Aerospace Sheet Metal

View a topic

Introduction

Aerospace Joggle

Starting the program and setting preferences

Lightening Cutouts

Creating Aerospace Sheet Metal features

Aerospace Unform

Aerospace Flange

Aerospace Reform

Introduction
NX Aerospace Sheet Metal accelerates designing of the most common type of sheet metal part found in
airframes. This application provides a focused environment for designing structural support ribs and various
other types of brackets that typically mate with the mold line of an aircraft body. The features provided by
Aerospace Sheet Metal permit the user to define flanges that are associated with mold line surfaces and are
joggled around other supporting structures. The application also provides the ability to form and uniform the
flanges using aerospace standards for flat pattern production. For easy and flexible design work flows, flanges
may be shaped in formed or unformed states.
NX Aerospace Sheet Metal provides special features for Aerospace Flange, Aerospace Joggle, Form, and
Reform. It also includes features from Modeling and NX Sheet Metal that are required to completely design
airframe ribs. These features include, but are not limited to Tab, Normal Cutout, Flat Solid, Bead, Hole, and
Extrude. NX Aerospace Sheet Metal design uses many of the features found in Modeling and NX Sheet Metal.
Users should become familiar with Modeling and NX Sheet Metal before using Aerospace Sheet Metal.

Starting the program and setting preferences

Where do I find it?
Application Aerospace Sheet Metal
Toolbar
Aerospace Sheet Metal

Menu

StartAll ApplicationsSheet MetalAerospace Sheet Metal

If the Aerospace Sheet Metal toolbar (below) does not appear:

1. Choose ToolsCustomize.
2. Under the Toolbars tab, check the Aerospace Sheet Metal box, then click Close.

Additional modeling features for creating sheet metal parts are available. If you do not see the following toolbar
on your screen, follow step 1 above, and select the Form Feature and Feature Operation boxes. Descriptions
of how to use these features can be found in NX Modeling.

Aerospace Sheet Metal provides default global values for typical sheet metal settings such as material thickness,
bend allowance, bend radius, and neutral factor. You do not have to set these values for each new feature. If you
change a global value the new value is applied to all existing and future features in that part file. If desired you
can override a global value for individual features by entering a new value when the feature is created or edited.
To access the global values, see Preferences Global Parameter Values and Application Options.

Feature

Sketch

Tab

Usage

Instruction Location

Create planar profiles

for Tabs and Cutouts.

Sketch task environment

Create the base web for

NX Sheet Metal
a sheet metal part.

Flange

Create non-linear
flanges associated with Aerospace Flange
mold line surfaces.

Joggle

Modify flanges to joggle

around other parts in the Aerospace Joggle
assembly.

Lightening
Cutout

Allows you to quickly

construct flanged
cutouts on Aerospace
Sheet Metal parts.

Aerospace Lightening Cutout

Flatten aerospace
flanges.

Aerospace Unform

Unform

Reform

Flat Solid

Flat Pattern

Bead

Refold aerospace
flanges after shaping in Aerospace Reform
the flat state.
Produce a solid in the
flattened state.

NX Sheet Metal

Creates a solid or
wireframe flat
representation of a 3D
sheet metal part.

NX Sheet Metal

Add a bead to the planar

NX Sheet Metal
web.

Using a planar cutout,

create a cutout that
NX Sheet Metal
maintains consistent part
Normal Cutout thickness.

Break Corner

Add blends and

chamfers to corners.

NX Sheet Metal

Add standard types of

For information on the Sheet Metal Relief see the Legacy Sheet Metal Formin
corner reliefs to the part
in NX 7.0 and earlier versions.
in the unformed state.

