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 objective of this challenge is to design a metal bracket with mentioned tools and measurements in sheet metal of sheet metal application of siemens NX.

Introduction: -

A bracket is a component used to support load or any attachment to structural element for heavy vehicle. It is subjected to different types of loading while the vehicle is in motion, one of the main common loadings is static loading which is assumed to be a constant throughout the operation.

Brackets can be made in various ways, such as casting or CNC machining, However, the best way to make simple brackets is sheet metal fabrication. One of the most common Sheetmetal processes is bending. In which a machine called a brake is used to bend sheet metal

Design methodology: -

Description: -

All the tools used in completing this challenge are mentioned below.

Sketch: - Use the sketch command to create a sketch on an edge, Curve, Datum plane, Or planer face.

Contour flange: - Use the contour flange command to create a flange by extruding a sketch along a vector, or by sweeping a sketch along an edge or chain of edges. NX adds bends automatically using the default bend radius value. To use a different bend radius value, draw arcs in the section, or change the default bend radius value.

Normal cut-out: - Use the normal Cut-out command to cut material by projecting a sketch onto the model and then cutting perpendicular to the faces intersected by the projection.

Break corner- Use the break corner command to round or chamfer sharp corners of a tab or flange

Advanced Flange: - Use this command to add a flange along an edge using a bend angle or a reference face. The edge and reference face can be curved.

You can select a single edge or a chain of tangent edges.

Hole- use the hole command to add the following types of hole feature in a part or assembly:

• General holes (simple, counterbored, Counter sunk, Or tapered Form)
• Drill Size holes
• Screw clearance holes (simple, Counterbored, or countersunk form)
• Threaded holes
• Holes On non-planer faces
• Holes through multiple solids as single feature
• Multiple holes on a single feature

Gusset: - Use the Gusset command to create a stiffening feature on a part.

You can:

• Create strengthening feature where extra strength is required in the bend region
• Create punched or embossed shapes in bend regions of Sheetmetal parts.
• Specify default dimensions for the gusset feature using customer default.

Unbend: - Use the unbend command to unbend a portion of the part to construct cut-out features, hole features, or deform features across a bend. You can later reform the bend to represent the true formed shape of the model.

Re-bend: - Use the re-bend command to return an unbend feature to its previous bent state. Any feature added after the unbend operation are properly repositioned during the re-bend operation.

Process: -

• First, we set the preferences for the sheet-metal and make a sketch in YZ plane for reference.
• Then we make another sketch in XZ plane and do a counter flange.
• Now by taking the first sketch as reference, we apply normal cut-out at appropriate positions as per the given instructions.
• We do another normal cut-out on the sheet with given measurements and then add break corner.
• Unbend the sheet-metal and add the normal cut-out in the shape of a hole with given measurements.
• Re-bend: - apply break corner advance flange at appropriate positions as per the instructions.
• Unbend the sheet metal and add feature like hole at given positions with measurements.
• Add Advanced flange to the normal cut-out.
• Apply gusset on the given faces by using reference and then come drafting.

Images: -

Isometric view: -

Front view: -

Side View: -

Top view: -

Bottom view: -

Part navigator: -

Draft Design: -

Conclusion: -

By completing this challenge of design of metal bracket on the sheet metal application of siemens NX, I have learnt how to analyse the given sketch and how to use different types of tools that are involved in completing this design like gusset, Normal cut-out, counter flange, Advanced Flange, hole, etc.