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Sheet Metal - want to make 45 degree cuts...

Question asked by Elizabeth Sorenson on Oct 17, 2012
Latest reply on Oct 29, 2012 by Mark McMullen

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that don't do thru the material but want to bend using the sketched bend function. I draw the line to use as bend line on the sheet metal yet it will not allow me to bend. Any help appreciated. Designing ACM (aluminum) panels for buildings and want the flattened state and the folded state. Do not want to use the edge flange in that it ADDS material. I have the exact size of aluminum in sheet metal and simply want to bend material now.

Aluminum has 45 cuts for the bend but does not go thru the material want to bend at the 45 degree channel I have made on the sheet metal.

Any help appreciated.

Thanks,

Elizabeth Sorenson

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23 Replies

Tony Cantrell Oct 17, 2012 12:44 PM
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Can you add a screen shot or the part.
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- Elizabeth Sorenson @ Tony Cantrell on Oct 17, 2012 12:54 PM
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  Hi Tony,
  
  Here is the part that I'm referring to. I think that Kelvin reply said that I now have different thicknesses therefore it does not respond with "sheet metal" properties anymore.
  
  Attached is scrren shot. Actually in SW should I make a pdf?
  Attachments
  - FLAT NO BENDS.SLDPRT.zip223.5 KB
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Kelvin Lamport Oct 17, 2012 12:45 PM
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Are you using a multi-body part? If not, once you have created the notch across the sheet, SW will no longer recognise the part as sheet metal because the part now has different thickness. SW sheet metal parts must have a constant thickness.
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- Elizabeth Sorenson @ Kelvin Lamport on Oct 17, 2012 12:50 PM
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  Hi Kelvin
  
  I am NOT using a multi-body part. I think you answered my question in why it will not respond as sheet metal now because it DOES HAVE different thicknesses now. How can I make it retain the properties of sheet metal but I MUST maintain the cuts that I have and then bend. Suggestions?
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  - Tony Cantrell @ Elizabeth Sorenson on Oct 17, 2012 1:09 PM
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    Make your cuts after your bends
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    - Elizabeth Sorenson @ Tony Cantrell on Oct 17, 2012 4:03 PM
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      Hi Tony,
      
      I went with your suggestion however, I can only make bends using the "sketched bend" tool on sides - when I try to bend resulting in a corner the message I receive is " Failed to make sketch bend" well I realize that! I made a line not interfering nor intersecting the bend portion to no avail.
      
      Attached you will find simple simple sheeet metal part. So your suggestion is to bend then use the 'extruded cut" tool to take out the material that I do not want. Is that correct?
      
      Basically I am working with 4mm ACM material and making panels to cover building. The sheet metal concept of SW is perfect in that I need the flattened panel for the CNC machine and want the 3D isometric for the guys in shop to actually fab the part and make sure they know what panel should be when in folded state.
      
      Any here is the most recent attempt at bending Sheet metal.
      
      Thanks,
      
      Elizabeth
      
      Can't get attachment to go it keeps blowing me out.
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      - Harold Lakoduk @ Elizabeth Sorenson on Oct 17, 2012 11:07 PM
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        Elizabeth,
        Isn't this the same question you posted here? https://forum.solidworks.com/message/320414#32041
        
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        Elizabeth Sorenson @ Harold Lakoduk on Oct 18, 2012 9:09 AM
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        It certainly is Harold. I simply can't find the solution to my folding/unfolding problem. I assume that one can not combine sheet metal and plain SW model and expect the sheet metal to maintain the sheet metal properties. Is this correct?
        
        Basic problem: Want to fold/unfold and NOT cut entirely thru material and NOT using the edge flange tool but the sheet metal sketched bend tool. Do not want to add material simply bend material that I have.
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      - Tony Cantrell @ Elizabeth Sorenson on Oct 18, 2012 7:00 AM
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        email it
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        Elizabeth Sorenson @ Tony Cantrell on Oct 18, 2012 8:20 AM
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        Here is a pdf
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        BEND-CUT.PDF95.7 KB
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        Tony Cantrell @ Elizabeth Sorenson on Oct 18, 2012 9:34 AM
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        To do what you want, you will need a third party fold unfold software. You can combine the SM and other SW functions and then have the 3rd party software unfold it.
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        Elizabeth Sorenson @ Tony Cantrell on Oct 18, 2012 9:39 AM
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        Thanks for response. So I can not do what I want with just SW. Correct?
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        Tony Cantrell @ Elizabeth Sorenson on Oct 18, 2012 9:44 AM
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        Not that I can see.
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        Kelvin Lamport @ Elizabeth Sorenson on Oct 18, 2012 11:16 AM
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        Model the finished panel as a multi-body part.
        The outer (folded) part will flatten separately if created as a SM part.
        A config will have to be used to create (or Move) the inner parts (bodies) in their "flattened" positions.
        
