Sheet metal welded box methodology 1

[KENAT]

Although I’ve been using SE for a good while I’ve never used sheet metal much for various reasons.

There’s one guy here who ends up making a lot of sheet metal boxes. Typically a sheet metal cube or box, open on one side with the mating edges/corner relief’s welded closed and ground down to make a nice radii (at least on the outside).

Due to our PDM/PLM/Configuration Management/IT infrastructure/Security policy (or lack there of) etc. we aren’t really set up to send the in flat dxf to vendors so that isn’t forcing us to use Sheet Metal.

How would you approach this in SE?

I’m tempted to suggest just creating it as a regular part. Create a cube/cuboid protrusion, apply appropriate rads to the edges and then shell it out to the sheet metal thickness. But this may just be because I’m not very familiar with sheet metal.

How would you do it and if you’d use sheet metal how do you handle closing the edges, we’ve never found a good way of closing the corners although others have had some success using weldments to close the edges.

I’ll be doing the sheet metal tutorials while I wait

 

[kjoiner]

Kenat,

Typically when I make a box, I create a base using the Tab command. Then I will form up the sides by using the Contour Flange command. You can either create just the side wall or you can also add other flanges. If the return flange bends to the inside, the Contour Flange command can miter the corners. After I create the profile for the contour flange I will let it run the flange around all four sides. This creates nice tight corners that lend themselves to welding. This does create alot of welding and grinding and possible warpage. Another option is to bend a flange on a side wall so that it laps behind the wall ajacent to it. Then you can spot weld the corners. We have done this on NEMA boxes and then we seal the joints. Solid Edge sheet metal is extremely powerful and I would encourage you trying it for making any part that calls for sheet metal. I think you will find it very efficient. Another tip, if the corners don't close how you like them, try the Close Corner command and look at its options for the type of corner relief. Also remember that you can unbend, add features, and rebend the flanges as well. Try it out and send me some more questions if you need help.

Kyle

 

[PatCouture]

As Kyle said I strongly suggest that you use sheet metal for anything that will be made of a sheet of metal just because you will be more aware of what is possible to accomplish in the real world. I've received a lot of drawings from client that are made in part instead of sheet metal and if the designer isn't well aware of how is model is made it can get very complicated for nothing.

Take a good look at all the features from the sheet metal environnement because as of now I didn't had any part that can be made in reality that I hadn't been able to modelise. The only exception is when you have a deformation of the material, in that case SE won't give you a flat pattern. But hey you just said you don't need it so you will be ok.

Patrick