I have this part and am trying to get the corners to show like if they were welded, any suggestions on how i could do this? I've attached the file and I want the weld on the outside of the corners.
I can't open your file but see if this discussion helps: Help with Sheet Metal Welded Corners
Mason,, I have attached an assembly file with your file (called modified although there are no modifications) and My file which is modified from yours. Had to alter the first sketch for Boss-Extrude2 (no reliefs) and added a corner relief feature. I made another configuration called "Welded Corners". This configuration suppresses the corner reliefs and adds the welds. Looks like the welded corners does not work if there is a relief. When the corner reliefs are unsuppressed they match up identically to yours which were created in your first sketch. You can use the "Welded Corners" for a visual and the "Default" for your flat pattern.
OK, thanks! I have one more question, In its folded state, the measurements from the outside face to the opposite outside face are supposed to be 24in and 27in, when I measure them it says that they are 24.02in and 27.02in. Any idea what I need to do to keep the design the same, but fix that measurement?
Change your driving dimension - .2 or in the edge flange option you can flip the dimension on the flange or extend the flange, so edit the edge flange feature.
Interesting dilemma.. By the way you constructed this part it looks like you started with a flat pattern and folded it up. I use to do that occasionally in order to have a model of a part created back in the day before solid modeling. With the new, improved, sketch bend feature which allows you to place multiply sketch lines and form all at once it makes it easier.
To solve your problem you can do this.
By changing the bend radius to .0005 you end up with an overall of 24 and 27. Just don't dimension your drawing beyond 2 places.
If you change the flange position to material outside (from bend outside) this works great except corners overlap slightly in the folded state. You would have to alter the sketch geometry for the corners.... or cut extrude all the corner edges a couple thousandths.
Of course you could alter the material thickness slightly (along with bend outside) if you really would like to nail down the overall. Nobody is going to find material exactly 0.1875in thick.
Another detail to add Dennis when bending .0005" radius, you need to add model details to the outer surface of the bend area to match the small tears of over stretching, which happens when the radius is too tight ..... lol
Yea,,, I wonder how you could do that John.. This will give me a project to work on and probably keep me out of trouble for a couple months.
Mason's original bend radius was .010 and since the sketch bend was set to "bend outside" his overall dims were .020 too much. It is not easy to work with a preexisting flat pattern. The k-factor (I like to use bend deduction) makes a huge difference in the height of the flanges. Mason needs to know what bend deduction was used in the original flat. I'm guessing the flanges are supposed to be 1.375 - 1.500 so the bd can be adjusted to achieve this.
Thanks for the project John
This is one thing that can get sheet metal designers into a lot of trouble, don't want to hijack the post, but I just wanted to point that out for any new sheet metal designers. For the final product, you really need to know what the fabricator is capable of and this depends on a lot of different factors..
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