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Edge Flange Transition from 90 Deg to 45 Deg

Question asked by Fred Vraj on Nov 24, 2014
Latest reply on Mar 4, 2015 by Fred Vraj

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Good day from DownUnder:-)

I am designing new mudguard for new utes and but I have come across to one edge that needs to have a smooth transition from 90 deg down to 45 deg.

( see photos bellow ) and MY PART SW ATTACHED.

I have done it using Surface Loft Feature ( pretty dodgy :but I need to get this done different way so it will also be a part of Flat Pattern.

At this stage, the mudguard looks ok but its only cosmetic. The Flat-Pattern is all wrong.

I am not sure how I could possibly do it. Can you help guys? Thank you so much :-)

Bryan Kohn Jan 15, 2015 1:28 PM

Correct Answer

Hi Fred, I don't think there is any way to make this a unfoldable sheet metal feature. I did find way to make the model look real good using a solid loft. At least it is satisfying to look at. You'll have to suppress the features for the drawing though and go in and manually clean it up as best as you can. Don't underestimate the power of a well written note to explain on the drawing.

First make the part as you and others already started.

Second go in and trim away the bit of metal so as to expose the 90 and 45 degree bends completely.

Then open up new sketches on each of the four faces and convert them to sketches. Make a loft from the two long straight faces using "Normal to Face" Start and End constraints.

For the final Loft use the edges of the curvy loft and the base flange as guide curves to keep everything in line and looking good.

Ah lookin' good!

See the reply in context

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MUDGUARD.SLDPRT.zip214.6 KB

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Frank Ruepp

Dec 4, 2014 12:18 PM

Hi Fred,

I cannot imagine a solution for this case. However you can model and unfold it. I would actually attach two flanges to the base flange. One with 90° the other one with 45°. For the lofted portion I would simply leave some space so that you can add the cosmetic portion as well.

With those two flanges you can unfold the part but you will have to add the missing "loft material" manually. You will get the length of the 45° flange and the length of the 90° flange (just in case they are not the same length) and then you will have to model the missing portion in between.

For the bent state I would add a cosmetic surface loft as it does not impact the flat pattern but looks nice (but you will likely have to display the surface on the drawing manually as it is usually turned off by default.

With it, the part should look as expected in the folded and unfolded view.

Thanks

Frank

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Fred Vraj @ Frank Ruepp on Jan 12, 2015 6:06 PM

Hi Frank,

I am answering a bit late but I have been away and then very busy. My apologies.

Thank you for you input. I will try everything ASAP and see how it goes.

I will be in touch. Again , thank you for sharing your thoughts.

Fred

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Roger Reed Dec 4, 2014 4:23 PM

Draw two sketches with equal amounts of lines in , fillet the lines and then use lofted sheet metal feature

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Frank Ruepp

@ Roger Reed on Dec 5, 2014 3:12 AM

Hi Roger,

yes, you are right, you can model and unfold the transition but from my understanding this is only one part of the required solution as the sheet metal component continues beyond the transition. There is a linear portion with a 45° angle and there is also the 90° portion as well. Yes, I can model the base flange with the 45° and the 90° flange attached to it and I can unfold those. As you showed, you can model and unfold the transition between those. But to my knowledge you cannot have both and unfold them. This is what I was referring to when I wrote "I cannot imagine a solution for this case".

Thanks

Frank

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Fred Vraj @ Roger Reed on Jan 12, 2015 6:09 PM

Hi Roger,

again, sorry about my late answer.

thank you for your help....

I will test everything as soon as I can and post my results....

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Paul Cullen Dec 6, 2014 5:33 PM

Hi Fred

As you have the part modeled with a loft feature you can use this for your drawing showing the finished part.

I would create a new configuration where I would just have a continious fold of either 45 or 90 deg this will be good enough for your flat pattern as the material will deform when you fold it to give you the transition. If the flange lengths are different for the 45 deg and 90 deg section I would just model the flange with a step in it where the transition will be but it looks to me like the flange length is the same for both portions of the bend so it would not need a step in the flange.

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Fred Vraj @ Paul Cullen on Jan 12, 2015 6:11 PM

Good day Paul,

I have just answered to the other guys that I appreciated theirs help.

I have been away so I could not answer to anybody.

Thank you for your input and let me try it...:-)

Fred

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Bryan Kohn Jan 15, 2015 1:28 PM

First make the part as you and others already started.

Second go in and trim away the bit of metal so as to expose the 90 and 45 degree bends completely.

Then open up new sketches on each of the four faces and convert them to sketches. Make a loft from the two long straight faces using "Normal to Face" Start and End constraints.

For the final Loft use the edges of the curvy loft and the base flange as guide curves to keep everything in line and looking good.

Ah lookin' good!

Attachments

45to90 Bend.SLDPRT.zip153.4 KB

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Fred Vraj @ Bryan Kohn on Mar 4, 2015 7:09 AM

Hi Bryan,

I did try all the options and I must say that yours is probably the one that suits me most. Looks perfect and note on the drawing should do the job.

