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How to clean-up sharp corners automatically?

Question asked by Philippe Keirse on Sep 6, 2008
Latest reply on Sep 18, 2008 by Andy Gordon

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If you have a base flange with a corner more than 90° and on each edge of these corner an Edge flange straight right, that gives troubles in the flat-pattern -> both edge flanges stick in each other.
See red arrow in picture of the flat pattern.
This can be solved with a chamfer on each edge flange but it is a gamble to find the correct chamfer to get a perfect corner.

Is there a way in SW to do this automatically, to have a correct corner as much as possible?

Peka.

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Steve Calvert Sep 8, 2008 10:39 AM
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Philippe, try using the 'Miter Flange' feature which will make all the flanges at the same time.

Steve
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- Philippe Keirse @ Steve Calvert on Sep 8, 2008 12:35 PM
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  Steve,
  With "miter flange" the problem keeps the same.
  The problem is in the flat, the material of both bends comes over each other.
  
  I would expect of SW have a command to clean up this automatically, something like "closed corner"
  
  In the meanwhile I figured out to make a perfect corner:
  unfold one adjacent bend,
  cut the material in the corner according to a centerline of the corner of both bend lines,
  fold the unfolded bend,
  and do the same for the other adjacent bend.
  And in the flat-pattern make a corner-trim.
  But this way keeps some time.
  
  Peka.
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  - Steve Calvert @ Philippe Keirse on Sep 10, 2008 4:26 PM
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    Sorry, I haven't gotten back, I just forgot to go back to this forum. You are 100%correct, I went back and tried it and when you have an inside corner, you'll see this. Damn inside corners...
    
    I think you could do as you have suggested with un-folding one or two bends but there has to be a way to do this automatically.
    
    Steve
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    - Dan Dangremond @ Steve Calvert on Sep 10, 2008 7:25 PM
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      Yes, this does seem to be a 'bug' that I hope gets fixed. Your work around 'works' just as long as you realize that the folded result will not be a 'closed corner'. An inside corner can not be folded closed.
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      - Philippe Keirse @ Dan Dangremond on Sep 11, 2008 7:02 AM
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        Dan,
        you rigth,
        the name "closed corner" is not good for the imagine command.
        A better name would be "open inside corner" or something like that.
        
        Pk
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        Michael Duncan @ Philippe Keirse on Sep 11, 2008 8:18 AM
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        Hi Philippe,
        I would always try and only use a cut-out on 1 flange as this reduces the infill pieces required to weld in place to close the flange.
        Michael
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        Steve Calvert @ Michael Duncan on Sep 11, 2008 11:17 AM
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        Dan, were I agree that this should work as expected, I don't think this is a "Bug".
        
        Steve
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        Brian Lindahl @ Steve Calvert on Sep 12, 2008 12:28 PM
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        I modeled up a sample of an inside corner, and a "best" (yes, it is possible to get a tighter corner yet) corner, and what worked is to flatten one of the bends, then trim the corner with a cut that bisects the internal angle of the flat before the flanges were added. Then re-bend the side, and repeat on the other flange. The pattern flattens with no overlapping of the material.
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        Wayne Tiffany @ Brian Lindahl on Sep 12, 2008 12:43 PM
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        Brian,
        
        Obviously you arrived at the same point as Philippe. What do you see in your method that is an advantage over what he did? I would think that one unfold, one feature to whack both flanges at the same time, and one fold would be desirable over 2 of each. I generally do it like he did but I'm curious why you chose to do as you did. Is there something I didn't understand?
        
        Also, just for your learning (maybe), you didn't have to add the plane to put the miter flange sketch on, you could have used the face of the material as the edge was normal to that face. Would just save a bit of time and a feature in the tree.
        
        WT
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        Brian Lindahl @ Wayne Tiffany on Sep 12, 2008 1:44 PM
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        After re-reading what Philippe posted, I think my feature tree is the same as he has described:
        
        In the meanwhile I figured out to make a perfect corner:
        unfold one adjacent bend,
        cut the material in the corner according to a centerline of the corner of both bend lines,
        fold the unfolded bend,
        and do the same for the other adjacent bend.
        And in the flat-pattern make a corner-trim.
        But this way keeps some time.
        
        As for the plane, when I picked the "miter flange" tool, I had no plane, and no sketch, then selected the first edge for the miter flange to be added to. SW adds the sketch plane at the nearest end of that edge (normal to), even if it coincides with an existing plane or face, and opens the sketch on the new plane. Do you create the sketch first, then use the "Miter Flange" button?
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        Wayne Tiffany @ Brian Lindahl on Sep 12, 2008 1:53 PM
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        Yes, I generally do the sketch first, then hit the miter flange button. But,,,, thinking about your method has some merit. I'll have to watch for that next time to see if I can see a benefit either way.
        
        I agree that your method of cutting the corners basically matched his - I didn't read it carefully enough and just looked at the picture. SW for Dummies?? :-)
        
        So, my method must be defined here as it is a bit different. I go ahead and make the flanges, either edge or miter, and then put in an unfold. On that face I put a sketch and cut that whacks both flanges with the one cut. Then fold and go on. In, out, done - no repeat.
        
        WT
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        Andy Gordon @ Wayne Tiffany on Sep 18, 2008 4:36 PM
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        The easiest way I have found is to chamfer the 2 edges by half of the feature angle. In this case it would be 51.151° devided by 2. and to a depth of your flange. Then adjust the depth to achieve the gap you require in the flat. Keeps the edges parallel and allows you to adjust the gap quickly and easily.
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How to clean-up sharp corners automatically?

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