Sheet Metal
Relief
Creating Aerospace Sheet Metal features

This topic describes how to create the features that are specific to Aerospace Sheet Metal: Aerospace Flange,
Aerospace Joggle, Unform and Reform. Instructions for how to use the other features found in Aerospace
Sheet Metal toolbar can be found in the Help guides for Modeling and NX Sheet Metal. The following table
shows the general usage of each feature and where to find its documentation.
Using feature dialog boxes
Aerospace Sheet Metal has a button for each sheet metal feature. Clicking the button for the feature brings up a
dialog box that contains all the options and functions necessary to create the feature. As an example, the
Aerospace Flange dialog box allows you to do the following:

Select the type of flange you want to create (By Value or By Reference). Selecting the type of flange
you want to create will change the number of selection steps that are required to define the feature.
Once the flange type is selected you will then step through the selection steps to fully define the flange
parameters. You may change to any desired selection step at any time to change your selections.

When the flange parameters are fully specified, the OK and Apply buttons will become active. You can
build a flange with the Apply button and then select new parameters for a different flange. The OK
button will build the flange and exit the dialog box.

The Cancel button will let you terminate the dialog box without building the feature.

Using dynamic input boxes and drag handles

When you're creating a feature, you are sometimes presented with drag handles and dynamic input boxes. These
functions appear on the graphics screen in the area of the feature you are creating. In the figure below, there are
three drag handles labeled A, B and C. Handles A and C are linear handles and can be changed by dragging the
arrow heads in and out along the vector. Handle B is a radial handle and can be changed by dragging it around
the radius of the arc path shown.

When you pick the drag handle, the corresponding dynamic input box appears next to it. To change the value for
the item:

Pick the handle and drag it in the direction that corresponds to the value you want, or
Click on the dynamic input box and type in a value.

You can switch the direction of visible linear drag handles by doubleclicking on the arrowhead for that drag
handle.

Aerospace Flange
The Aerospace Flange
feature allows you to quickly construct complex flanges along non-linear edges.
The flange may also be associated with and formed to align with non-planar surfaces. A flange consists of a
region known as the bend region and a flange body known as the web. The bend region attaches the flange to
the body of a selected base edge.
The Aerospace Flange has a By Value option that lets you define parameters values for radius, angle, and
length of the flange. The Aerospace Flange also has a To Reference option that lets you select a face that
defines the variable angle(s) of the flange required to align the flange with the face. When a face is selected, an
option is also available to let the length of the flange be determined by the size of the face.

Where do I find it?

Application Aerospace Sheet Metal
Toolbar
Aerospace Sheet MetalFlange
Menu
InsertBendingFlange

Aerospace Flange dialog box

The Aerospace Flange dialog box contains parameters for controlling the type of flange, the placement of the
flange and the inclusion of various types of reliefs.
Type group
Define flange by entering parameter values (see step 4).
By Value
Defines flange by selecting a reference face or datum plane (see step 5).
To Reference
The selection steps that are available at any given time depend on the flange type and the completion of other
selection steps.

Bend Parameters defines how the flange is attached to the existing part and defines how the Length parameter
is used to define the length of the flange.
Base Edge group
This is the first step for both types of Aerospace Flanges: By Value and To Reference. The
selected edges determine the location of the By Value flange. For To Reference flanges only
Select Base one edge is required. It determines the body that will intersect with the selected surface to
define the flange location.
Edge(s)
Reference Geometry group
This step is only active for To Reference flanges. The selected surface or datum plane, define
the angle of the flange and the shape of the web of flange. The length of the flange can be an
entered value or can be inferred by the shape of the selected surface.
Select
Faces
Two selection steps are used for both the By Value and To Reference flanges to provide an
option to trim and taper the ends of the flange. The first selection step is used to select or define
Inferred a datum plane for the start of the flange. The second selection step is used to select or define a
datum plane for the end of the flange. On-screen handles for start and end may also be used to
Plane
activate these selection steps.
Bend Parameters group
The flange is inset into the base material such that the flange body is to the inside of the bend.
The Length parameter defines the normal distance between the outside edge of the flange and
the intersection between the outside faces of the base and flange. Use this option to build a part
Material inside of another part.
Inside

Material Inside bend down

Material Inside bend up

Material
Outside

The flange is inset into the base material such that the flange body is to the outside of the bend.
The Length parameter defines the normal distance between the outside edge of the flange and
the intersection between the inside faces of the base and flange. Use this option to build a part
on the outside of another part.

