCE SHEET METAL DESIGN USING NX CAD
CHALLENGE - 2 , BOX ASSEMBLY
OBJECTIVE - TO DESIGN A SHEET METAL BOX ASSEMBLY WITH DETAILED REPORT ON SHEET METAL COMPONENT WITH MODELLING TOOLS APPLIED THROUGHOUT THE MODELLING.
INTRODUCTION - SHEET METAL IS THE BASIS OF ALL ENGINEERING TODAY.WE CAN SEE IT EVERYWHERE - FROM CARS & MACHINERY TO HOUSE FACADES & FURNITURE.
SHEET METAL IS ANY METAL THAT HAS A THICKNESS IN BETWEEN 0.5 - 6mm.
THE THICKNESS OF SHEET METAL STARTS FROM 0.5mm AND GOES UPTO 6mm,ANYTHING ABOVE THAT IS A METAL PLATE.THE THIN SHEET METAL IS EASY TO FORM,WHILE STILL PROVIDING GREAT STRENGTH,AT A RELATIVELY CHEAP PRICE,IT MAKES A GREAT FIT FOR MOST ENGINEERING PURPOSES.
DIFFERENT WAYS OF PRODUCING SHEET METAL -
THERE ARE TWO WAYS OF PRODUCING SHEET METAL - HOT ROLLING & COLD ROLLING.IN CASE OF CONSTRUCTION STEELS,COLD ROLLING ONLY GOES UPTO 3mm,FROM THERE ON,THE SHEET PLATES ARE HOT ROLLED FOR COST EFFICIENCY PURPOSES.
ALTHOUGH THE HOT ROLLING PROCESS AGAIN STARTS FROM 3mm FOR STAINLESS STEELS,COLD ROLLING COVERS ALL THE SHEETS,i.e. UPTO 6mm.
FOR THE ENGINEERING PURPOSES IT IS IMPORTANT TO DIFFERENTIATE THE TWO.FOR PRECISION APPLICATIONS,COLD ROLLED STEELS ARE PREFERRED AS WE HAVE MORE CONTROL OVER THE FINAL DIMENSIONS.THIS IS BECAUSE IN HOT ROLLED STEELS,AFTER COOLING,THE STEEL SHRINKS SLIGHTLY & THE SHAPE MIGHT CHANGE A LITTLE.
DIFFERENT FORMING PROCESS USED FOR SHEET METAL -
A. SHEET METAL BENDING
BENDING IS A FORMING PROCESS IN WHICH SHEET METAL IS BENT INTO DESIRED SHAPE BY APPLTYING BENDING STRESS.THE SHEET METAL IS BENT SO PLASTIC DEFORMATION IS REACHED.THAT PREVENTS THE METAL FROM REGAINING ITS FORMER SHAPE.
PARTS SUCH AS FLANGES & CORRUGATIONS ARE CREATED BY BENDING.THE MOST COMMON FORM OF BENDING IS V-BENDING.THERE A V- SHAPED DIE AND A PUNCH PRESS TOGETHER TO GIVE THE SHEET THE DESIRED FORM.
EGDE BENDING IS ANOTHER COMMON BENDING METHOD TO BEND FLANGES USING A WIPING DIE & A PUNCH.
B. SHEET METAL CURLING
CURLING IS THE PROCESS OF FORMING A CIRCULAR RING AT THE EDGE OF THE METAL SHEET TO MAKE IT SAFER FOR HANDLING.
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THERE IS A DIFFERENT BETWEEN A CURLED EDGE & A TEAR SHAPED HEM.IN CURLING,THE INITIAL EDGE IS ROLLED INTO THE FORMED CIRCLE WHEREAS,IN THE TEAR SHAPED HEM,THE INITIAL HEM IS STILL EXPOSED.
C. SHEET METAL DECAMBERING
DECAMBERING IS THE PROCESS OF REMOVING CAMBER FROM A SHEET OF METAL.IN A SHEET OF METAL,ESPECIALLY IN STRIP-SHAPED PARTS,A HORIZONTAL BEND IS PRODUCED WHEN IT IS FLATTENED INTO SHEETS.
IN DECAMBERING ,WE REMOVE THIS HORIZONTAL BEND BY FLATTENING THE EDGES TO REMOVE THE CAMBER.THE FORCE IS APPLIED ON A DEFORMED EDGE,& NOT THE FACE,TO PUSH IT INTO A STRAIGHT FORM.IT IS USUALLY CARRIED OUT ON LIMITED SECTION LENGHTS.
