I frequently work with sheetmetal parts that have a large bend radius, but only a small angle of arc. An example would be a 1/2 inch metal plate with a 450 inch inside radius and a 5 degree arc. When I model it as a revolved feature I can flatten it, but SolidWorks sometimes alters the edges of the part. When I try to create the bend from the flat, I keep getting a "This radius is too large" error message. Any ideas on how to do this?
Here's what I was trying to get you to try. The errors you see are because I didn't fix the dangling dimensions - I wanted to leave them visible for you as I didn't know what you wanted to reference.
The point here being that if you start the part with an open sketch and make the first feature the base flange, it seems to work pretty nicely.
WT