Linear weld corner; closing up miter gap -or- alternative workflow welcome (beginner)

[timothybdk]

I am working on a box design out of 3/16" aluminum sheet metal. the picture shows the corner mitered flange gap at the top/rim of the box (formed that way for strength/rigidity).  I think the material will allow for tighter gap in the mitered flange (I am ok with the gap on the radiused part of the corner but open to suggestions there as well).  

 

Also the fabricator recommends two opposite sides of the box be welded on.  So my workflow was to create the bottom & sides as one body, create a new offset plane and sketch the front panel to meet the 3 edges of the bottom & sides, create that as a SHEET METAL flange outward from the plane and then go into the SOLIDS tab to combine the two bodies, that allowed me to pull the 3 top flanges into the configuration in the picture (prior to combining I wasn't able to pull the 3 flanges together and take advantage of the miter/linear weld function at the corners).  Will I be able to separate the front panel later and supply the fabricator with 2 flat patterns for cutting from the sheet stock?

thanks tons.

[aliobidi]

Hi ,
you can save this option when it separate then work what do you want on it and make option 2 
or you can back on timeline 
also you will be able to separate in future if the geometry is clean 
there is a lot options  make what you see the best for you 

[timothybdk]

thanks, good to know I can easily separate later.  here is a better view of how I put the front panel in place (only meeting at the apex of the sheet metal edges).

this view also shows how large the gap is that needs to be spanned when welding the panel in place.

 

[TheCADWhisperer]

Can you File>Export your *.f3d file to your local drive and then Attach it here to a Reply?

[timothybdk]

this is what I have so far:

[TheCADWhisperer]

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@timothybdk wrote:

Also the fabricator recommends two opposite sides of the box be welded on.  

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Just to make sure - so your Design Intent is for this to be 3 components?

I can do it just as it is, but making sure of the true Design Intent before I start.

If yes, is this the desired position of the end caps (to the outside, not to the inside)?

[timothybdk]

yes, wanting to have mitered looking welded corners.

[carl.j.barker]

Just going to throw my 2 cents in here.

This is a method I use fairly often, starting with a sketch of the top flanges and building down.

Can also be used if the top flanges are of a different length or not cut at 45 degrees, You'll have to remove the mirrors and use a combine body though. There are of course obvious limitations to the shape of the box.

[TheCADWhisperer · Accepted solution]

See Attached...

[timothybdk]

this looks to be satisfactory to the welder, great!  thanks.  I have looked into the timeline a bit and tried to follow the workflow but I think you are a magician so far.  could you tell me was the profile of the cut to either side of the mitered flange joint something you knew from experience or calculated or generated by a feature in the software?

thanks very much for solving this!

[timothybdk]

have you had boxes with this type of corner welded up before?  it is a recommendation from the fabricator and I have yet to see a sample other than welding tutorials using similar thickness aluminum on outside corners.  thanks for posting the file.

[timothybdk]

Tip: follow the timeline from the beginning to see the workflow! 

I did not know the entire process was in such a small timeline so I was guessing that theWhisperer started adding to my file/drawing, not so.  At first glance I tried to look at the Right end panel sketch and see the miter detail but couldn't follow.  By chance I clicked back to the beginning of the timeline and stepping forward one step at time made the process very clear.  I still did not know how the miter worked but I am now able to reproduce the effect if needed.   thanks again!