It is so shame that State of the Art Software worth of so much can not do this. This transition of 2 bend angles is very common in my field.

Would be so good to have it.

Thank you again and thanks to the other guys so much for their input. I do appreciate it!!!!!

Actions

9 Replies

Frank Ruepp Dec 4, 2014 12:18 PM
Mark Correct
Correct Answer
Hi Fred,

I cannot imagine a solution for this case. However you can model and unfold it. I would actually attach two flanges to the base flange. One with 90° the other one with 45°. For the lofted portion I would simply leave some space so that you can add the cosmetic portion as well.
With those two flanges you can unfold the part but you will have to add the missing "loft material" manually. You will get the length of the 45° flange and the length of the 90° flange (just in case they are not the same length) and then you will have to model the missing portion in between.
For the bent state I would add a cosmetic surface loft as it does not impact the flat pattern but looks nice (but you will likely have to display the surface on the drawing manually as it is usually turned off by default.
With it, the part should look as expected in the folded and unfolded view.

Thanks
Frank
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- Fred Vraj @ Frank Ruepp on Jan 12, 2015 6:06 PM
  Mark Correct
  Correct Answer
  Hi Frank,
  I am answering a bit late but I have been away and then very busy. My apologies.
  Thank you for you input. I will try everything ASAP and see how it goes.
  I will be in touch. Again , thank you for sharing your thoughts.
  Fred
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Roger Reed Dec 4, 2014 4:23 PM
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Correct Answer

Draw two sketches with equal amounts of lines in , fillet the lines and then use lofted sheet metal feature
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- Frank Ruepp @ Roger Reed on Dec 5, 2014 3:12 AM
  Mark Correct
  Correct Answer
  Hi Roger,
  
  yes, you are right, you can model and unfold the transition but from my understanding this is only one part of the required solution as the sheet metal component continues beyond the transition. There is a linear portion with a 45° angle and there is also the 90° portion as well. Yes, I can model the base flange with the 45° and the 90° flange attached to it and I can unfold those. As you showed, you can model and unfold the transition between those. But to my knowledge you cannot have both and unfold them. This is what I was referring to when I wrote "I cannot imagine a solution for this case".
  
  Thanks
  Frank
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- Fred Vraj @ Roger Reed on Jan 12, 2015 6:09 PM
  Mark Correct
  Correct Answer
  Hi Roger,
  again, sorry about my late answer.
  thank you for your help....
  I will test everything as soon as I can and post my results....
  Like • Show 0 Likes0
  Actions
Paul Cullen Dec 6, 2014 5:33 PM
Mark Correct
Correct Answer
Hi Fred

As you have the part modeled with a loft feature you can use this for your drawing showing the finished part.

I would create a new configuration where I would just have a continious fold of either 45 or 90 deg this will be good enough for your flat pattern as the material will deform when you fold it to give you the transition. If the flange lengths are different for the 45 deg and 90 deg section I would just model the flange with a step in it where the transition will be but it looks to me like the flange length is the same for both portions of the bend so it would not need a step in the flange.
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- Fred Vraj @ Paul Cullen on Jan 12, 2015 6:11 PM
  Mark Correct
  Correct Answer
  Good day Paul,
  I have just answered to the other guys that I appreciated theirs help.
  I have been away so I could not answer to anybody.
  Thank you for your input and let me try it...:-)
  Fred
  Like • Show 0 Likes0
  Actions
Bryan Kohn Jan 15, 2015 1:28 PM
Unmark Correct
Correct Answer
Hi Fred, I don't think there is any way to make this a unfoldable sheet metal feature. I did find way to make the model look real good using a solid loft. At least it is satisfying to look at. You'll have to suppress the features for the drawing though and go in and manually clean it up as best as you can. Don't underestimate the power of a well written note to explain on the drawing.

First make the part as you and others already started.

Second go in and trim away the bit of metal so as to expose the 90 and 45 degree bends completely.

Then open up new sketches on each of the four faces and convert them to sketches. Make a loft from the two long straight faces using "Normal to Face" Start and End constraints.

For the final Loft use the edges of the curvy loft and the base flange as guide curves to keep everything in line and looking good.
Ah lookin' good!
Attachments
- 45to90 Bend.SLDPRT.zip153.4 KB
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- Fred Vraj @ Bryan Kohn on Mar 4, 2015 7:09 AM
  Mark Correct
  Correct Answer
  Hi Bryan,
  I did try all the options and I must say that yours is probably the one that suits me most. Looks perfect and note on the drawing should do the job.
  It is so shame that State of the Art Software worth of so much can not do this. This transition of 2 bend angles is very common in my field.
  Would be so good to have it.
  Thank you again and thanks to the other guys so much for their input. I do appreciate it!!!!!
  Like • Show 0 Likes0
  Actions

Edge Flange Transition from 90 Deg to 45 Deg

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