Material outside bend down

Material outside bend up

This option is only available for By Value flanges. The flange is attached to the existing part
without removing any material. The Length parameter defines the normal distance between
the outside edge of the flange and the edge on the base part on the inside of the bend angle.
Bend
Outside

Bend outside bend down

Bend outside bend up

Length and angle parameters
The Length parameter may be set by using the dialog box's dynamic input box or by using the on-screen
handles. For To Reference flanges the Length parameter also contains an option to infer the length from the
shape of the selected surface or by entering a value. The Length parameter defines the normal distance between
the outside edge of the flange and either the inside or outside edge of the base part, depending on the Bend
Location option.
The Angle parameter is only available for By Value flanges. The value may be set by using the dynamic input
box or by using the on-screen handles. The angle for To Reference flanges is determined by the intersection
between the base body and the reference surface.
Bend parameters
The Bend Radius defaults to the global bend radius value. To change this value the sheet metal preferences can
be changed. This will update all flanges that are using the global value to the new bend radius value. The global
value can be overridden by clicking off the User Global check box. A new value may then be entered in the
Aerospace Flange dialog box to define a specific bend radius for the flange.
Bend relief
The Bend Relief option allows round, square, or no bend relief to be added to the ends of the flange. This
option works the same as the Bend Relief option in NX Sheet Metal. SeeBend Parameters for more information
on the bend relief parameters.

Corner Relief
The Corner Relief option trims an adjacent flange to match the width of the new flange.

Flange without corner relief

Flange with corner relief

Preview
Select the Preview check box to see what the flange will look like before it is created.
Create contour curve
Select the Create Contour Curve check box to have a curve generated at the position of the contour points
along the length of the flange. For any given flange cross section, the contour point is a point where the outside
face of the flange would intersect the outside face of the body.

Flange with blue contour curve

Aerospace Joggle
The Aerospace Joggle
feature allows you to quickly construct the geometry that is required to offset a
portion of a flange to properly match the flange to other parts in the assembly. A minimum set of inputs will
result in a flange being divided into three regions: 1) a region that does not change (stationary region), 2) a
joggled region and 3) a transition region between the stationary and joggled regions.
Two types of joggles may be created, a Single Joggle and a Twin Joggle. A Twin Joggle contains two
transition and stationary regions, one on both sides of a single joggled region.

Single joggle
In the figure above, the number 1 indicates the joggled region of a twin joggle.

Twin joggle
Where do I find it?
Application Aerospace Sheet Metal
Toolbar
Aerospace Sheet MetalJoggle
Menu
InsertBendingJoggle

Aerospace Joggle dialog box

The Aerospace Joggle dialog box contains parameters for controlling the type of joggle, the placement of the
joggle, and the definition of joggle parameters.
Type group
Defined by a single joggled region, transition region, and stationary region.

Single
Defined by a single joggled region and two transition and stationary regions.

Twin
Selection group
This is the first step for both types of aerospace joggles: Single and Twin. This step
identifies the flange to joggle by selecting a bend face of the flange.
Select flange
bend faces
(Side 1) For both types of joggles a step is available to select or define a datum plane.
The datum plane is used to define the location of the joggle on the selected flange.
Inferred Plane
(Side 2) For twin joggles, a second Inferred Plane step is added. Two datum planes are
required for twin joggles. The datum planes define the limits of the joggled region.

Inferred Plane
Depth parameters
The Depth parameter defines the distance and direction that the joggled faces of the flange are offset along the
Side 1 datum plane. To define the depth value, drag the arrow of the on-screen handle or enter a value in the
dynamic input box.

