I have a lot to learn, can you suggest a starting point for me based on where I need to end?

[yeep79]

Just starting on Fusion360. For the last couple of years I have been on FreeCAD as I am pretty much only on Linux. I recently got a mac for a work machine and decided to see if I could learn more about Fusion360. 

Current Project:

I am working on designing some weld together suspension brackets for my project I am building in the garage. I can only show pictures of other brackets here in an effort to explain where I need some help in planning. 

I would like to end up with a bracket similar to this one:

Bracket is available here for purchase: https://artecindustries.com/collections/axle-brackets/products/adjustable-link-tower-single. I am not trying to make money, and won't be selling what I make, it is only for my purposes. 

So my design needs to be taller (longer distance between top of axle and center of bolt hole), provide for larger bolts with adequate steel between the holes. (This bracket is built for 9/16" bolts, I am using 3/4").  These issues are relatively easy to handle in a new design.

The two issues that I am having trouble with are:

1. Bending the outer plates outward to provide a wider base
   1. Knowns:
      1. I know the radius of the bends I can achieve with my finger brake press. 
      2. To use a FreeCAD term, I know that I need to execute a "Boolean operation" after the bends are drawn up (an operation where shape of one part is removed from another) to make sure the coping on the bracket will form more of an elliptical shape to sit on the axle.
   2. Unknowns/assumptions:
      1. Im assuming that I can "un-bend" the plates after all this is done so I can provide an accurate drawing to my buddy with the plasma table. Is this true?
      2. I do not know what the operation is called described above in #2. Can someone point me toward where I can look this up?
2. Bracket needs to be rotated on axle
   1. Knowns:
      1. The artec bracket above assumes that the control arm connected to it comes in at a perpendicular angle to the axle when viewed from above.
      2. My brackets need to point "outward" at approximately 13 degrees (when viewed from above referencing a direction starting at the axle and ending at the chassis).
      3. This rotation will necessitate the sides of the bracket to not be symmetric in their outer shape as the "outer" side will be more toward the front of the axle, and the "inner" side will be more toward the back of the axle (when viewed from above).
      4. The rotation needs to be based on the center of the bolt or at least the calculated position of the center of the bolt. 
      5. This rotation will affect the coping for the axle bracket as well so it must happen before.
   2. Unknowns:
      1. How can I learn about rotating an entire "object" that is comprised of several sketches/ pads (is this a fusion 360 term?)/objects. 
      2. FreeCAD has a "formula editor" where you can manipulate constraints in a mathematical way and, more importantly, reference other sketches. Can this be done in Fusion 360? I feel like this will become important when it comes time to rotate, but please correct me if I'm wrong.

Current plan of action in order of the way I think I should do this:

1. Create the axle tube as a cylinder centered on origin.
2. Draw one of the side plates to my required specs.
3. Replicate the above and set its' position on the axle tube based on inside distance from the other.
4. Bend each plate at a specific line so they have that "outward angle".
5. Create the adjoining front and rear plates between the inner and outer ones (hoping to use a little tab and slot for easy assembly)
6. Rotate the entire assembly 13 degrees "outward".
7. Adjust the Inner and outer plates to compensate for rotation (assuming they wont have good contact with the axle tube on the sides that rotated off)
8.  Use a method to "remove" the space the axle tube takes up from the other parts of the drawing for coping.
9. Flatten all bent plates and figure out how to extract them individually so they can be used in a plasma table.

EDIT: after reading this, I feel like step 5 needs to come after step 7. No reason to create those sides before I know Im going to have to change them.

Does the above seem like a reasonable way to tackle this? Any suggestions?

Steel/Plasma table related concerns:

1. I do not think I should make the bolt holes exactly 3/4". This is not a laser cutter or water jet and I expect them to not turn out perfect. I have an annular cutter in my drill press, and would like to use a centering tool on it to hit the mark. I feel like I should take advantage of using CAD to give myself a mark where to center the hole rather than trying to measure it out after the fact. I have read all the arguments about smallest reliable holes size based on thickness of steel. Is that basically the size of the hole I should try to make so I have something to center my annular cutter on?
2. Still researching this, but Im not sure what an acceptable amount of play should be for tab and slot. When I look that up, I get into a bunch of engineering related reasoning, which makes sense. However, I am really just using the tab and slot so I can assemble the bracket easily before welding it together. Any suggestions here?

Thank you so much, sorry for the swarm of questions, but I figured I would just put them all into one post.

EDIT: I figured why not include a couple pictures of my project currently!

This was about a year ago...

