Advanced Sheet Metal Design Using NX Cad Challenge_6_Bracket

Advanced Sheet Metal Design Using NX Cad Challenge_6_Bracket

Objective :

The main objective of this project is

• To create sheet metal modeling of the Bracket using NX Cad
• To learn about the sheet metal modeling features and applications

Introduction :

Sheet metal is metal formed by an industrial process into thin, flat pieces. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Countless everyday objects are fabricated from sheet metal.

Sheet metal is used in automobile and truck (lorry) bodies, airplane fuselages and wings, medical tables, roofs for buildings (architecture), and many other applications. Sheet metal of iron and other materials with high magnetic permeability, also known as laminated steel cores, has applications in transformers and electric machines

Design methodology:

Description:

Step1: Creating a sketch in the XZ plane.

The sketch is drawn on the XZ plane with the required Dimensions and is shown in the below figure.

Step 2: Creating a Contour Flange

You define a single contour flange by selecting an open profile. Contour flanges can be created along an edge or edge loop. The inventor previews the flange material thickness along with the selected profile and toward the material of the selected edge. However, you can reverse the thickness direction.

Step 3: Creating a Normal Cutout

a. Initially the sketch is drawn on XY plane for the required dimensions of the cutout. As shown in the below sketch.

b. After the sketch is drawn, it is used to execute the Normal Cutout command.

Normal Cutout command extracts volumes from sheet metal by using sheet metal production principles. Cutting faces will be perpendicular to the sheet metal surface.

Step 4: Break Corners

Corners of the brackets are trimmed with R25, R30, and R60.

Step 5: Unbend

Unbend - To flatten a sheet metal feature.

Basically, this feature is used, when the workflow needs to add more features like beads, dimples, holes, and more.

Step 6: Adding Bead to the Model

Beads are elongated recesses that are stamped into the sheet metal parts to increase the stiffness. To maximize this effect, the length and stamping depth of the bead must be adapted to the size and thickness of the workpiece.

Beading is one of the common bending operations which are used to form beads at the end of the sheets. In beading, the periphery of the sheet metal is bent into the cavity of the die as shown in the following figure.

Initially, a sketch is drawn for our Bead on the XY plane, called as Bead centerline.

Step 7: Rebend

Rebending the Model.

Step 8: Adding Holes to the Model.

The sketch is drawn for the holes references as shown in the Figure.

Final Model views - Bracket

Drafting

Drafting is a vital tool that allows users to add to their work instructions, hold associativity, and create full prints of tooling and fixturing. New capabilities in NX 12 allow for the jump to drafting from manufacturing while in previous versions of NX, you could only jump to drafting from modeling or assembly.

Conclusion

• Sheet metal modeling of the Bracket is successfully created.
• Understood the NX Cad sheet metal features and its application.