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

OBJECTIVE:

To write a detailed report on Sheet Metal Component with good explanation on Sheet Metal modelling tools applied throughout the modelling. Also attach the Final model Images (Min. 4 images) of Sheet Metal Bracket.

The main importance of this project is to model a sheet metal bracket with some advanced features of sheet metal operations like Advanced flange, Gussets to provide the bracket with stiffening feature.

Given drawing as follows :

INTRODUCTION:

A bracket is an architectural element: a structural or decorative member. It can be made of wood, stone, plaster, metal, or other media. It projects from a wall, usually to carry weight and sometimes to strengthen an angle.In mechanical engineering a bracket is any intermediate component for fixing one part to another, usually larger, part. What makes a bracket a bracket is that it is intermediate between the two and fixes the one to the other. Brackets vary widely in shape, but a prototypical bracket is the L-shaped metal piece that attaches a shelf (the smaller component) to a wall (the larger component): its vertical arm is fixed to one (usually large) element, and its horizontal arm protrudes outwards and holds another (usually small) element.

DESIGN METHODOLOGY: The flowchart is as follows:

Description (Features used while designing):

• Sketch: The profile that needs to be drawn for featuring is done in sketch command.It is a 2D representation

Sketch-1 as shown below :

Sketch-2 as shown below :

• Counter Flange: It is used to create flanges as per the required shape. Using sketch-2 as shown below

• Normal Cut Out: It is a feature used to cut the sheet metal at the required profile normally. Using sketch-1.

• Unbend: It is used to unbend the bend profiles. unbend and repeat Normal Cutout

• Rebend : used ro rebend the unbended portions.

• Breaking Corners: It is used to make round corners instead of sharp ones

• Advance Flange: Used create flanges for the curved profiles(peofile should be smooth no sharp corners)

• Unbend the bend profiles and create holes using Hole feature as shown below

Lets create a normal cutout for a profile again as per DWG

• Rebend : used ro rebend the unbended portions.
• Gusset: Used for strengthening of the sheet metal between two flanges/Tabs.

Creating 4 Gussets here in the bend portion

• Flat Pattern: It is used to make the sheet metal into a flat pattern for manufacturing.

MODEL VIEWS :

ISOMETRIC VIEW :

SIDE VIEW :

TOP VIEW :

FRONT VIEW :

CONCLUSION :

Metal Bracket-II is created as per given Drawing using NX Software.