Advanced Sheet Metal Design Using NX Cad Challenge_6_Bracket

Metal Bracket Design

Objective – Create Bracket (Sheet Metal) Part by using given drawing sheet.

Introduction

Sheet Metal - There is no clear definition for it. As a rule, it is understood to be a flat piece of metal whose width is significantly greater than its thickness.

The thickness of sheet metal starts from 0.5 mm and goes up to 6 mm.

Below 0.5mm it will be called as coil/foil papers

More than 6mm it will be called as metal plate.

Sheet Metal operations Need to create bracket

Bending Operation - Metal bending is a process by which metal can be deformed when applying force to the subject, which causes it to bend at an angle and form the anticipated shape.

A press brake is a tool used in order to bend sheet metal and uses a punch and die to do this.

Sheet Metal Bending Methods

1 - V-bending

2 - Air Bending

3 - Wipe Bending

4 - Roll Bending

Cutting Operation

Trimming - Trimming is a relatively simple but important process that is used to clear up borders of the workpiece from excessive material. This is often one of the last, if not the last, operations in the manufacturing process involving machinery that works with sheet metal.

Parting - Separating a part from the remaining sheet, by punching away the material between parts.

Cutoff - Separating a part from the remaining sheet, without producing any scrap. The punch will produce a cut line that may be straight, angled, or curved.

Removing sharp edges and burrs

By using different metal finishing process be can remove sharp corners.

Sheet metal stamping

Sheet metal stamping is a crucial process in the manufacturing industry, enabling the creation of intricate and precise components and also create beads. And another bending operations are use to create beads.

Design methodology

Description (tools/ Features used while designing)

Sketch - This is used to create a basic sketch of the design on selecting the desired plane, then later it can be modeled for the requirement.

Contour flanges - Contour flanges are flanges with several contours by extruding a profile that represents its cross-section. They can be used as a base feature or a feature added to a sheet metal part. Contour flanges can contain one or more bends at any angle.

Normal Cutout - This feature is used to cut the portions of the sheet metal Perpendicular to the sheet metal surface.

Break Corner – Break Corner is use to remove the sharp corner of the sheet metal edges. Basically, we can say it is use to provide fillet (Blend) or chamfer to the sheet.

Unbend – It is a powerful tool basically use for analyzing the sheet metal features, dimensions, and also use for creating some features on sheet which is easily create when sheet is flat.

Beads – Bead is similar feature like dimple the only difference is that by using dimple we lift an area while in bead we lift the contour of the sketch. It also added to strengthen the component. beads are also use to give strength and rigidity to the flat sheet.

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.

Rebend - Rebend is used to restore the unbend feature to its previous bent state along with any features added after the unbend feature. This is done by using rebend feature and selecting all the bends carefully in order they unbanded.

Hole – Hole is a feature which is used to create holes and standard tapping (Metric, BSW, BSP) on the sheet or solid model.

Different Views

Isometric View

Top View

Front View

Bottom View

Side View

Drafting

Conclusion

1 - We learn about sheet metal workbench.

2 – Commands of sheet metal and how to use it.

3 – Learn designing process of sheet metal component.

4 – By doing this project understand and develop ideas how to proceed to create a sheet metal part. Improve thinking process for developing sheet metal parts.