Sheet Metal Bracket II Design Using Siemens NX

SHEET METAL BRACKET II DESIGNING USING SIEMENS NX

OBJECTIVE

To Create a Sheet Metal Bracket design using Siemen NX cad software and to improve Sheet Metal designing skill

INTRODUCTION

Sheet metal is one of the most versatile materials in the manufacturing industry. It’s made from steel, aluminum, brass, copper, tin, nickel, titanium, or precious metals. It ranges in thickness from wispy leaf through light foil to heavy plate. It takes a variety of forms: plain flat sheets, embossed, etched, ribbed, corrugated, and perforated. And its uses expand across many different industries including transportation, aerospace, appliance manufacturing, consumer electronics, industrial furniture, machinery, and more.

Sheet metal components can have deceptively complex manufacturing processes and the design process itself can be similarly tricky. CAD softwares such as Siemens NX cad ,SOLIDWORKS etc. are used to design the complex Sheet Metal components .

Sheet metal design software considers the fabrication methods needed for manufacturing. As you create flanges and add bends, the sheet metal design software will accurately represent the flat pattern required. The flat pattern can be used to document and manufacture associatively as the design changes.

Here in this project we are dealing with the Sheet metal Bracket designing using the software Siemens NX cad

DESIGN METHODOLOGY

• Apart from the other projects ,the Bracket for this project is created from its own previously given Draft images (2D) . The Bracket here consist of different Repeated features like cut-outs, bends, Advanced flanges, holes etc. Every feature is designed in an order following the industrial procedure to keep the design intent. The design methodology used for this project can be summarized as depicted in the flowchart below:

COMMANDS USED

• Sketch
• Contour Flange
• Normal Cut Out
• Break Corner
• Unbend
• Rebend
• Advanced flange
• Hole
• Flat Pattern
• Draft

Sketch

Sketches are the basic element or we can say the foundation of a design model. A base sketch is needed to perform most of the operations in Sheet Metal designing including Tab , Dimple , Bead , Hole , Contour Flange etc. The sketches can be created using the various sketch tools provided top left corner of the interface

Contour Flange

We can create a contour flange from an unconsumed or shared open profile sketch.The profile sketch consists of lines, arcs, splines, and elliptical arcs. Sharp corners in the geometry profile results in bends in the contour which honor the bend radius value of the sheet metal style. We can offset the contour flange to either side of the profile sketch, or use the sketched profile as the flange mid-plane.

Normal Cut Out

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

Break Corner

The command used to break or round the corners in a solid body in order to avoid accidents by the sharp edges

Unbend

Use the Unbend tool to unbend one or more curved surfaces such as Bends or Curved walls to a flat configuration in a Sheet Metal part .For performing a Unbend feature its must to define a fixed planar face or edge. We can either select bend geometry individually or automatically select all the bend geometry.

Rebend

Command use to Rebend the un bended parts along with the feature applied after unbending. After addition of sketches and features the sheet metal is to be re bended to its required shape. This operation is done by box selecting all of the bends and clicking the ReBend command.

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 insert type are defined along with bend parameters , end limits and relief

Hole

Hole feature in sheet metal design workbench is just like in the model workbench. It can create either simple or counterbore or countersink or tapped holes. For this casing, first, the four points are sketched symmetric to the x-axis in position and the hole feature is applied

Flat Pattern

Flat pattern is the representation of the entire sheet metal component in the 2D form with all the bends, cut-outs, holes, and additional features in the form of lines or edges. The flat pattern ensures the ability to cut the sheet metal out of the raw sheet metal plate. It removes the possible errors such as interference or collision within the same component.

Draft

After the modelling ,the manufacturing of the component a technical 2D drawing of the component with accurate dimensions or scales denoted. For achieving this we are using the command Draft.

Procedure

• Create two sketches in YZ plane as shown in the picture. This sketch is used for performing multiple Cut outs from the model.

• Create another sketch in XZ plane as shown below

• Using the sketch in the XZ plane create a Contour Flange with a thickness of 3000 mm

• Do a normal cut out using the required curves from the first sketch as shown with a depth of 120 mm

• Break the edge shown in the picture using a radius 4.5 mm

• Now perform multiple cut outs using the first sketch with a depth 120 mm as given.

• Break the corner of the small Rectangle cut out with a radius 4 mm

• Unbend the model

• Create a new sketch and do another Normal cut out as shown

• Create two holes of 6 mm diameter and 30 mm apart.

• Rebend the model

• Break the corners as shown

• Add a advanced flange of length 5 mm

• Unbend the model

• Perform a normal cot out as shown in the picture

• Create another Advanced flange , length 4 mm

• Re bend the model

• Create Gussets

• Create a flat pattern of the model

Draft images

sheet size - A4 , scale -1:1

sheet size -A4, scale- 2:1

Some Standard views of the model

Conclusion

The Bracket Design is created successfully with the required scales