I am looking for some opinions as to whether it makes sense to approach my part design using the SW sheet metal module (which I am not very familiar with). In a nut shell, we first cut out multiple layers of various materials (polymer-based) in a flat condition. Next we assemble them in a cylindrical manner at which time we bond them together (see attached). The layers often consist of various sizes, thicknesses and even different shapes. We also create various holes or cutouts in the layers as well. The attached model gives a simplified version of what I am describing. I created this as a multi-body part for simplicity.
What I am looking to accomplish:
1. I need to be able to show the finished formed part as shown in the attached file.
2. I need to be able to flatten out the individual components in order to create flat DXF files. I think that 2010 has a direct “send to DXF” option.
3. We custom build these parts and therefore have an infinite number of variations in terms of diameter, lengths, cutouts, layer combinations, etc. This drives the need to make changes as easy as we can. For example, if I need to change a hole location or size I want to change it once and have it reflected in all the components.
4. Ideally I would like to be able to show some type of exploded view, preferably with the components in the flattened state. The purpose of this would be to give someone that assembles the components a clear picture of the various layers and how they go together.
Am I barking up the right tree in terms of using SW sheet metal? I saw that 2010 will have the multi-body function. Would this be the direction to head? Any thoughts are greatly appreciated regarding how to approach this and whether I should use the sheet metal tools. Providing some sort of example file would be even better since I am new to sheet metal. Thanks for your time.
Dear Allen Boldt,
Your problem can be solved in a number of ways.
1. Use VBA or VB.net or C++ and write a code block.
2. Create a model capturing all your variants and drive it using a simple set of rules created using Drive Works. You can build a neat
interface as well without the need for coding.
3. Create a design table and update the table either inside or outside of Solidworks and update your part and assembly.
Since you need to flatten the geometry created it is essential to use Sheetmetal . There is no other option.
Sheetmetal multi body capability can be exploited if you want to do everything in a single part file. Its easily doable.
You can then link up the sketches to drive the individual cylindrical strips nested to form the assembly.
Which ever technique you use remember that since the geometry in curved you have to flatten it first before you add in the
hole. This is essential to ensure that the hole remains a circular hole in your flat pattern geometry and not an ellipse or an interpolated approximation .Solidworks will spline it. If you water jet cut your parts its possible that the CAM software will complain.
Or the hole thats cut is unacceptable.
The method in my solution consists of a single cylinder and multiple configurations. The link between the various parts is
in the design table. They all fit perfectly.
You have an animated exploded view in the flattened state and cylindrical state as well.
This is a simple elegant approach and exploits the strengths of Solidworks basic software structure.
All your manipulations are done in the design table no messing with the model.
This approach covers all your needs. Flat pattern . Hole in one go . Exploded Views for the shop . Animated Views for
more clarity.
Infinite variations in length angular notching and thicknesses are possible in a flash.
Tweak and Enjoy.
Pankaj Bir
Attachments
Pankaj,
I finally got SW 2010 installed to look at the example files you provided. I was able to open the files but have one other issue. My company does not provide us with Excel 2007 therefore I can't open the Design table. Could I trouble you to re-post the same files with an Excel 2003 Design table, if you can do this without too much trouble. I would greatly appreciate this.
Allen