Reverse Direction
To change the direction of the joggle, double-click the arrow of the on-screen
handle or click the Reverse Direction button on the Joggle dialog box.
Side 1 and Side 2 parameters
Tabs are available to access the joggle parameters for the transition regions. By default, both sides use the same
parameter values. The Side 2 Tab is only active for Twin Joggles when the Side 1 = Side 2 check box is
cleared.
The following parameters are used to define each transition region. All distances are normal to the associated
(Side 1 or 2) datum planes.
Option
Runout (R)

Description
Defines the normal distance and direction between the start and the end of the transition
region. To change the value, drag the arrow of the on-screen handle or enter a value in the
dynamic input box. For single joggles, this parameter also defines the direction of the
transition region relative to the datum plane. To switch the transition region to the opposite
side of the datum plane double click the arrow of the on-screen handle or click the Reverse
Direction button on the Joggle dialog box.
Clearance (C) Defines the normal distance between the datum plane and the start of the transition region.
To change the value, drag the arrow of the on-screen handle or enter a value in the dynamic
input box.
Stationary
The radius of the blend between the stationary region and the transition region. By default,
Radius (R1) this value is defined by a global preference. To change this value, change the global
preference to update all joggles in the part. To change the radius value for this specific
joggle, clear the Use Global Value dynamic input box and enter the desired value.
Offset Radius The radius of the blend between the transition region and the joggled region. By default,
(R2)
this value is defined by a global preference. To change this value, change the global
preference to update all joggles in the part. To change the radius value for this specific
joggle, clear the Use Global Value dynamic input box and enter the desired value.
Click this option and you will see a schematic showing how Side 1 and Side 2 parameters
define the shape of a joggle. When the dialog box is expanded, the schematic for the
currently selected joggle type is shown at the bottom of the dialog box.
Expand
Dialog

Single joggle parameters

Twin joggle parameters

Preview
Select Preview

to review the joggle before it is created.

Apply compensation
Flat pattern compensations are applied to single joggles when they are unformed by the Flat Solid feature. Flat
pattern joggle compensations are not applied to twin joggles.
Compensations are only applied to single joggles if the following conditions are met:
Option
Apply
Compensation
Joggle Length <
Depth Threshold

Joggle Depth >=

Depth Threshold

Description
You must select this check box in the Joggle dialog box. A customer default defines
the default preference for this check box.
The joggle length is the distance from the end of the flange to the end of the joggle
transition region. The Distance Threshold is a Joggle Compensation preference
defined in the sheet metal preferences under the Joggle tab. A customer default
defines the default value for the Distance Threshold.
The Depth Threshold is a Joggle Compensation preference defined in the sheet
metal preference under the Joggle tab. A customer default defines the default value
for the Depth Threshold.

Joggle unformed without compensation

Joggle unformed with compensation

Joggle flat pattern compensation rules
Compensation is applied by the Flat Solid feature by rotating the end and outside edges of the joggle region by:
Compensation Angle = arctangent (joggle depth / joggle length). In the figure below, the Joggle Length is the
linear length from the end of the flange to the end of the transition region. For a non-linear flange, the Joggle
Length is the arc length of the contour line in the joggled region plus the runout and clearance distances. Joggle
Depth is always equal to the depth parameter value. In the figure below, point 1 indicates the Joggle Length,
and point 2 indicates the Compensation Angle.

Lightening Cutouts
The Lightening Cutout
command allows you to quickly construct flanged cutouts on Aerospace Sheet
Metal parts. You can define the outline of the cutout by a sketch, and use the options to specify the length of the
flange, rounding of the sketch vertices, and the angle of the draft.
Lightening Cutout is very similar to Drawn Cutout in NX Sheet Metal; however, the Aerospace Sheet Metal
Lightening Cutout feature can be unformed while the Drawn Cutout feature cannot.

Where do I find it?

Application Aerospace Sheet Metal
Toolbar
Aerospace Sheet MetalLightening Cutout
Menu
InsertPunchingLightening Cutout

Lightening Cutout dialog box

Type group
You either select and existing sketch, or select a placement face, at which time the system drops
you into the sketch task environment line of the cutout.
By
Section
The system asks for a placement face and center point and you define the diameter of the
circular cutout region.
Hole
Section group (when Type is set to By Section) and Center Location group (when Type is set to Hole)
Select Curve
Lets you select an existing section of define one inside the Sketch task environment
(Section group)
by selecting a placement face upon which the sketch will be built.
This is the first step for the By Section type of cutout.
Select Planar Face Lets you select the planar face to which the hole will be applied.
Section group (when Type is set to By Section) and Center location group (when Type is set to Hole)
Specify Point (Center Location
Lets you select or create a center point to define the center of the
group)
circular cutout.
Cutout Properties group
Diameter
Appears only when Type is set to Hole.
Sets the diameter of the circular cutout.

