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Anyone interested in a good challenge?

Question asked by Matt Conlin on Oct 6, 2008
Latest reply on Oct 8, 2008 by Anna Wood

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I've been working on this part for a few days now, and I can't figure it out. I'm starting with a flat sheet metal part, adding sketched bends, using forming tools, different combinations of bends and form tools, and I can't make it work. I get so close and then SW decides it doesn't like my design. I know I'm not asking the impossible, because the real part is sitting on my desk. The manufacturer builds it with real life forming tools.

So if anyone wants a challenge, here is the part for you to enjoy. I modeled it pretty close using just the basic commands.

for some reason, I can't attach the actual model, but here is a jpg.

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stamped pin solid.jpg70.1 KB

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Matt Conlin Oct 6, 2008 10:39 PM
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One of the things that is giving me trouble is the thickness of the sheet metal and the minimum radius of curvature of the form tool.

Everyone knows that the thickness of the sheet metal must be less than the minimum radius of curvature of the form tool. For some reason SW is getting confused about this.

The sheet metal thickness is .040
The minimum radius of curvature for the form tool is .050

I've tried adjusting both values a little more both ways to try and make it work.
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- Matt Conlin @ Matt Conlin on Oct 6, 2008 10:59 PM
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  My VAR is gonna get an earful tomorrow. I hope they prove me wrong so I can get on with my work.
  
  GRRRRRR
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Kelvin Lamport Oct 6, 2008 10:39 PM
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You have to compress (zip) SW part files to be able to upload them.

Just as SW can create parts which are impossible to create in the real world, parts that exist in the real world aren't necessarily create-able in SW.

If the real part involves actual plastic deformation (stretching and thinning of material) SW will not be able to reproduce it as a flatten-able sheet metal part.
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- Matt Conlin @ Kelvin Lamport on Oct 6, 2008 11:07 PM
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  Kelvin Lamport wrote:
  
  You have to compress (zip) SW part files to be able to upload them.
  
  Just as SW can create parts which are impossible to create in the real world, parts that exist in the real world aren't necessarily create-able in SW.
  
  If the real part involves actual plastic deformation (stretching and thinning of material) SW will not be able to reproduce it as a flatten-able sheet metal part.
  
  Thanks. I'll zip the files.
  
  I know that solidworks can't do some things. There is definitely some stretching going on with this part. I really don't care if this part is flattenable. But it does need to look like the real thing.
  
  But why does SW give me some bogus excuse about why it can't do a certain funciton?
  
  Attached are the EXTREMELY simplified versions of my parts.
  Attachments
  - pin tool 2.zip44.9 KB
  - stamped pin blank.zip49.5 KB
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  - Anna Wood @ Matt Conlin on Oct 7, 2008 5:47 AM
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    Can you post a picture or two of the real part sitting on your desk?
    
    This may be a part that will work out better if you use surfaces and thicken (model the inside of material). Hard to tell without seeing the real part.
    
    I had a part not to long ago, that if you used regular sheet metal tools and standard SW features you would not get a realistic looking part. Using surfaces and thickening gave a more realistic model.
    
    Couldn't flatten the part when I was done. That was not a big deal though. Just used some old school manual drafting techniques to get a pretty good approximation of the blank we needed.
    
    I had to dig into my automotive product design experience and use some of the skills I learned back in the day when all we had was a wireframe and surface modeler.
    
    Cheers,
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    - Dan Riffell @ Anna Wood on Oct 7, 2008 12:30 PM
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      If you don't care if the part is flattenable, then why are you fighting to make it a sheet metal part?
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      - Matt Conlin @ Dan Riffell on Oct 7, 2008 1:31 PM
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        I found a camera. Attached are pics of the real part.
        
        Thanks for the suggestion about using surfaces. I'm just weird and I have to model things the exact way they will be manufactured. Maybe it's OCD. It drives my boss crazy. I might have to try something different this time. I guess I can just draw a solid model, or use surfaces to make a drawing for this part. The thing that is bothering me is why SW is not letting me use the form tool because of the thickness problem that it thinks it sees, when clearly, the thicknesses should be compatible.
        
        The weird thing about this part is the first time I used the form tool, it worked. It worked wonderfully. I can't remember why now, but I had to start over. Now I can't get it to work.
        
        Attachments
        top2.JPG752.9 KB
        bottom1.JPG723.7 KB
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        Anna Wood @ Matt Conlin on Oct 7, 2008 2:34 PM
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        Matt,
        
        Thanks for the pictures. Looks like there are a few ways to go about modeling this part. Always a fun challenge to model some different types of parts.
        
        I will give it a go next week when I get back to the shop. I am actually on vacation this week. A busy, working vacation as scorekeeper for a big model airplane contest we hold down in Tucson, AZ. So in about an hour when I hit the road for Tucson I will not have much time for my other hobby, SolidWorks.
        
        Cheers,
        
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        Matt Conlin @ Anna Wood on Oct 7, 2008 2:46 PM
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        Anna Wood wrote:
        
        I am actually on vacation this week.
        
        Cheers,
        
        What are you doing on here while you are on vacation? Put the computer down, and step away slowly.
        
        Go relax and have some fun watching model airplanes.
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        Anna Wood @ Matt Conlin on Oct 7, 2008 3:45 PM
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        Matt Conlin wrote:
        
        What are you doing on here while you are on vacation? Put the computer down, and step away slowly.
        
        Go relax and have some fun watching model airplanes.
        
        Matt,
        
        I am the scorekeeper for the contest, I wish I could relax. This is a working vacation. Heck I will be at the model field at 6-7 each morning. During a normal work week I don't even roll out of bed until 8 am.... :-) That said the contest is a hoot with some great model airplane flying to watch in between entering scores.
        
        Cheers,
        
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  - Kenneth Barrentine @ Matt Conlin on Oct 7, 2008 3:01 PM
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    see attachment.
    
    blank size was changed to a .04" cube so that no second operation was required (trimming blank).
    one of the end faces where tube transitions to flanges set for removal.
    did not have a "slit" and the "tube end" being removed.
    
    hth
    Attachments
    pin_tool.zip212.9 KB
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    - Matt Conlin @ Kenneth Barrentine on Oct 7, 2008 4:19 PM
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      Kenneth Barrentine wrote:
      
      see attachment.
      
      blank size was changed to a .04" cube so that no second operation was required (trimming blank).
      
      one of the end faces where tube transitions to flanges set for removal.
      
      did not have a "slit" and the "tube end" being removed.
      
      hth
      
      You are awesome. I never thought of using a much smaller blank size. I think I can get it figured out now.
      
      I'll post again when I get the finished product done.
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      - Matt Conlin @ Matt Conlin on Oct 7, 2008 8:02 PM
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        WOO HOO!!!!
        
        I finally got it to work. I really don't know what I differently. I used the form tool, and a .0478" cube for the blank.
        
        Attachments
        stamped pin.jpg131.2 KB
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        Anna Wood @ Matt Conlin on Oct 8, 2008 4:08 AM
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        Matt,
        
        That looks sweet..... It is fun to get a challenging model to work. :-)
        
        Cheers,
        
        Anna
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