Suggested approach to sketching multi-sided Fuel Tank

[Anonymous]

Hi,

I am hoping for a little direction for sketch methods. 

The Fuel tank will most likely be an assembly of parts (sides) manufactured from 3mm aluminium which will be welded together. 

My idea is to draw a solid shape, and project each side to an offset plane, developing each side as required and then bring together, fitting all the parts  in an assembly. Consideration must be given to the interface between all edges, so the design will be made to aid assembly and welding. 

I am about to proceed with this, yet a little unsure if maybe i would be best doing it another way??????????? A screen-cast is attached to give an idea of the fuel tank design.

Any useful pointers appreciated, i am new to Fusion, and have little Inventor experience. 

Thanks, Barry

[TheCADWhisperer]

No Screencast attached. 

You must Preview and then Insert to embed link.

Do you have a link to a still image of something similar?

Will this be a "boxy" design from press brake sheets or

will this be an "organic" design from deep drawn dieform (like a motor cycle tank)?

[Anonymous]

Equipment is limited. No bends etc and using a CNC router, if each side is done this way it allows for an exact fit-up which should help with welding.

(Screencast added in Edit)

Thanks,

Barry

[TheCADWhisperer]

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

I notice that you have two Form nodes in the timeline - this doesn't make sense.

I don't understand your statement about projecting to planes - simply Split up the sheets and you should be good to go.

What is your sheetmetal thickness?  Oops, I see you already stated 3mm.

[Anonymous]

I think i have corrected the form node problem, i am unsure but file should be attached here.......

I have also added a new screencast which should explian my "project to offset plane" idea. 

Very uncertain on best approach, i am thinking of using my solid shape purely as a form reference and projecting all the parts from it.

Perhaps dissecting a 3mm shell model into seperate sheets is an alternative approach.

[jeff_strater]

Hi @Anonymous,

I have a couple of approaches in mind.  The first is the simplest, basic approach:  Unstitch the solid into a series of surface bodies, then thicken each one.

Here is a screencast:

As I point out in the screencast, though, the problem with this approach is how the edges are joined together.  I have an idea for a different approach, but I need to try it first...

Jeff

[jeff_strater]

OK, so I worked out how to do the more complex version of this, but it's a bit involved.  If the first unstitch then thicken method works, I'd use it.

Anyway, here is the more complex version:

Hope one of these will work for you.

Jeff

[etfrench]

The first method would be best for welding.  In order to get good welds on the second method, you would need to chamfer the edges.

[Anonymous · Accepted solution]

This is excellent,

The second one is my preferred method i think as it will aid fit up if everything goes together tightly. However, as already pointed out, the first method facilitates the welding process nicely, a nice groove to put the filler rod into. I will have a play around and try to see if i can do additional work to the second method in order to incorporate this. 

Many thanks!

Barry

[JDMather]

---

@Anonymous wrote:

... No bends etc and using a CNC router, if each side is done this way it allows for an exact fit-up 

---

Will your cuts all be perpendicular to the flat or will you be able to change to angled cutting tools for cuts beveled to the flat?

[Anonymous]

Ah yes,

I think i see where you are coming from with that one........... Must give this some more thought, the tooling capabilities are indeed perpendicular to the flat workpiece. 

Thanks,

Barry

[TheCADWhisperer · Accepted solution]

Plan out your order of welds as some of the beads (4) (to angled plates) need to be done from inside.

Download attached.

File>New Design From File, browse to download location and select file.

[Anonymous]

Yes,

That looks very good, i will need to examine your file closely and work out where i could not manage this, the inside corners were problematic for me. 

I am also trying to improve the design for assembly, i figure that by extending the top face by 1.5mm and extruding 1.5mm, this creates a step. The trouble is that this leaves a seamline which i need to remove. In other words i would like to combine this as one part. 

Screencast included if anyone may help.

Thanks,

Barry