Hello,
I am trying to create a flat pattern for a square to round sheet metal part. I am trying to build a universal design with criteria which will calculate an accurate flat pattern. So far I have a sketch with many sketch relations. The problem I am encountering is when I change a value determining the overall dimensions of the part that the sketch becomes overdefined. I will include my part drawing for references. If I open it up and change the box dimensions from 6inx6in straight to 16inx16in the corresponding flat pattern will rebuild weird. But, if I change the dimensions from 6x6, to 11x11, then to 16x16 it rebuilds fine. I know what Solidworks is doing here and have countered most of the issues regarding that rebuild error.
My real error is in the 3D sketch becoming overdefined when I know it shouldn't. For example: as soon as I try to build the box to 18x18 the sketch becomes overdefined. Although, if I first change the diameter of the round and then set my box dimensions, then return my round diameter to the same number the error does not occur. Hence by using a workaround technique I can obtain the same final dimensions without an overdefined sketch. I'm curious if anybody knows what might be going wrong here and how I might fix it (and avoid this problem in the future). I have already tried to force complete rebuilds. I also did a sketch diagnosis and even when I do nothing sometimes the sketch becomes defined. I did the flat pattern in a 3D sketch because 2D sketch was not easily translating the equal length relation from my other 3D sketch.
Sorry, but I'm not sure what you are really trying to accomplish with the part you uploaded. It seems way too complicated.
Take a look at the Rectangular 2 Round example in Design Library > Parts > Sheet Metal > Lofted Bends. It has multiple configs and no apparent problems. You may be able to adapt it to your needs.