So i have here a part that i want to flatten. I go into the sheet metal parameters so i can change the bend radius from .080 to .032(which is what we use at our brakes) and the over all dimension changes from 96mm (3.780in) to 93.624mm (3.686in). Any reason as to why my overall changes so drastically? the flanges dont change, the only thing that changes is my overall.
I downloaded your part and with the default dimensions I get a flat length 10.318 in. When I change the bend radius to 0.032, the flat length changes to 10.318; a 0.053 change in length. While is is true that the length of the flange does not change, the distance between flanges changes (by 2x the difference in the radius) due to you using the bend outside flange position option; if you want the distance between flanges to remain the same, you need to change the flange position option to material inside or material outside. Is the model you uploaded the same model you took your dimensions from; the 6.5 difference in flat length is not right.