Sheet Metal and Autodesk

[tim-tim]

Originally Posted by MysterE

Ok everyone -

I am looking for as many resources as I can get my hands on as to the proper way to design sheet metal parts on Autodesk. We don't have any design mentors so I am trying to become one if possible :-p. All things to all people as they say.

While there are probably some best practices out there on sheet metal part design, most people design things slightly differently.

If you search CD there are a lot of threads out there, like this one. I like this one because you can see and follow some of the progressions and lessons learned over the years of a team.

What capabilities does your team/sponsor have? Depending on the resouces available, your design style could and probably should change.

As far as how to teach the students to design sheet metal parts, honestly have them start with the tutorials to understand the basics. Once the students are comfortable with the concept, allow them to explore. I know it is like beating a deadhorse on CD, but have them work through a chassis (or some other assembly) to understand the interactions and consequences for different design choices and tradeoffs.

I could go on and on about different things, but what exactlyh are you looking for? Is there a specific field or target area?

If there is one thing I (and probably others) can't emphasize enough, please understand and know your team's true resources and capabilities.

As always, feel free to contact with questions or a discussion.

[JCharlton]

Our team has started using sheet metal in several areas of our robot, and my students are starting to see the benefits of lighter weight, faster build, and more than adequate strength. Cosmetically our robots are looking better, and we reduce the cost of using extrusion.

We use Inventor to design, but also a lot of measure/bend/cut to fit. Despite being a Mech Eng there's a LOT I don't know about sheet metal standards and building, hasn't stopped me from trying.

The best exercise is to make things out of stiff cardboard and staples. Anything you can staple you can punch a hole and avoid drilling (look into getting a Roper Whitney punch). Also a pneumatic rivet gun makes everyone happy.

Good luck!

[MysterE]

Originally Posted by JCharlton

Our team has started using sheet metal in several areas of our robot, and my students are starting to see the benefits of lighter weight, faster build, and more than adequate strength. Cosmetically our robots are looking better, and we reduce the cost of using extrusion.

We use Inventor to design, but also a lot of measure/bend/cut to fit. Despite being a Mech Eng there's a LOT I don't know about sheet metal standards and building, hasn't stopped me from trying.

The best exercise is to make things out of stiff cardboard and staples. Anything you can staple you can punch a hole and avoid drilling (look into getting a Roper Whitney punch). Also a pneumatic rivet gun makes everyone happy.

Good luck!

The cardboard idea sounds flipping amazing. Anyone else do this?

[tim-tim]

We tell the students to take a piece of paper and make things. "If you can make it with paper (or cardboard) you can make it with sheet metal" The one thing to keep in mind is a minimum bend radius and its effects. Paper you can bend on a point, or zero inch radius; sheet metal you can't.

This exercise is good to help students visualize things because sometimes it's hard to see on the computer.

[kramarczyk]

We've done Cardboard Aided Design in the past, although most notably for large plastic parts. The best example is our 2010 control board which we made for 1/8" ABS. We modeled what we wanted in Inventor and then mocked it up in cardboard to sense check ourselves and make sure that everyone understood what the end product would be like. The cardboard is a huge help.

Cardboard Mockup
https://picasaweb.google.com/finneyr...06561378797554

Sense Check
https://picasaweb.google.com/finneyr...06583701230130

Final Product
https://picasaweb.google.com/finneyr...13921786997378
https://picasaweb.google.com/finneyr...97045504596098