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Edge flange dissapear

Question asked by Priit Junkin on Nov 15, 2016
Latest reply on Nov 16, 2016 by Dennis Bacon

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Hello!

Has anyone seen such problem that edge flange disappears in flat pattern?

I have attached a SW2015 file in which I have a hole in a constant radius sheet metal part and on one edge of that hole is a tongue which is bent to something lika a spring.

When I apply flat pattern, the hole remains nicely where it should be but the bent tongue (spring) disappears.

I tried to make the tongue (spring) in similar way as the base flange 1 in the file is done and combined the parts but it still dissapears in flat view.

Has anyone some idea what is wrong or how could I have the flat tongue (spring) in flat view (automatically not manually )?

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Part1.SLDPRT.zip199.3 KB

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Jim Steinmeyer Nov 15, 2016 11:53 AM
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Priit,
I think the problem stems from the cut being placed in the rolled spring rather than in the flat state. If you go back to where you created the planes, before the cut and unfold the part you can then create the cut and it will be perpendicular to the face of the material. you can then either build the tab or fold and then build the tab. I am in '16 or I would send you a model to show you.
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- Jim Steinmeyer @ Jim Steinmeyer on Nov 15, 2016 12:10 PM
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  correction,
  I have been playing with this and am having problems as well so that may not be the solution.
  Sorry
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John Stoltzfus Nov 16, 2016 7:34 AM
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I would send the part to your VAR, there seems to be an issue with creating an edge flange from a Revolve Cut, or maybe Dennis Bacon can chime in?......
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- Steven Barry @ John Stoltzfus on Nov 16, 2016 2:26 PM
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  John, it does seem like the revolve cut could have something to do with it. Using extrude cuts, I was not even able to select the edge to add an edge flange, miter flange, jog, sketch bend etc.
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Phaneendra Maylavaram Nov 16, 2016 9:11 AM
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because of No radius on the surface of edge flange .solidworks can not generate flatpattern with out deleting them
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- Jim Steinmeyer @ Phaneendra Maylavaram on Nov 16, 2016 9:54 AM
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  There is still a problem here. Using the logic from Phaneeadra, which appears valid, I flattened the spring and created the cut leaving a tab on one side to use for the start of the flange. This looks good. However Solid-doesn't-Works still will not allow me so select an edge on the tab to create another flange. It also will not allow me to create a sketched bend, even when the spring is flat. So we are still without a final solution.
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Priit Junkin Nov 16, 2016 9:52 AM
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Thank you all for trying to find the solution.
The “no radius” part, pointed out by Phaneendra in the part is the offset in the edge flange feature, so it should not be the issue for SW to flatten it. Anyway if I remove the offset, and no flat part remains in the bent tongue – it still disappears in the flat pattern. And if i add offset to the flanges in the end of the part - then they remain in flat pattern and work really well..
At the moment in the real model I have 3 such hooks, and the dimensions are pretty final, so no problem to make the flat pattern manually but if there were some adjustment needed then it would be nicer if there were some way to do such ordinary thing automatically.
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- Phaneendra Maylavaram @ Priit Junkin on Nov 16, 2016 9:59 AM
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  when you try to create edge flange it will be normal to the edge selected.so you will not get radius in your edge flange.
  i think because of that we are not getting flat pattern.
  
  only way i think could be possible is create the big radius using forming tool option after all the internal bends are created.
  i think your approach in designing the part need to be skewed.
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  - Jim Steinmeyer @ Phaneendra Maylavaram on Nov 16, 2016 10:11 AM
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    I think you are correct. I think this might work if the part is created flat initially and then formed afterwards but I don't have time to attempt it at this point.
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Steven Barry Nov 16, 2016 2:11 PM
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So I decided to take a stab at this, and got a little creative about it. I included the rolled portion and tab as part of the Base Flange feature. I used "Boss-Extrude" features to extend the rolled region, and it was surprisingly successful.
Note: I was forced to perform an "Unfold" in order for the flat pattern feature to work.

The problem came when the geometry formed a closed loop within the bend region:

Now, a workaround would be to extend that 3rd boss extrude just a hair away from the other end, so that the loop is technically open. You might have to delete or hide any extraneous lines from your drawing in that case.
I attached my file in case you want to play around with it or see what I did.
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- Part2.zip175.2 KB
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Dennis Bacon Nov 16, 2016 3:21 PM
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Hi Priit,,, I took a slightly different approach on this. First I don't think a swept cut can be trusted for your cut. In theory it should work but all too often it is slightly skewed. I used your geometry and recreated it. I did have to add a 2mm flat in your Base-Flange1 exactly centered on the edge of of a new cutout I made using a cut extrude with normal cut option. I did have to add new flanges. You can see in the attached assembly file (2015) that the flanges on the ends don't exactly match up with yours. I did assume you wanted these centered. Obviously the short flat in the curve for the base flange is a work around but it does work and won't effect your flat pattern.
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- Tongue in Cheek.zip513.3 KB
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Edge flange dissapear

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