Current state in testing, notice my very much prototype only upper axle brackets... 😎

[TrippyLighting]

Start with the "Self Paced Learning" courses. You'll still have questions, but will be much better equipped to ask them:

[terry_fusion]

As a new Fusion user myself, it can be daunting to learn a new CAD package even if you have experience with other software products.

I was a little behind the 8 ball when I first started because I had to leave some of my preconceived ideas/methodologies behind.

Especially coming form Inventor, I erroneously expected Fusion to be a cross feature for feature, process for process twin.  It is not, nor should it be (I'm slow, but I learn. lol)

Coming from a little ahead of where you are, I wish I had followed my own advice that I'm giving you now when I started.

1. Start with the self-paced learning as said above, understanding how Fusion works is 80% of the game.

2. Also there are some very good videos on YouTube for all types of fusion related workflows.

3. Scour the forums for already answered question, although when you don't know how to describe what you want to do or the tools used in fusion to do those things it can take a little hunting. The folks the work the forums have in my experience been very patient and helpful.

4. Start small, start with what you know and build upon that. For example using Fusion I've had to understand that using a multi-feature set of tools, surfacing with solid geometry is sometimes what you need to get the correct results.

5. Have fun, enjoy the ride.

[TrippyLighting]

Thanks for sharing the pictures as well.

I am not a "car guy" and it would probably help if you can create  some simple paper-pencil sketches explaining the shape you're looking for. I can then try to show how to create the shapes you're looking for.

[davebYYPCU]

Some terminology to help, referring to that first picture.

5 Components in one Assembly.

Rule No. 1.  Each Component contains all it needs to make the part.

Your plate parts are Sheetmetal.  Sheetmetal Environment Unfold allows for additional operations like boundaries and holes before Refold.

Flat Patterns one per Component, (Rule No. 1)

Use a layout sketch for in place dimension extraction.

Assemble the components with Joints.

Might help.....

[rodY8GH3]

I found the Titans of CNC Academy videos helped immensely https://academy.titansofcnc.com/category/mill-building-blocks

 Its free to join and you can self pace. If you have a desk top and a laptop you can combine the two to speed up learning by running your fusion file on the desk top(bigger screen) and then run the training videos simultaneously on the laptop and follow along getting real time screen shot to look at while running fusion. Great exercise using both sides of you brain running a mouse in each hand! 

[yeep79]

@TrippyLighting - Sorry Im unsure what you are looking for outside of the picture of the bracket I showed. Are you thinking like several 2D sketches? I can actually steal some screen shots from my freeCAD drawings.

Here is a sketch of one of the "outer" plates:

Here is a shot of both outer plates (Freecad term is "pad") sitting on the axle tube. 

No rotation or bending at this point. I think if you compare the above screenshot to the original image from artec it might help. Let me know if I can do anything as far as describing.

[yeep79]

@terry_fusion 

Thank you for the response, I will take your advice with all of this.

[yeep79]

@rodY8GH3 Cool! I have watched those guys' videos on youtube before, I did not know they had something like that. Thanks for the suggestion.

[yeep79]

@davebYYPCU This is the kind of stuff I needed! The terminology is key to being able to look up information you need. Thank you for suggesting stuff like Joints, that gives me something I can look for and learn about.

[yeep79]

Everyone - Im not exactly how it works here, but is it considered inconsiderate if I do not "accept solution"? I am enjoying seeing people's opinions and input at this point and don't want that to end.

[TrippyLighting]

Do not accept a solution until you have one!

A solution also might be "cannot be done" but I don't see that being he case here.

The Artec Industries bracket is easy to replicate, however what I did not understand is you point #2 :

"Bracket needs to be rotated on axle" I don't understand what needs to rotate around what.

That needs to be considered at the start of modeling!

[TheCADWhisperer]

---

@yeep79 wrote:

Here is a sketch of one of the "outer" plates:

Here is a shot of both outer plates (Freecad term is "pad") sitting on the axle tube. 

---

@yeep79 

Recreate this sketch in Fusion 360 and then Attach your *.f3d file here foe Fusion specific tips and tricks. 
Tip 1: I recommend that you take all dimensions from a single datum - the Origin would be logical datum.

Tip 2: In general rarely use Fillets in sketch.  Use placed Feature Fillets instead of Sketch Fillets when possible and practical.

Tip 3: I would model this in finished form in the Sheet Metal workspace - but let’s concentrate on Steps 1 & 2 first.

[g-andresen]

Hi,

Get out of here with your advertising messages!

günther