Advice - First Sheet Metal Frame

[tim-tim]

One other thing to double check is your "k" factor for your bends in your modeling software. The aluminum actually stretches as you bend it. This will affect your flat pattern and tolerances of the formed (bent) pieces.

A quick way to double check is through simple bend deduction or bend allowance calculations. Again, check with your manufacturer and make sure everything is good.

[Nuttyman54]

It's a great start! I assume you probably have some plans for a belly pan for electronics and the like, but you should make sure it's at least somewhat structural. The flanges on the front and back rails are good, but they won't hold up to abuse * without some stiffener in the form of a structural belly pan, or additional center supports. Bumpers will help some, but you don't want to rely on those.

*These pictures are of the damage to the reinforced repair of a 2x2x0.125" aluminum angle, since the original 1/8" sheet chassis couldn't hold up.

[Akash Rastogi]

Originally Posted by tim-tim

One other thing to double check is your "k" factor for your bends in your modeling software. The aluminum actually stretches as you bend it. This will affect your flat pattern and tolerances of the formed (bent) pieces.

A quick way to double check is through simple bend deduction or bend allowance calculations. Again, check with your manufacturer and make sure everything is good.

Going to quote this for emphasis.

Talk to your shop about what material you'll be using, what they want you to use, and anything else they need from you in your CAD.

[trilogy2826]

Though it may sound excessive, our CNC bend operator prefers the bend annotation dimension on the print down to 3 places past 0 (ie: 1.203").

My personal preference, especially when running structural components with sheet is to radius every single corner. Not only does it look better, but according to multiple FEA analyses on our previous frames can decrease stress concentrations and facilitate a long term stable solution.