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

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

Objective :

The main objective of this project is

• To create sheet metal modeling of the Metal bracket-II 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 sketches in YZ and XZ planes.

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

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

Step 2: Creating 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.

Contour is creating using the sketch drawn on the XZ plane.

Step 3: Normal cutout part 1

Initially, the sketch is drawn on a YZ plane or Sheet metal face for the required dimensions of the cutout. As shown in the below sketch.

Step 4: Normal cutout part 2

Initially, the sketch is drawn on a YZ plane or Sheet metal face for the required dimensions of the cutout. As shown in the below sketch.

Step 5: Normal cutout part 3

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

Step 6: 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 7: Normal Cutout

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

Step 8: Rebend

Step 9: Advanced Flange

Advanced Flange adds flange along the edge using the reference face or bend angle. The edge and reference face can be curved. Flange Properties namely Length, angle, length reference and inset type are defined along with bend parameters, end limits and relief.

Step 10: Break Corners

Corners of the brackets are trimmed with R 5, and R10.

Step 11: 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 12: Adding Holes to the Model.

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

Step 13: Normal Cutout

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

Step 14: Advanced Flange

Advanced Flange adds flange along the edge using the reference face or bend angle. The edge and reference face can be curved. Flange Properties namely Length, angle, length reference and inset type are defined along with bend parameters, end limits and relief.

Step 15: Rebend

Step 16: Adding Gusset

Sheet metal gussets are formed with special tooling which has a ridge going across the v opening. ... This triangular section is known as a gusset and can be used to stiffen or strengthen a bend.

Final Model views - Metal Bracket-II

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 Metal Bracket-II is successfully created.
• Understood the NX Cad sheet metal features and its application.