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How To? any advice for jog bends

Question asked by Rodney Hall on Apr 24, 2007
Latest reply on Apr 26, 2007 by Rodney Hall

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I am trying to create a square tube in sheetmetal. I can butt the ends together on one face ok, but would prefer to use a jog and overlap the ends (inside face to outside face) when I edit flange lengths to overlap condition the jog pukes with an error? I am new to sheetmetal so not sure what gives? see attached file or .jpg

Rodney Hall Apr 24, 2007 3:32 PM

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Jeff,
Works fine, but my observation is SWX doesn't allow the jog to be "contacting" the flange that it overlaps. Is this expected? Does the same rule apply for overlapping flange in box corners, etc? Otherwise, I can do what I want by creating this "Fake" gap between the inside of the jog and the face of the flange under it.

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Tube Jog Overlap.JPG29.1 KB

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Jeff Mirisola Apr 24, 2007 12:21 PM
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You need to make sure that the jog distance is greater than the thickness of the material. Are you creating the jog in the sketch or as a separate feature?
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- Rodney Hall @ Jeff Mirisola on Apr 24, 2007 1:29 PM
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  Tried jog in sketch and as separate feature. both give me the same error when overlap occurs. I verified that inside to outside dim => zero for jog.
  The end result here is to get a flat pattern of this detail to create a label that wraps around a square shaft and overlaps itself to promote adhesion without risk of snagging edge of the label. Do you have a sample part you could attach for me to see how overlap jog is done properly? TIA
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  - Devon Sowell @ Rodney Hall on Apr 24, 2007 2:01 PM
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    Hello Rodney-
    
    See the attached .jpg
    
    Is this deselected?
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    Self-intersection.JPG71.6 KB
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    - Rodney Hall @ Devon Sowell on Apr 24, 2007 3:54 PM
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      Devon,
      Selecting or deselecting this option seems to have no effect on the jog in question?
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      - Devon Sowell @ Rodney Hall on Apr 24, 2007 4:18 PM
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        Rodeny-
        
        Actually, I meant to say selected, sorry. This worked for me a few weeks ago when I was creating a bend >90 deg., sort of like the bend in a question mark. (?)
        
        Sorry to hear it has no effect on your model.
        
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  - Jeff Mirisola @ Rodney Hall on Apr 24, 2007 2:05 PM
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    Let me know if this works...
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    - Rodney Hall @ Jeff Mirisola on Apr 24, 2007 3:32 PM
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      Jeff,
      Works fine, but my observation is SWX doesn't allow the jog to be "contacting" the flange that it overlaps. Is this expected? Does the same rule apply for overlapping flange in box corners, etc? Otherwise, I can do what I want by creating this "Fake" gap between the inside of the jog and the face of the flange under it.
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Drew H Apr 24, 2007 7:26 PM
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Hi Rodney,
Is this what you're looking for?
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- Jog.zip127.5 KB
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Gerald Davis Apr 25, 2007 12:52 PM
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Rodney Hall wrote:

I am trying to create a square tube in sheetmetal...

Rodney -
It looks like Drew already posted a pretty good suggestion for this (changing the bend angle of the jog). My solution is a slight variation on the theme (I change both the bend radius and the bend angle on the jog in order to get the desired jog offset).

You've probably already discovered that sheet metal faces don't like to touch each other (SW needs to discriminate between adjacent faces in order to flatten the part). That's why my jog offset is > than material thickness by .001".

If you edit the Base-Flange1 (1.500 dim in sketch1) you can position the jog on the side wall. The amount of Jog1 overlap is controlled by the .500 dim in Sketch5.

In my experience as a brake operator, jog tooling will coin the tooling's inside radius into the sheet metal (a very small inside radius when compared to air bending). The bend angle of a jog is seldom 90° - it is usually less than that. So, my contention is that this jog "trick" is fairly realistic.

You may have to talk with the brake operator to figure out what to twiddle with in order to get the perfect flat layout.

.005"-.010" for the inside jog radius is probably a reasonable guess, but check the tooling. As Drew suggested, the bend angle is your primary adjustment in SW to meet the minimum target for the jog offset. I've had pretty good success using the same k-factor as with the rest of the bends (in this case the part is 18 gauge cold roll with a K-Factor of .478), but you may end up needing to overide the default K or BD for the jog in order to get the right flat layout.
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- JogTube.zip183.0 KB
- jogtube.jpg19.0 KB
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- Rodney Hall @ Gerald Davis on Apr 25, 2007 11:28 PM
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  Hey Gerald!
  
  My life path has taken me back down the sheetmetal road. I took up an offer with another employer, so now I will learn to create sheet metal in solidworks. I spent 12 years doing punch and brake and cnc metal work early in my career. Unix based 3D Wireframe CAM and G-Code Post processing. So I am very fluent in fabrication and prototype of sheetmetal. I used to just make a test jog in a scrap metal strip to calculate "real" material shrinkage or stretch. Used to read the "fabricator" magazine all the time. This jog application I discussed here was to create a vinyl label to wrap around a square shaft and be able to create an accurate layout for the label shop. I will be learning more about SWX sheetmetal functions. I am sure I will post here often... perhaps I will get to be good like you, Matt, Jeff and Devon. BTW, check out my other sheet metal project! see pic.
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  - My 1967 Chevelle.JPG964.5 KB
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  - Gerald Davis @ Rodney Hall on Apr 26, 2007 1:56 AM
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    Rodney Hall wrote:
    
    ...My life path has taken me back down the sheetmetal road...
    
    Tin benders like us would think of it as back up the road.
    
    That's a very lovely set of fenders! One could get lost in the paint job. I hope there's not a lot of bondo under there.
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  - Devon Sowell @ Rodney Hall on Apr 26, 2007 2:49 AM
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    Very nice Rodney!
    
    1964?
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    - Rodney Hall @ Devon Sowell on Apr 26, 2007 6:31 PM
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      1967 Chevelle SS 396 "Clone"
      
      454cid, Tremec 5 speed, 12 bolt 3:73, Garnet Red Metallic Pearl,Bucket Seats, Console, Vintage Air, Disc Brakes... Work in progress, labor of love. I am 2nd owner. I've had this low bondo, rust free 1967 Malibu for 22yrs & just began total restore 2yrs ago.
      
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How To? any advice for jog bends

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