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

Advanced Sheet Metal Design Using NX CAD

Metal Bracket-II Design

Objective:

The main objective of this project is to design a sheet metal BRACKET II in NX cad sheet metal application workbench. Also, to perform the drafting for the bracket part.

Software used: NX 12.0

Introduction:

Sheet Metal Basic Principles

Sheet Metal Fabrication is the process of forming parts from a metal sheet by punching, cutting, stamping, and bending. 3D CAD files are converted into machine code, which controls a machine to precisely cut and form the sheets into the final part.

3D CAD files are converted into machine code, which controls a machine to precisely cut and form the sheets into the final part.

Sheet metal parts are known for their durability, which makes them great for end use applications (e.g. chassis). Parts used for low volume prototypes, and high volume production runs are most cost-effective due to large initial setup and material costs.

Because parts are formed from a single sheet of metal, designs must maintain a uniform thickness. Be sure to follow the design requirements and tolerances to ensure parts fall closer to the design intent and cutting sheets of metal

In our project We used NX12

NX CAD

NX delivers a tailored environment for sheet metal design, with onscreen controls and modeling commands for typical features in sheet metal components. NX Sheet Metal Design includes tools for unfolding bends to create accurate at patterns for fabrication.

The sheet metal design tools within NX allow companies to apply defaults – based on both industry and company best practices – to the values used in the creation of sheet metal parts. For example, bend radii and neutral factor values can be set to commonly used values to encourage re-use and save design time. Folded and unfolded views of sheet metal components can be used in both the

3D environment as well as downstream in 2D documentation and for manufacturing.

Design Methodology For Design Bracket II

Description:

The sheet metal Bracket II has been done with the above flow chart process. While designing the default thickness, bend radius relief depth and relief width value are set to 1mm at the Menu → Preferences → Sheet Metal here you can change the Sheet Metal thickness whenever necessary.

The sketch is drawn in the YZ plane and the Contour flange command is used for creating the base of the part.

Explanation and Procedure:

Sketch for contour flange

Contour flange:

In Siemens nx sheet metal contour flange command is used to create a base feature by extruding a sketch along a vector, or adding material by sweeping a sketch along an edge or chain of edges.

From the menu: Insert -> Bend -> contour flange.

Contour flange creation:

The contour flange is a flange created using the open sketch created in a plane. It is different from a regular flange because it can be created in any shape and it does not require choosing the edge of any tab or existing flange. It can be at any position or at any angle. For this bracket design, a contour flange is created using the earlier sketch as the curve.

A contour flange can be created from any open curve. For this bracket, the sketch is created in an XZ plane with the following dimensions.

Normal cutout:

Using the NORMAL CUTOUT tool we remove the material from the required location.

Normal cutout creation:

It cuts away the material at the right angle with respect to the sketch plane. A closed sketch is created on the YZ plane to cut away the unnecessary material. Sketch 1 is projected and the required closed contours are sketched wherever cuts are required. Then the operation normal cut out is carried out.

Break corner:

Break corner and chamfer tools are used to make some changes over sheet metal body. Both the tools provides a different activity in creation of the parts.

Rounds or chamfers a sharp corner of a tab or flange. Here by using this tool we can do two different operations.

One is Forming Bend to part and secondary is Forming chamfer.

Bend: Completely formed with radius and creates smooth edges.

Chamfer: This tool is applicable by distance and creates sharp edges.

Break corner creation:

Select the edges want to apply the break corner command.

Unbend:

As the tool name indicates the bend tool is used to bend the sheet metal bodies and the unbend is viceversa of the bend tool,It is to unbend the bent regions.

The part is unbend to create additional features such as hole, dimple, beads which otherwise cannot be created if it not unbend. Moreover it also helps to check whether the part is a sheet metal or not. If the part is unbending then it is a sheet metal otherwise it is still a solid body or dumb body.

Unbend creation:

Select the stationary face and select the bend faces to form the unbend.

Re-bend:

As the tool name indicates the bend tool is used to bend the sheet-metal bodies and the re-bend is viceversa of the bend tool, It is to re-bend the un-bended regions.

Re-bend creation:

Open the re-bend command and drag the cursor over the faces to be re-bend.

Advanced Flange:

Unlike base simple base flange, the advanced flange can create flange from any edge which can be either curved or straight line, open or closed profile. This allows creating a flange with a match face also.

Advanced flange creation:

For this bracket, the advanced flange is created at the upper portion with proper parameters as shown.

Holes creation:

The additional features holes are also created. Hole command is available in the sheet metal workbench of the NX CAD.

Gussets:

Gussets are the strength stiffening features. They add strength and stiffness to the sheet metal parts.

Gusset creation:

The face and the plane is selected for the gussets to be created and the profile is generated. The profile can be automatically generated or the sketch can be created.

Flat Pattern:

Flat pattern is the representation of the entire sheet metal component in the 2D form of the flat sheet metal 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.

Flat pattern creation:

Open the flat pattern command and select the flat face as reference and apply…

Drawing View

Isometric view

Front View

Side View

TopView

Drawing Sheet

CONCLUSION:

• Finally, the Metal bracket II of the sheet metal is designed on the Siemens NX12.0

• The tools and features used for the Metal bracket II are learn to apply correctly.