Challenge

Advanced Sheet Metal Design Using NX Cad Challenge_5_Odd Shaped Enclosure

MMd Rahmanuddin19 Oct 2022

Title of the Project :DESIGN OF SHEET METAL ENCLOSER

Objective

To design an odd shaped encloser in sheet metal by using nx cad siemens.

Introduction

Sheet Metal -

The sheet metal is formed by an industrial process into thin, flat pieces. Sheet metal is one of the fundamental forms used in metal working, and it can be cut and bent into a variety of shapes. The metals which are less 6 mm thickness are considered as sheet metals. The sheet metal is available in flat pieces or coiled strips.

The various forming processes that are used to deform the sheet metals are -

Bending
Curling
Deep drawing
Hemming and Seaming
Punching
Blanking and Peircing
Rolling, Spinning and Stamping

Sheet metal is used in automobile and truck bodies, airplane fuselages and wings, medical tables, roofs for buildings and many other applications.

NX CAD Sheet Metal Module - Creating fast, accurate flat patterns is the goal of any organization that manufactures products which contain sheet metal parts. 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.
With NX Sheet Metal, formed and unformed representations of the parts are created closely following the industry workflows and best practices for bending calculations, tooling, and sheet metal features. The value lies in improving quality and reducing cost of sheet metal parts by producing an accurate sheet metal pattern as the correct input for part manufacture, whether internally or to a supplier.

This project is to create the enclosure, by creating the solid model and wraping the sheet metal over the solid surface. Then we need to add the features in the wrapped sheet metal.To add more features like Dimple, Louver, Beads then the sheet metal has to be unbend. Finally flat pattern has to be created to check the manufacturing fesability of that product.

DESIGN METHODOLOGY

while design of an encloseer we have to assuming some parameters so our product will perform well in manufacturing place

which are given below

uniform thickness
keep holes diameter atleast larger than sheet metal thickness
spacing between holes atleast 2 times the sheet metal thickness.

use bead to strenthen our product.

Description (Need to explain tools/ Features used while designing)

Features Used In the Modelling :-

The software used to design this component is NX-CAD also called as Unigraphics. We are exploring the Sheet metal Module of NX CAD in this project. Some of the commonly used features through this modelling are explained as below.

Sketch - It is the basic of any design.
Extrude - It creates a feature by extruding a section along a vector.
Sheet Metal from solid - It builds a sheet metal model that takes its shapes from a collection of planar faces. This command is used to convert the solid body into a sheet metal body. After selecting the command and the solid body, we can also remove the edge sharpness by removing the material at these places.
Tab - Tab is a command used to create a base for any sheet metal part that can be extruded from a sketch. The sketching plane can be selected as per the designer’s choice.
Flange - It is used to create an extended part (bend) of a sheet metal. It is created at the edge of one side of the model. This command will allow us to select the edge of the base to create a projecting flat extruded surface. The angle, width, length, and type of flange can be determined as per the requirements.
Jog - It modifies the model by lifting material on one side of a sketch line, adding a flange between the two sides. Jog is created at another end of the model opposite to the flange. Jog is a command to lift off one whole side of the part. By selecting a line and the plane, the material can be pushed down or lifted off depending on the situation.
Unbend - This feature is used to unbend the adjacent bends and flatten them. Here it is used to create more features. This command is used to unbend the sheet metal parts to create geometries and work on complicated designs. In this command, we have to select a stationary face and then select the corners of flanges to unbend.
Rebend - It is used to rebend the corners that were bent before along with any features added after the unbend feature.
Bead - It lifts material along the contour of a sketch that simulates a stamping tool, it is used for giving strength to the sheet metal. Here two beads are created on the unbent surface. The selected sketch is lifted off from the base to provide strength to the material. Similar to dimple, the material can be removed in both directions.
Hole - It adds a hole to one or more solid bodies in a part or an asembly with options for counterbored, countersunk and threaded. Here six simple holes are created on the unbent surface with a diameter of 10mm. It can be used to make customized or standardized holes along with a defined point or path. The dept of the hole can be controlled.
Flat pattern - It creates a flat pattern feature from the formed sheet metal part. The user chooses this command to create a flat view of the sheet metal after unbending all the sides and faces. This view can be used in drawing the flat pattern along with the bend radius and other dimensions.