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I can't bend this drawing in SolidWorks and I don't even know if it is possible?

Question asked by Sarah King on Sep 28, 2015
Latest reply on Oct 1, 2015 by Sarah King

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Hello,

I am new to Solid Works and have been learning it for the past week. I need to figure out if it is possible to bend this sheet metal piece along those grey lines I have placed? I have been messing with it for HOURS!!!!!!!!!! I sent the drawing to the professionals who cut out our parts and he says it is possible to bend along these lines but I just can't make SolidWorks do it! I have watched several tutorials about this but can't seem to figure it out. Thank you for reading this, any help is very much appreciated.

Ron Flaugh Sep 29, 2015 1:30 PM

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This is what I was talking about Sara, in your assembly you show a bottom that connects the parts together. I didn't add the last flange so its 1 short but Im sure you will understand.

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Ingvar Magnusson Sep 28, 2015 12:28 PM
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Did you try "sketched bends"

2014 SOLIDWORKS Help - Sketched Bend PropertyManager
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Sarah King @ Ingvar Magnusson on Sep 28, 2015 1:02 PM
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Ingvar,

Thank you for your response. I have tried this tool and I just tried following the directions in the link you gave me. When I choose the sketchbend tool and error message pops up that says, "Invalid Sketch. The Sketch must have disjoint lines. So now I will research what that means lol....Do you know what it means?
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Ingvar Magnusson @ Sarah King on Sep 28, 2015 1:15 PM
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I did not open up your image before I answered, only saw the half of it. If it where only half of it, "sketched bends" would be the tool for you but we need some workaround here.
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Charles Winter @ Ingvar Magnusson on Sep 28, 2015 1:24 PM
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Sarah,
You can use sketched bend but you have to use it twice, once for each line, can't do both bends with one.
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Dennis Bacon @ Ingvar Magnusson on Sep 28, 2015 1:25 PM
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I did the same and thought your suggestion to use sketch bends was the way to go. Certainly that will not work on this part. As a matter of fact I don't think anything will. I believe that only by modeling (non sheet metal) in the formed state is a valid solution here. There would be a bunch of calculations required to do this.
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Dennis Bacon @ Charles Winter on Sep 28, 2015 1:29 PM
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Charles... did you click on the image to view its entire? It is a window. No openings around the outside.
I edited this.
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Charles Winter @ Dennis Bacon on Sep 28, 2015 1:34 PM
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No, I only saw half of it too.
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Charles Winter @ Dennis Bacon on Sep 28, 2015 1:49 PM
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Possible to model in sheet metal, but you can't unfold it and probably can't make it, maybe with thin sheet metal bent by hand or so kind of forming tool.
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- Part3.SLDPRT.zip184.6 KB
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Dennis Bacon @ Charles Winter on Sep 28, 2015 2:12 PM
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Interesting. I learned (or relearned) something from your file. Thank you. I'm wondering if the bends are supposed to be just creases. Maybe 1deg or so on thin (flexible-springy) material that could be done on a brake. I think we all assumed 90deg.
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Charles Winter @ Dennis Bacon on Sep 28, 2015 2:18 PM
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You may be able to use cross break if they are.
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Sarah King Sep 28, 2015 2:31 PM
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Yes it is supposed to be 90 degree 1/2" bend. I have moved on at the moment. I have some other sketches that need bending too and I am about to get to them to see if the sketch bend tool works on them. I am not an engineer or anything but was pretty certain this part could not be bent....thank you everyone for you input
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William Weltman Sep 28, 2015 2:57 PM
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Best way that I've found is to create the finished part. You will have to create reference geometry to make sketching planes to create features. Extrude them into each other then blend the surfaces with fillets inside and out. The OD fillet radius will have to match the ID fillet radius plus the material thickness.

When you are happy with the finished part then go to Insert > Sheet Metal > Bends then check your bend id, adjust to match the part, pick a flat face for reference then pick ok.

Solidworks creates a new configuration called Flat Pattern that will be suppressed. If you un-suppress it, you will see the developed sheet metal. It will also provide bend centerlines that can be referenced in a drawing if needed.

Now that I see your complete part, you'll find what you want to do isn't possible. You will be stretching, distorting metal somewhere since your bend axes do not align.

Best way to think of using sheet metal is duplicating what you can do with a press brake. Other stamping operations will need other techniques.
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Sarah King @ Charles Winter on Sep 28, 2015 2:55 PM
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WOW! How did you even draw it that fast???
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Sarah King @ William Weltman on Sep 28, 2015 2:59 PM
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So basically what you are saying is do all the steps in reverse?
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William Weltman Sep 28, 2015 3:06 PM
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Pretty much, create the finished part then let Solidworks figure out the pattern. This part would be easier to do as a 2 pc assembly.

It might even be better to fabricate it that way as well.
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Dennis Bacon @ William Weltman on Sep 28, 2015 3:35 PM
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You are correct William. The axis do not align and the material would have to stretch. I just did this in paper when it dawned on me. The part would potato chip something fierce. Looks like 4 maybe 2 pcs if it is developed correctly.
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Charles Winter @ Dennis Bacon on Sep 28, 2015 3:47 PM
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You can actually make this as one part with a weld, see attached.
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- Part3.SLDPRT.zip208.3 KB
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Aaron Godwin @ Charles Winter on Sep 28, 2015 4:12 PM
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That's what I was thinking.
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Dennis Bacon @ Charles Winter on Sep 28, 2015 4:36 PM
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Agree Charles and I did that with your first file. Of course when I flattened it, it sprung open (non rectangle). I was thinking that the part already exists rectangular as shown in Sarah's pic. If that is not the case this is the way to go. Nice...
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Chris Shaw Sep 28, 2015 7:11 PM
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Hi Sarah,
This can be done but would need an extra couple of folds. I think the part would also not really be what you are imagining. Please see attached.
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- sarah king.SLDPRT.zip207.7 KB
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Ron Flaugh Sep 29, 2015 3:51 AM
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Sara, This is a limitation of SolidWorks because of the stress / stain that world need to be calculated to unfold, if there is a further need this model can be unfolded in a Gold Partner addin called 3DQPress.

@Chris Shaws part works because of the slot that separates the end of the model.
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Darryl Wakefield Sep 29, 2015 5:22 AM
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This part can't be bent in Solidworks because this part can't be bent. Even if you model a finished form, it will not convert to a Sheet metal feature. I can't visualize the finished part, but you might try using lofting to simulate the formed part. But it will have to be draw formed or special tooling used to actually fabricate the part.
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Dan Taschler Sep 29, 2015 9:15 AM
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The only answer possible is 42!!!

In all seriousness, the bends you are implying are physically impossible. If you printed your flat pattern to paper and attempted the bend, the paper would tear; and so would your sheet metal! We've discussed this among the engineers here, and are wondering if you are looking for a finished part with the two triangular sections parallel to each other, with the smaller sections holding them together at a fixed distance. If that is the case, the smaller sections should be rectangular rather than trapezoidal as drawn in the original part. If this is the case, then the flat pattern would not connect to itself, requiring a weld to finish the part.

Hope this helps!
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Sarah King @ Dan Taschler on Sep 29, 2015 11:15 AM
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Dan,

I think you are right. originally drew this piece in multiple parts like this:

Then my boss was wondering if we could bend it? I think I will just put the welds on there.
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Ron Flaugh @ Sarah King on Sep 29, 2015 11:23 AM
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Sara; That piece can be bent, attach this model and I can show you how. Or at least it will take you down to 1 weld on 2 tabs.
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I can't bend this drawing in SolidWorks and I don't even know if it is possible?

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