Advanced Sheet Metal Design Using NX Cad Challenge_7_ Metal bracket-II

Aim :

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 Bracket.

Solution :

First we will discuss about few terms :

1.Beads :

Drawbeads are used to control the flow of sheet metal into the die cavity during stretch-draw forming of large panels. They prevent wrinkling in formed panels, reduce the blankholder force, and minimize the blank size needed to make a part.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 following figure. A bead or a round corner is formed at the end of the sheet.

2.Gussets

Sheet metal gussets, or “Stiffeners”, used to strengthen a bend. Gussets are formed with a specially made tool. There are at least two ways that a gusset tool can be created. One is by drilling a hole across the die opening and inserting a pin of the appropriate diameter.

3.Notch :

Notching is a metal-cutting process used on sheet-metal or thin bar-stock, sometimes on angle sections or tube. A shearing or punching process is used in a press, so as to cut vertically down and perpendicular to the surface, working from the edge of a work-piece

Now we will create the model as shown below :

We have created the side view sketch as shown below :

Now we will create the contour flange :

Now we will create a cut out as shown :

Now we have created another cut out :

We have done another cut out as shown below :

After creating holes and doing unbend we get the following :

We have created a cutout as shown below :

After rebending we get the following :

Now using advanced flange we get :

Now we will rebend and create cut out as shown below :

We will again use the advanced flange option as shown below :

Now we will add gussets as shown below :

Hence we have got our final product as :