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New to Sheetmetal - How do I close reliefs?

Question asked by Jonathan Gwinn on Jul 1, 2020
Latest reply on Jul 28, 2020 by ömür tokman

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Hey everyone!

I work at a manufacturing company that emphasizes on aluminum fabrication. We've recently purchased a plasma table to cut flat pattern parts on. Currently, to get our flat pattern, we are drawing the parts flat rather than using the sheetmetal tool. I've frankly had issues getting to be a quick, effective solution without large reliefs, or gaps resulting in larger welds and cranky welders.

I've attached a sample "tank" below, this would be made of 0.125" 3003 aluminum. What is the best way to go about flattening this model without odd reliefs or gaps? I need this to have corners about touching (I know they can't touch at all). I know this is possible since we used to cut these with just a band saw.

Also, important to note, we usual manual hand brake to bend these parts currently.

I'm all on board for suggestions and tips. Thanks for your time.

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sample tank.SLDPRT.zip85.7 KB

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Dario Karalic Jul 2, 2020 9:22 AM

Currently, to get our flat pattern, we are drawing the parts flat rather than using the sheetmetal tool. I've frankly had issues getting to be a quick, effective solution without large reliefs, or gaps resulting in larger welds and cranky welders.

I cant open your part because is is a feature version for me but i would recommend drawing parts using sheet metal tools. (after you have your parts in bended condition with correct dimensions , you get flat pattern)

Unfortunately , without seeing your parts , i cant help with that large gaps and reliefs . Maybe someone other will help.

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Steve Labonte Jul 6, 2020 8:22 AM

Jonathan here's a rough sample did one half

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TANK.SLDASM.zip345.4 KB

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Scott Leacox Jul 27, 2020 3:50 PM

Trying to make the corners nominal cuts. To do this with 3D sheet metal you will end up using the following workflow.

Tab, Flanges, unfold, sketch cut corners (nominal dims), refold.

The real problem curve you have in front of you is understanding your equipment better.

What the bend radius of the metal with each tool and for each thickness/hardness of material. You have to find that out to set up works with the correct K and R. (Neutral factor and inside bend radius)

taking a step back. Cad and sheet metal have an interaction the shop does not like. The corner notches are the result of picking a thickness, bend radius, neutral factor, and flange length. not the other way around. If you want nominal corner notches, that will be a separate operation or a dial in of the typical workflow. Look at this as a change to make welding and fit up easier with more accurate corners.

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Elmar Klammer Jul 27, 2020 3:21 PM

Can you attach a step file

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Jim Steinmeyer Jul 27, 2020 4:33 PM

Here is an attempt to do what you are looking for. If you are on SW2020 let's see how this will work for you.

One thing you may not find easily is that when I created the first edge flange I created both sides at the same time and I selected the sketch for each side and edited the sketches to create the angled bottom.

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tank.zip183.4 KB

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Elmar Klammer @ Jim Steinmeyer on Jul 28, 2020 4:45 AM

Not sure about the size of your trough. Having the bends on the vertical edges increases your wasted material after nesting. Looking at the flat pattern I would tend to bend the sidewall along the angled up edge. Makes for a smaller flat layout and less welding.

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Jim Steinmeyer @ Elmar Klammer on Jul 28, 2020 9:51 AM

Elmar,

You are correct. I was hurrying with an additional project and thought this looked interesting. I was also trying to get it so our guys who do not have narrow knife sections would need to bend it. They would be able to bend the bottom and end then use the end of the brake to bring the sides around.

This was more to show the OP how to close the corners.

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ömür tokman @ Elmar Klammer on Jul 28, 2020 10:11 AM

I think, there is a separate piece for the two sides that are logical and then make the welding.

it is hard to bend this part with the press brake.

Maybe marking is done from twist lines and bends manually from markings, but if there are lots of parts, manual will be difficult.

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8 Replies

Dario Karalic Jul 2, 2020 9:22 AM
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Correct Answer
Currently, to get our flat pattern, we are drawing the parts flat rather than using the sheetmetal tool. I've frankly had issues getting to be a quick, effective solution without large reliefs, or gaps resulting in larger welds and cranky welders.
I cant open your part because is is a feature version for me but i would recommend drawing parts using sheet metal tools. (after you have your parts in bended condition with correct dimensions , you get flat pattern)

Unfortunately , without seeing your parts , i cant help with that large gaps and reliefs . Maybe someone other will help.
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Steve Labonte Jul 6, 2020 8:22 AM
Mark Correct
Correct Answer
Jonathan here's a rough sample did one half
Attachments
- TANK.SLDASM.zip345.4 KB
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Actions
Scott Leacox Jul 27, 2020 3:50 PM
Mark Correct
Correct Answer
Trying to make the corners nominal cuts. To do this with 3D sheet metal you will end up using the following workflow.

Tab, Flanges, unfold, sketch cut corners (nominal dims), refold.

The real problem curve you have in front of you is understanding your equipment better.

What the bend radius of the metal with each tool and for each thickness/hardness of material. You have to find that out to set up works with the correct K and R. (Neutral factor and inside bend radius)

taking a step back. Cad and sheet metal have an interaction the shop does not like. The corner notches are the result of picking a thickness, bend radius, neutral factor, and flange length. not the other way around. If you want nominal corner notches, that will be a separate operation or a dial in of the typical workflow. Look at this as a change to make welding and fit up easier with more accurate corners.
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Elmar Klammer Jul 27, 2020 3:21 PM
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Can you attach a step file
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Jim Steinmeyer Jul 27, 2020 4:33 PM
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Here is an attempt to do what you are looking for. If you are on SW2020 let's see how this will work for you.
One thing you may not find easily is that when I created the first edge flange I created both sides at the same time and I selected the sketch for each side and edited the sketches to create the angled bottom.
Attachments
- tank.zip183.4 KB
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- Elmar Klammer @ Jim Steinmeyer on Jul 28, 2020 4:45 AM
  Mark Correct
  Correct Answer
  Not sure about the size of your trough. Having the bends on the vertical edges increases your wasted material after nesting. Looking at the flat pattern I would tend to bend the sidewall along the angled up edge. Makes for a smaller flat layout and less welding.
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  - Jim Steinmeyer @ Elmar Klammer on Jul 28, 2020 9:51 AM
    Mark Correct
    Correct Answer
    Elmar,
    You are correct. I was hurrying with an additional project and thought this looked interesting. I was also trying to get it so our guys who do not have narrow knife sections would need to bend it. They would be able to bend the bottom and end then use the end of the brake to bring the sides around.
    This was more to show the OP how to close the corners.
    Like • Show 1 Like1
    Actions
  - ömür tokman @ Elmar Klammer on Jul 28, 2020 10:11 AM
    Mark Correct
    Correct Answer
    I think, there is a separate piece for the two sides that are logical and then make the welding.
    it is hard to bend this part with the press brake.
    Maybe marking is done from twist lines and bends manually from markings, but if there are lots of parts, manual will be difficult.
    Like • Show 2 Likes2
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New to Sheetmetal - How do I close reliefs?

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