Length

Note This diameter defines the size of the cut, and the flanged region is then added to the
inside of this cut hole.
Sets the length value defines the length of the flanged region. This distance is measured from
the relative intersection of the flange to the end of the web. This is similar to an Outside
Length measurement on an Flange feature.

Angle

A sample length measurement

Sets the angle value is the angle of draft for the flanged region. It is measured as the angle of
bending down from the flat.

A sample angle measurement

Reverses the direction of the flanged region.

Reverse
Direction
Rounding group
Die Radius Sets the die radius to the inside of the bend on the flanged region.
Corner
Appears only when Type is set to By Section.
Radius
The corner radius is used to round off sharp edges of the sketch profile in a By Section type of
lightening cutout.
Standards Appears only when a material is selected from the material standards file and the selected
material points to a table containing Lightening Cutout properties.
the lightening cutout standard table defines a list of standards and the parameter values
corresponding to each standard.
The following example shows a sample standard table.
Display Name Diameter Length Clearance Angle
STD_DIA-35

35

45

STD_DIA-55

55

6.5

45

The Display Name will be the name shown on the dialog box and the values in the other
columns define the corresponding parameter values for each standard. If a standard is selected
and it controls a parameter, that parameter cannot be edited from the dialog box. In the table
show above, if a standard is selected, the diameter, length, clearance and angle will be defined
using the values from the table and you cannot edit them.
Unform a Lightening Cutout feature
You can use the Unform command to unform a Lightening Cutout feature. Select the base planar face of the
Lightening Cutout as the stationary face and select the bend region of the Lightening Cutout as the bend to
unform.
You can also unform a Lightening Cutout feature using the Flat Solid or Flat Pattern commands.

Aerospace Unform

Use Aerospace Unform

to unform aerospace flanges, including flanges containing joggles. Flanges can be
unformed before adding a corner relief, flange relief, or flange shaping. For instance, if a cutout needs to cross a
bend region, it may be necessary to unform the flange before adding the cutout. After shaping the flange,
Aerospace Reform

can be used to return the flange to its formed state.

The Unform feature is intended for use during the construction process. When a part is ready for flat pattern
generation, the Flat Solid feature should be used to produce a version of the part in its unformed state.

Six formed aerospace flanges

Six unformed aerospace flanges

Where do I find it?
Application Aerospace Sheet Metal
Toolbar
Aerospace Sheet MetalUnform
Menu
InsertFormingUnform

Aerospace Unform dialog box

Bend Allowance Neutral Factor

The length of the unformed flange depends on the Neutral Factor defined in sheet metal preferences. The
Neutral Factor is a number between 0 and 1. It defines the position of the neutral surface as a percentage of the
material thickness relative to the inside bend. The neutral surface is a theoretical surface which does not stretch
or compress when the material is bent. The length of the neutral surface is the length of the flange in the
unformed state. The Neutral Factor depends on the material properties. When the preference value is changed,
all Unform features will update to reflect the new neutral surface.

Number 2 indicates
position of neutral
surface for Neutral Factor
1.

Number 1 indicates the

position of neutral surface
for Neutral Factor 0.

Number 3 indicates position of neutral surface for

Neutral Factor 0.33.

Aerospace Reform
Use Aerospace Reform
to return a flange to the formed state after it has been unformed to add a feature
such as a cutout across a bend.
For instance, to add a Sheet Metal Relief feature, first Unform the flanges.

Then add the Relief and use Reform to return the flanges to their formed state.

Where do I find it?

Application Aerospace Sheet Metal
Toolbar
Aerospace Sheet MetalReform
Menu
InsertFormingReform

Aerospace Reform procedure

1. In the Aerospace Sheet Metal application, choose Reform
2. Select the aerospace flange you want to reform.

Pick the bend region

of an Unform feature to select the flange you want to reform. You can reform
more than one flange in one operation by selecting multiple bends.
3. Click OK to finish the feature.