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Extruded cut on sheet metal...not following bend. What did I screw up?

Question asked by Jason Munger on Feb 10, 2012
Latest reply on Jan 10, 2014 by Jason Munger

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Hopefully this screen shot will answer any questions I fail to explain properly.

Solidworks 2010

Sheetmetal

I sketched the rectangle that you see when the part was unfolded. I then added the "Extruded Cut" feature. I need this "cut" to be done while it is in the flat, NOT when it is bent. Does that make sense? The rectangle is cut out BEFORE the sheet is bent, to the exact size of the blue sketch. THEN it is bent. The problem I'm having is that the "depth" of the cut is the only portion showinig up on the front face.

I've actually exagerated the size of the blue sketch (changed the dimensions) for demonstration purposes. In reality it is much narrow and does just creep onto the front face, about the same depth as the extrusion so at first we didn't even catch this this was happening.

Wayne Matus Feb 10, 2012 12:35 PM

Correct Answer

It looks to me like the sketch is not before the piece is bent. Add an unfold feature that unfoldes the one bend before your cut extrude. Then add a fold feature after the cut to bend it back.

I looked at your model. Just drag the cut extrude below the unfold feature.

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John Stoltzfus Feb 10, 2012 11:14 AM

Good morning Jason,

Edit the Cut Extrude and look for a check box that says normal cut and check that,

Later,

John

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Jason Munger @ John Stoltzfus on Feb 10, 2012 11:43 AM

It was already checked.

Tried un-checking it...no change.

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John Stoltzfus @ Jason Munger on Feb 10, 2012 12:00 PM

Good afternoon Jason,

Could you upload the part??

Later,

John

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Jason Munger @ John Stoltzfus on Feb 10, 2012 12:03 PM

Here you go...

Thanks!

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HJ-16ga.SLDPRT.zip169.3 KB

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John Stoltzfus @ Jason Munger on Feb 10, 2012 12:22 PM

Good afternoon Jason,

You mentioned above you need to have this cut in the flat not the bent part, I missed that.

If you want to just show the cut in the flat than add a configuration called A or what ever and than unsupress the flat-pattern, than do your cut.

When you go to the bent state it shouldn't show,

Later,

John

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J. Becker @ Jason Munger on Feb 10, 2012 12:24 PM

Did you just want to 'link to the thickness'? and cut the top face. This will then flatten out well. Or are you wanting to bring the cut line down past BaseBend1?

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Jason Munger @ J. Becker on Feb 10, 2012 12:30 PM

The cut needs to be the exact size of the blue rectangle when it is in the flat. Then, we will bend the piece. So to answer your question, the cut line has to come down past BaseBend1.

Once I get this working correctly, I will then need to create several versions with the rectangular sketch at different distances from the stop (to the upper right of the blue sketch). So I can't simply just calculate how far down the front face the cut out will go. I'd like Solidworks to calculate this based on the location of the sketch/cut when in the flat.

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John Stoltzfus @ Jason Munger on Feb 10, 2012 12:34 PM

Good afternoon Jason,

Oh!

Just add a plane to how deep you want the cut to go and then cut extrude up to surface and select the plane, than SW will calculate it for you,

Later,

John

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Bernie Daraz Feb 10, 2012 12:27 PM

Jason,

Let me take a shot here and suggest using the sketch much as you have it in the view shown (folded) and just increase the depth of the extrude up to your depth dimension. Then SW will apply your bend deduction/K factor to the flat and the cutout will be the right size.

Just judging by the scale the depth of cut would be 1". To do that in the flat you would have to figure in your bend deduction, then if you update the part to another material thickness that cutout would not update properly.

One of a few ways, but the way I would do it.

Bernie

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Wayne Matus Feb 10, 2012 12:35 PM

It looks to me like the sketch is not before the piece is bent. Add an unfold feature that unfoldes the one bend before your cut extrude. Then add a fold feature after the cut to bend it back.

I looked at your model. Just drag the cut extrude below the unfold feature.

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Jason Munger @ Wayne Matus on Feb 10, 2012 12:40 PM

Ahh...that's it! Thanks. I must have deleted the fold. I had some "redundant" folds I deleted and I think I screwed up the order of things. That's why I was so confused because I've already made 10-15 of these (similar) parts using the same method and they work fine.

Thanks for EVERYONE'S help!

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Erik Bilello Feb 10, 2012 12:46 PM

Jason,

You need to use the "Unfold" and "Fold" features. I suspect from your screen shot that you are just switching to the flat pattern and back, not the same thing.

Put an Unfold before your cut and then a Fold after.

