Alignment tabs/holes

[flssfabrication]

Can somebody teach me the proper way to create alignment tabs and holes? I've tried numerous ways (as you can see with the mess of sketches in my history marker) and every time I come out with odd extrusions and/or the dimensions don't line up. For some reason my tabs (as is) are sticking out of the top and bottom .004 inches. Obviously, I am doing something incorrectly. Please don't mind my MESS of sketches. This project was going well up until I tried to add these tabs and holes. Let me know if you have questions for me. Thanks in advance. 

[davebYYPCU]

Where to start.  Not studied the whole thing yet,  Few things to get you thinking,

Your required output from Fusion should be driving your input,

Manufacturing - Laser or Router /Mill? 

Fusion CAM or External.

You have mirrors far to early in the timeline.

I like to do the same thing once.  Fusion will duplicate the rest.

Make one of each individual part, then ask fusion to duplicate and place them as required.

That said, your extrudes are deeper than the material it will be cutting, so same dimension for both will fix the height.

But the tabs are able to be added to the side profile, and flanged in one go.

Use Parameters and patterns, where possible.

Why Sheet Metal?  What tolerance will be required for the sockets. 

Might help....

[jhackney1972]

You are so close but your Extrusions are to a Distance and not To an Object which will flush up the pin to the surface.  After getting all your Extrusions changed, at the end use the Combine command to cut the holes but do not forget to Keep Tools so you will not lose the components with the tabs.  Please remember this method creates the square hole, for each tab, metal to metal.  If you need clearance between the tab and the hole, that is another process.  Model completely finished is attached.

[flssfabrication]

John, thanks for getting back to me. I must've been on fusion too long yesterday, I dont know why I didnt think of extruding to an object. Thanks for showing this step. Also, my intention of the holes was to have a .3125 hole centered on the square pins. Sorry I did not clarify this. If I had the machinery to machine very small square holes and pins accurately, I would use your method. I usually oversize the holes a little bit from the pins so I have some wiggle room. 

The method I have been trying is to project the pins to the top of the plate, create a .3125 hole centered on the pin, and extrude (cut) down to the surface. For some reason, the extrusions cut into the side pieces. I know I am doing something wrong here, and you seem very knowledgeable about the smart way to do things. Do you have tips/tricks to make circular holes centered on the square pins? 

Thanks John. 

[flssfabrication]

John, here is my best attempt at the concept I'm trying to complete. I activated the top and bottom separately, located the holes, and extruded (cut) to an object. This way seems to work, but I know you probably have a better trick up your sleeve. Let me know what you think. Sorry for the mess of a history timeline. 

[flssfabrication]

I cut all of my material with a plasma cutting table. I tend to keep this in mind as I am designing my parts. I use sheetmetal so I can use flanges, and flat patterns to export as dxf's to my external CAM program. Thanks for getting back to me!

[jhackney1972]

No, I do not have any fancy tricks up my sleeve for this one.  I would speed things up a bit by creating the holes on one side of each plate, then Unfolding it, create a midplane and mirror the other side holes.  Finished model is attached.

[davebYYPCU]

When sketching a Hole for the tabs, 

project 2 diagonal points off the tab. 

2 point circle (construction)

Offset circle for finished size.

Do one and pattern it.

Might help....