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

TITTLE: DESIGN OF SHEET METAL BRACKET

OBJECTIVE

• To understand the 2d drawing in a right way and design a metal bracket from a complex 2 dimensional diagram.

INTRODUCTION

• we have created a sheet metal bracket in the previous session. here we are going to create a bit complex geometry bracket from a given give 2 dimensional drawings.as we know these brackets are used so many applications like tv mount.
• To increasing the strength and stiffness of the sheet metal part here we are going to use gusset and flanges. it will hekp to prevent from frature failiure.
• most importantly here we are going to learn about converting 2 dimensional sketches into sheet metal part.

DESIGN METHODOLOGY

• It is a single sheet metal part. we can develop a sheet metal part just correctly appling all the dimensional information in a right way.

PROCESS FLOW DIAGRAM

PROCESS STEPS AND DESCRIPTIONS

SKETCH 1

• first i have created a sketch of front view on the right side plane{zy} it is up to us. i only created what i think is important. rest of the profile we can add afterwe bring a thickness to our sheet metal part.

SKETCH 2

• then i have created a right side view sketch on the front plane where i'm going to create a contour flange.

CONTOUR FLANGE

• Create a contour flange by selecting a last sketch and give a uniform thickness of 3 mm.

CONTOUR FLANGE

• Create a contour flange by selecting a last sketch and give a uniform thickness of 3 mm.

NORMAL CUTOUT

• Cutout it is used to cut a bodies normal to a part plane here we are using our sketch 1 as our normal cutout profile. final out come will look like this.

UNBEND

• then the next step will be un bend the sheet metal part to add some cut profile on the bend areas as shown in the figure {note: all thse features are added with a guidance of 2d diagram}

REBEND

• it is used to bring our part to the original position in other words to undo a unbend command.

BREAK CORNERS

• apply break corners on the sheet metal edges to make a appropriate geometry as given the 2d diagram. it helps to provide a smooth corners instead of sharp edges

NORMAL CUTOUT 2

• one more cut out profile to make it similar to the original. for that we have to follow the steps that we did for a normal cutout 1.

steps are given below

1. unbend
2. hole - create an exact point to make a hole as shown in the 2d diagram.
3. sketching profile
4. normalcutout
5. rebend

GUSSETS

• Gussets are created to improve the stiffness of the part generally gussets are created on the bend region which will connect the two faces in the specific model we are using rounded gussets

NORMAL FLANGE

• flange can be added in the sheet metal edges to create a profile on the adjacent side. which has a sheet metal part thickness and it has a bend radius that actually controllable. it is a handy tool to create a profile.

basic parameters

length of flange{L}

ANGLE

OFFSET

we can modify the length reference by its reference adjustment and inset.

there are plenty of options we can choose right one for our desired purpose.

it also has some limitations which are given below

1. it cannot perform in curved edges

2. not able to create a flange on tangent profile

3. only applicable for narrow line or edge.

ADVANCED FLANGES

• Advanced flanges we can use this along an edge to create a flange. it is very useful where we can not create a normal flange . normal flages generally not performimg in the tangent edges. i'm not able to describe the advanced flange because i don't have a lisence to work on that.

pics of advanced flanges

ADVANTAGES

• we can create a flange along an edge using a bend angle or reference face. the edge and the reference plane can be curved,

FRONT VIEW:

RIGHT SIDE VIEW:

ISOMETRIC VIEW:

DRAFTING

Drafting is nothing but creating two dimension drawing of the model for better understanding.

It also makes it easy for the manufacturer for understanding.

CONCLUSION

• Finally a complex sheet metal bracket part has been created. while designing the bracket i have learned how to read a 2d drawing and convert to a 3d part. understanding of advanced features in NX_CAD.