Erik,

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Jason Munger Jan 10, 2014 3:18 PM

Funny...I needed to this again and since I only use SW 3-4 times a year I forgot how to do it. So I did a google search and found this post. Until I opened it I couldn't believe I found someone with the SAME problem.

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13 Replies

John Stoltzfus Feb 10, 2012 11:14 AM
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Correct Answer
Good morning Jason,

Edit the Cut Extrude and look for a check box that says normal cut and check that,

Later,

John
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- Jason Munger @ John Stoltzfus on Feb 10, 2012 11:43 AM
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  It was already checked.
  
  Tried un-checking it...no change.
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  - John Stoltzfus @ Jason Munger on Feb 10, 2012 12:00 PM
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    Good afternoon Jason,
    
    Could you upload the part??
    
    Later,
    
    John
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    - Jason Munger @ John Stoltzfus on Feb 10, 2012 12:03 PM
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      Here you go...
      
      Thanks!
      Attachments
      HJ-16ga.SLDPRT.zip169.3 KB
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      - John Stoltzfus @ Jason Munger on Feb 10, 2012 12:22 PM
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        Good afternoon Jason,
        
        You mentioned above you need to have this cut in the flat not the bent part, I missed that.
        
        If you want to just show the cut in the flat than add a configuration called A or what ever and than unsupress the flat-pattern, than do your cut.
        
        When you go to the bent state it shouldn't show,
        
        Later,
        
        John
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      - J. Becker @ Jason Munger on Feb 10, 2012 12:24 PM
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        Did you just want to 'link to the thickness'? and cut the top face. This will then flatten out well. Or are you wanting to bring the cut line down past BaseBend1?
        Like • Show 0 Likes0
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        Jason Munger @ J. Becker on Feb 10, 2012 12:30 PM
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        Correct Answer
        The cut needs to be the exact size of the blue rectangle when it is in the flat. Then, we will bend the piece. So to answer your question, the cut line has to come down past BaseBend1.
        
        Once I get this working correctly, I will then need to create several versions with the rectangular sketch at different distances from the stop (to the upper right of the blue sketch). So I can't simply just calculate how far down the front face the cut out will go. I'd like Solidworks to calculate this based on the location of the sketch/cut when in the flat.
        Like • Show 0 Likes0
        Actions
        John Stoltzfus @ Jason Munger on Feb 10, 2012 12:34 PM
        Mark Correct
        Correct Answer
        Good afternoon Jason,
        
        Oh!
        
        Just add a plane to how deep you want the cut to go and then cut extrude up to surface and select the plane, than SW will calculate it for you,
        
        Later,
        
        John
        Like • Show 0 Likes0
        Actions
Bernie Daraz Feb 10, 2012 12:27 PM
Mark Correct
Correct Answer
Jason,

Let me take a shot here and suggest using the sketch much as you have it in the view shown (folded) and just increase the depth of the extrude up to your depth dimension. Then SW will apply your bend deduction/K factor to the flat and the cutout will be the right size.

Just judging by the scale the depth of cut would be 1". To do that in the flat you would have to figure in your bend deduction, then if you update the part to another material thickness that cutout would not update properly.

One of a few ways, but the way I would do it.

Bernie
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Wayne Matus Feb 10, 2012 12:35 PM
Unmark Correct
Correct Answer
It looks to me like the sketch is not before the piece is bent. Add an unfold feature that unfoldes the one bend before your cut extrude. Then add a fold feature after the cut to bend it back.

I looked at your model. Just drag the cut extrude below the unfold feature.
Like • Show 0 Likes0
Actions
- Jason Munger @ Wayne Matus on Feb 10, 2012 12:40 PM
  Mark Correct
  Correct Answer
  Ahh...that's it! Thanks. I must have deleted the fold. I had some "redundant" folds I deleted and I think I screwed up the order of things. That's why I was so confused because I've already made 10-15 of these (similar) parts using the same method and they work fine.
  
  Thanks for EVERYONE'S help!
  Like • Show 0 Likes0
  Actions
Erik Bilello Feb 10, 2012 12:46 PM
Mark Correct
Correct Answer
Jason,

You need to use the "Unfold" and "Fold" features. I suspect from your screen shot that you are just switching to the flat pattern and back, not the same thing.
Put an Unfold before your cut and then a Fold after.

Erik,
Like • Show 0 Likes0
Actions
Jason Munger Jan 10, 2014 3:18 PM
Mark Correct
Correct Answer
Funny...I needed to this again and since I only use SW 3-4 times a year I forgot how to do it. So I did a google search and found this post. Until I opened it I couldn't believe I found someone with the SAME problem.
Like • Show 0 Likes0
Actions

Extruded cut on sheet metal...not following bend. What did I screw up?

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