Advanced Sheet Metal Design Using NX Cad Challenge_7_ Metal bracket-II
SHEET METAL BRACKET II DESIGNING USING SIEMENS NX
OBJECTIVE
To create a sheet metal Bracket design using Siemens NX cad software and to improve 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 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 process and the design process itself can be similarly Tricky. CAD software’s such as Siemens NX cad, SOLID WORKS etc. are used to design the complex sheet Metal components
Sheet metal Design software considers the fabrication methods needed for manufacturing. As we 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 METHODOLGY
The Bracket created for this project consists of various features like Contour flange, Flange .Bead, Hole 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 flow chart below
COMMANDS USED
Sketch
Contour flange
Normal cutout
Break corner
Unbend
Re bend
Advanced Flange
Hole
Flat pattern
Draft
SKETCH
Sketches are the basic element or we can say he 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 flanges 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, spine sand epileptically 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
Norma l cutout command extracts 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 shape
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 re bend the Un bended parts along with the feature applied after the unbend. After addition sketches and features the sheet metal is to be re bended to its required shape. This operation is done by box selecting all the features and clicking the Re bends 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 work bench is just like in the model workbench. It can create either simple or counter bore or countersink or tapped holes. For this 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 modeling, 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 XZ plane create a contour flange with a thickness of 3mm
Do a normal cutout using the required curves from the first sketch as shown with a depth of 120mm
Break the corner of small rectangle cut out with a radius 4mm
Unbend the model
Create a new sketch and do another normal cutout as shown
Create two holes of 6mm diameter and 30mm apart
Re bend the model
Break the corner as shown
Add a Advanced flange of length 5mm
Un bend the model
Re bend the model
Create gussets
FLAT PATTERN
Draft images
Some standard views of the model
CONCLUSION
The Bracket Design is created successfully with the required skills