I think age is starting to affect my memory, I have a .09 thick a sheet metal pan 1" deep that has to be made water tight. Corner is .31 radii, outer.
I tried several options, but they all seem pretty clunky, when I flatten it fails. any hints?
I used no special tools in SW and here is what I have (2012).
At that bend radius you'll likely need corner filler pieces. If you have a talented welder he/she might be able to 'fill' those corners.
I know they can do it, the idea was to create a flat pattern as close as possible.
Check the model I attached, you have no .31 outer radii corners, that's the problem.
Hi Jesse,, Yea that age thing is taking a toll on me too but I do remember how we used to do this back in the day. Of course back then we had to plot all the points in the flat pattern then form it up to see where we made an error. A piece will have to be added for the ball corner or you can add it to the bend and hammer it over. We used to do this quite frequently but on thinner materials. This may not be what you are looking for but this is my take on it.
I did the ball corner in a separate file with a swept flange then added it into the base part. This will not develop in the flat pattern like you would expect but you can cut the taper on it for a good approximation of what the flat pattern of it would look like. Use the "For Flattening" config prior to flattening.
The "Added Corner" config is for a good visual of the formed part prior to welding.
Edit:.. I didn't take the time to develop this (just eyeballed it) but here is a couple pics so you can see what it would look like prior to hammering the corner. After tapping this into shape there would be minimal gaps to fill. As Bernie mentioned it might be a good idea to slit the protruding tab to make it easier to tap around.
Here's an alternative which may give you some ideas.
Thanks to all of you, for the help. Like the brain in Scorpion said "There is always an answer, we just have to find it"
This is a great site to look in.
Thanks, Kelvin, this is very helpful.
Your model reminds me of a part I came up with once. I didn't try and have the sheet metal shop we use now make it, but I've worked at a place that I know could have without much trouble.
I don't believe you had a model available when I offered my solution. I now see the difference you're speaking of. Don't hesitate to mark another answer as correct, I would agree with Dennis Bacon in this regard. We have actually slit the radius portion with the laser to make the corners easier to 'tap' in for the welders.
Thanks Bernie for the help.
I guess that SW does not answer everything, that's why we will always need and depend on the sheet metal guys.
Most of my experience has been that I make the flat pattern, but leave it up to the sheet metal shop to do their thing, they have the knowhow.
This what is called a Coved Corner. SW cannot do this because it is a bending process & Then technically a forming process (using a hammer).
We made sink bowls at my old company. If you search coved corner there are a few threads on the subject. By basically you'll have to have a manually designed flat pattern.
Appreciate your input, thanks, will research it.
I know we have beaten this to death but I just have to share this video from Top Solid. Now this would be a nice feature in SW! It doesn't get any easier than this.
Advanced sheet metal made easy with TopSolid 7
This has also been covered in a couple other threads as well. Check them out for useful info.
Closed rolled sheet metal corners function in SW 2012?
Closed Rolled Sheet Metal Flanges/Corners
You can do this with closed corner but it wont produce a true flat pattern
actually I correct myself
done closed corner then extrude cut through the corner
makes good flat pattern
Ned,, You do realize that if you uncheck "Corner Treatment" you do get a true flat pattern.
I know this is off subject but just wanted to make sure that you were aware of this.
tried to uncheck corner treatment didn't seem to change the flat pattern
I think u need that extrude cut for the corner treatment
Here is your file back. I deleted the cut extrude, unchecked corner treatment. Sure seems to change to me.
cant find corner treatment check box anywhere
I managed to apply corner relief to achieve without extrude cut
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