D. DEEP DRAWING
DEEP DRAWING IS A SHEET METAL FORMING PROCESS IN WHICH A SHEET'S SHAPE IS CHANGED TO THE DESIRED SHAPE IN MULTIPLE STAGES USING A SERIES OF DIES.ONLY IF THE DEPTH OF THE SHAPE FORMED EXCEEDS THE ORIGINAL DIAMETER OF THE SHEET,IT IS CONSIDERED DEEP DRAWING.
PUNCHES & DIES ARE USED TO CREATE CHANGES AT EVERY STAGE.USING THIS PROCESS,A SHEET IS CONVERTED INTO MANY DIFFERENT SHAPES LIKE A FUEL TANK,SINK & AUTOMOBILE PARTS.DEEP DRAWING IS MOSTLY USED FOR LARGE BATCH PRODUCTION.
E. HYDROFORMING
IN THIS PROCESS ,THE METAL IS PLACED ON A DIE,BUT INSTEAD OF A PUNCH,HIGH PRESSURE FLUID IS USED TO SHAPE THE SHEET.
WITH THIS PROCESS,MORE COMPLEX PARTS CAN BE CREATED IN A SHORTER TIMR FRAME,IT IS ALSO COMPARITIVELY CHEAPER & REQUIRES LESS WORK.HYDROFORMING IS ALSO COMPATIBLE WITH ALMOST ALL MATERIALS SUCH AS STAINLESS STEEL,ALUMINIUM,CARBON STEEL,BRASS.
SINCE MATCHING DIES ARE GENERALLY NOT NEEDED,HYDROFORMING CAN BE USED TO FORM UNCONVENTIONAL SHAPES.
IN SHEET METAL APPLICATION WE CAN CREATE A UNIFORM THICKNESS SHEETMETAL PART USING BASIC FEATUTE SUCH AS TABS,FLANGE & JOGS,WE CAN ALSO DO BEND CORNERS,CUTOUT,BEAD ETC.
THE SHEETMETAL APPLICATION PROVIDE AN ENVIRONMENT TO DESIGN THE METAL PARTS USED IN MACHINERY,AUTOMOTIVE & AEROSPACE ENCLOSURES ETC.
THE COMPLEX SHEET METAL PART CAN BE DESIGNED IN THE SOLID MODEL WORKBENCH & THEN WE CONVERT IT INTO SHEETMETAL PART.WE CAN ALSO IMPORT,CLEAN UP & CONVERT A NON SHEET METAL PART INTO A VALID SHEET METAL PART.FLAT PATTERN SHEETMETAL DATA CAN BE USED FOR THE MANUFACTURING PROCESS.THE MATERIAL PARAMETERS SUCH AS THICKNESS,BEND RADII & BEND RELIEF CAN BE EASILY SET FROM DEFAULT SETTINGS.
# APPROACH WITH DESIGN METHODOLOGIES -
# TOOLS APPLIED WHILE MODELLING -
SKETCH - IT'S A BASIC COMMAND TO DRAW 2D MODELS.
TAB - IT IS USED TO ADD PARAMETERS TO THE SKETCH.
BEND - IT'S AN OPERATION TO BEND THE TAB AT A PARTICULAR POSITION WITH REFERENCE.
FLANGE- IT'S AN OPERATION TO EXTEND OFF A SHEET METAL WITH EDGE OF AN TAB.
UNBEND - IT IS USED TO FLATTEN THE CREATED 3D MODEL TAKING ONE FACE AS STATIONARY FACE.
HOLE - IT IS USED TO CREATE DIFFERENT TYPE OF HOLE LIKE TAPPING,NORMAL DRILLING ETC,ON THE SURFACE OF AN SHEET METAL.
DIMPLE - IT IS A PROJECTION COMMAND OF A PARTICULAR SHAPE WITH REFERENCE TO SKETCH WITH CERTAIN DEPTH.
BEAD - IT IS ALSO A TYPE OF PROJECTION FORM WITH REFERENCE TO THE SKETCH WHILE GIVING STRENGTH TO THE MATERIAL.
REBEND - THIS COMMAND IS USED TO REBEND THE ALREADY FLATTENED SHEET METAL.
# DIFFERENT VIEWS OF BOX ASSEMBLY -
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# DRAWING SHEET IMAGE -
# CONCLUSION - BY THIS CHALLENGE I CAME TO KNOW ABOUT THE DIFFERENT COMMANDS & SHEET METAL PROCESSES ALONG WITH DRAFTING WORKBENCH,THUS CREATING THE FINAL BOX ASSEMBLY.
# ALL PART FILES ARE ATTACTHED BELOW -