        See attached for the basic idea.
        Attachments
        ACM Panel - KL.SLDPRT.zip128.9 KB
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        Elizabeth Sorenson @ Kelvin Lamport on Oct 18, 2012 11:25 AM
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        Kelvin very excited and want to see your ACM panel part BUT...
        
        I have SW version 10 can you save it so I can read with my SW version 10.
        
        Thanks,
        
        Elizabeth
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        Kelvin Lamport @ Elizabeth Sorenson on Oct 18, 2012 10:09 PM
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        Unfortunately not. It would import as a dumb solid and you would not see the necessary features.
        
        Maybe some kind soul with access to SW10 & 12, will recreate a SW10 version for you.
        
        It's actually quite simple;
        Create the formed outer panel as a SM part
        Create the inner (composite) portion as non-merged bodies
        Create the inner aluminum panels as non-merged bodies
        Create a config called say Unfolded
        Select the outer panel body & hit the Flatten tool. The outer body should now be shown flattened & all other bodies should be hidden.
        Recreate the inner bodies on the flanges ... or Show the bodies & use the Move/Copy Bodies tool to re-position them.
        Create an Unfold feature
        Create the inner (composite) portion as non-merged bodies
        Create the inner aluminum panels as non-merged bodies
        Create a Fold feature
        Suppress the Fold Feature
        In the Default config make sure the Fold is Unsuppressed
        
        You should now have a formed & "flattened" (unfolded) config.
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        Elizabeth Sorenson @ Kelvin Lamport on Oct 18, 2012 4:33 PM
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        Mark here is the youtube link:
        http://www.youtube.com/watch?v=vr9PCtpWcQM
        
        under www.psmetalltechnik.ch
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Mark McMullen Oct 18, 2012 1:25 PM
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I see this more as a machine shop part then a sheetmetal part, with that in mind I made a base, 2 long sides and 2 short sides, then
bringing them together in a assembly file and making 2 configurations one for flat and one for bent up viewing to make them look like a
sheetmetal part. I don't have that old of SW so saved in couple formats and 2 jpeg views. The difference between the views is I rotated
the sides on an axis.
Hope it helps.
Attachments
- FLAT NO BEND-01.zip1.1 MB
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- Elizabeth Sorenson @ Mark McMullen on Oct 18, 2012 4:24 PM
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  Mark I am SO excited. You have done exactly what I wish to do!!!! However I can't open your SW files - says "future Version". Darn it. I want to see how you accomplished this feat and if I could look into the SW files you created it would be so much easier. Is it possible that you could save them "down" in another version of SW?
  
  So are you actually using the Sheet Metal tool or are you using configurations to sorta "cheat" SW? Are you simply making 2 different parts? Your reference of making them "look like a sheet metal part" is where I am confused. So are you actually drawing them in the sketch as part of the profile and extruding?
  
  If I could open the SW files I would know this.
  
  Objective: To model part in sheet metal and bend/fold and unfold. With what I want to do:
  
  1- I have 2 different thicknesses of sheet metal after I take the cut extrude ( I created this by taking the cut extrude) - therefore (I think) making the model NOT a sheet metal model therefore it will not bend.
  
  2- Am I creating a problem taking a "cut extrude" within the sheet metal model?
  
  Can I do what I want within the Sheet Metal "world" with the design needs of this part?
  
  Thanks you've been a great help but I wish I could open your files. I feel as if this should be easy for SW Sheet metal. I watched a utube of exactly what I wish to accomplish however it was strictly silent.
  
  Elizabeth
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  - Kelvin Lamport @ Elizabeth Sorenson on Oct 18, 2012 10:15 PM
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    See if these images help. Also re-read my previous post for an edited step by step method.
    Attachments
    Formed ACM Panel - KL.jpg119.0 KB
    Unfolded ACM Panel - KL.jpg125.1 KB
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  - Anna Wood @ Elizabeth Sorenson on Oct 22, 2012 4:58 PM
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    What is the internal bend radius on the form portion of your part? What k-factor/BD?BA do you plan to use for calculating the flat blank?
    
    Cheers,
    
    Anna
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John Wilkes Oct 22, 2012 5:22 PM
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Hi Elizabeth,

You can always just re-draw the part on a different plane (or from a different point of creation), and then add material thicknesess and bend radia as you progress - sometimes this is the easiest way. Don't ever be afraid to throw something in the bin and start again. And if you are using the K-factor, then personally I'd recommend 0.5 for Aluminium.

John
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Mark McMullen Oct 29, 2012 10:02 AM
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After watching the youtube videos and looking at watch Kelvin said in his reply,
I looked at this from another angle, it appears SW needs 1 material thickess
to work with, in your file first sent you have a thickness of .020 from the bottom
of cut grooves so if you model the part thinking sheetmetal material thickness
of .020 first then you can add pretty much anything you like in the unbent areas.
You'll see in the file I sent theirs 3 configurations, each shows how irrelvant the
material thickness OUTSIDE the bend regions is, I was able to find someone
who still was using SW2006 hope this helps.
Attachments
- box-01.zip346.3 KB
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