DESIGNING OF METAL BRACKET 2 - NX SHEET METAL APPLICATION

Designing of Metal Bracket -2 - NX Sheet Metal Application

OBJECTIVE:

In this project we are going to design a Bracket in NX using sheet metal application.

INTRODUCTION :

Sheet metal refers to metal that has a high surface area to volume ratio. Sheet metal work stock, used for sheet metal processes, is usually formed by rolling and comes in coils.

Bracket - An overhanging member that projects from a structure (such as a wall) and is usually designed to support a vertical load or to strengthen an angle.

DESIGN METHODOLOGY/APPROACH:

DESCRIPTION:

Application : Sheet metal, Drafting.

A. Sheet Metal- Starts the Sheet Metal application, which provides tools to design straight-brake and more complex sheet metal parts.

Feature Tools : Counter Flange, Break Corners,Unbend, Hole, Normal cutout, Gusset, Re-bend, Advanced Flange, Flat Pattern.

Counter Flange- Creates a base feature by extruding a sketch along a vector or adds material by sweeping a sketch along an edge or chain of edges.

Normal Cutout - Cuts material by projecting a sketch onto the model and them cutting perpendicular to the faces intersected by the Projection.

Break Corner - Rounds or chamfers a sharp corner of a tab or flange.

Unbend - Flattens a bend and the material adjacent to the bend.

Hole - Adds a hole to one or more solid bodies in a part or assembly with options for counterbored, countersunk and threaded.

Advanced Flange - Adds a flange along an edge using a bend angle or a reference face. The edge and reference face can be curved.

Re-bend - Restores an unbend feature to its previous bent state, along with any features added after the unbend feature.

Gusset - Creates a stiffening gusset on the part.

Flat pattern - Creates a flat pattern from the formed sheet metal part.

B. Drafting - Starts the Drafting application, which provides tools to create and maintain drawings of the design model

Feature Tools: New Sheet, Base View.

New Sheet - Creates a new drawing sheet.

Base View - Creates a model based view on the drawing sheet.

PROCEDURE:

1. Open a new Sheet Metal Part file and save it as Bracket 2.prt

2. Sketch Creation:

1. YZ Plane - Create a sketch as per drawing using lines, circles, rectangle & arcs. Exit the sketch.

3. Counter Flange Creation:

1. XZ Plane - Create a sketch as per 2D drawing using lines, arcs and fillets. Apply dimensions and relations to it and exit the Sketch.
2. Use Counter Flange feature and select the sketch and extrude it.

4. Normal Cutout:

1. XY Plane - Create a sketch by drawing as per drawn sketch in step 2 using lines & arcs. (the portion that has to be removed). Exit the sketch.
2. Use Normal cutout feature to cut the unwanted material.
3. Similarly repeat the steps on the other sides also.

5. Breaking Corners:

1. Apply fillets to the required edges by using Break corners feature.

6. Normal Cutout:

1. XY Plane - Create one more sketch by drawing as per drawn sketch in step 2 using circles in the middle portion (the portion that has to be removed). Exit the sketch.
2. Use Normal cutout feature to cut the unwanted material.

7. Breaking Corners:

1. Apply fillets to the rectangular edges by using Break corners feature.

8. Unbend Sheet Metal:

1. Unbend the sheet metal by selecting stationary face as larger face & bend faces to bend.

9. Normal Cutout:

1. YZ Plane - Create a sketch by drawing a circle at the bottom portion (to make hole). Exit the sketch.
2. Use Normal cutout feature to cut the unwanted material.

10. Re-bend Sheet Metal:

1. Re-bend the sheet metal by selecting Bend face which is previously used to un bend.

11. Breaking Corners:

1. Apply fillets to the bottom edges by using Break corners feature.

12. Advanced Flange Creation:

1. Select the top edges of Bracket and use Advance flange feature to curve it.

13. Unbend Sheet Metal:

1. Unbend the sheet metal by selecting stationary face as larger face & bend faces to bend.

14. Adding Holes:

1. XY Plane - Create a sketch by drawing a few sketch point as per drawing.
2. Use Hole feature to create holes.

15. Normal Cutout:

1. YZ Plane - Create a sketch by drawing a Ellipse shape using lines & arcs at the bottom portion (to make hole). Exit the sketch.
2. Use Normal cutout feature to cut the unwanted material.
3. Do one more Normal cutout at the left top edge as per drawing.

16. Advanced Flange Creation:

1. Select the edges of created normal cutout in step 15 and use Advance flange feature to curve it.

17. Re-bend Sheet Metal:

1. Re-bend the sheet metal by selecting Bend face which is previously used to un bend.

18. Creation of Gussets:

1. Select the bend face and Proper plane in Gusset feature to create gusset.
2. Create one more gusset at same place at a distance.
3. Repeat the same procedure at lower bend face to create Gussets.

19. Drafting:

1. Use Flat Pattern and select the flat face to create flat pattern.
2. Create a new drafting file of A4/A3/A2 Size and add Base view by giving proper scale(Rotate the model if required).

CONCLUSION:

At the end Bracket Designed in NX cad using Sheet metal as application. Additional features like Gussets, holes added as per Drawing.