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					SolidWorks Sheet Metal – Why Do I Do It Like
This or That?
                                 Wayne Tiffany
                                 Automatic Systems, Inc.
                                 wayne.tiffany@asi.com
Purpose of session

   Not intended for stamping die forming
   No regurgitation of the Help or tutorials
   Examples of modeling options
   Reasons to choose one method over another based
     on information you have
   Learn to look ahead (multiple configurations?)


   Keep in mind that sheet metal calculations are
     never exact.
   A lot of info to cover – refer back to it.
   If you see it, download it. (www.kcswug.com)
       If you hear it, write it down.
                                                     2
Good practices

   Hotkeys
   Save often
   Symmetry
   Hole Wizard if you intend to put fasteners in
   Do not manually unsuppress the Flat-Pattern feature
     – use the toolbar button




                                                         3
Sheet metal is fun – origami in metal!

    Learn – how?
       •   Classes
       •   Tutorials
       •   Help
       •   Models made by others




                                         4
Definition of a Sheet Metal part

    Metal (?)
    How thick is it?
    Uniform thickness
    Bends
    Cuts
So, how do I start?



Study your available information, then decide what method
  or methods best suit the task at hand.


                                                            5
Should it even be a sheet metal part?

                                 Can a sheet metal part be:
                                          Simpler?
                                          Cheaper?
                                          Better?




                                                              6
How will the part be made?


                             Multiple parts?
                             Weld?




                                               7
One piece or two?



            Form as     Form front, and
            one piece   weld back on




                                          8
Flat pattern of each


                       What sheet size?




                                          9
Extrude flanges – base extrudes




                                  10
Extrude flanges – first flange


                                 Multiple features.




                                                      11
Extrude flanges – second flange


                                  Disjoint edges.




                                                    12
Extrude flanges – third flange


                                 Odd shapes both ends.




                                                         13
Extrude flanges – fourth flange


                                  Flanges hang over.




                                                       14
Extrude flanges – fifth flange

                                 Flanges 2 directions
                                 & odd shapes.




                                                        15
Extrude flanges – bends added - finished


                                           Insert bends.




                                                           16
Advantages - extrude flanges

   Imported sketches - convert
   Flanges that extend past the edges
   Maybe fewer total features than some other methods
   In-context modeling - convert edges




                                                        17
Angled part with flanges - drawing




                                     18
Angled part with flanges – extruded




                                      19
Angled part, extruded – base




                               20
Angled part, extruded – angle cut




                                    21
Angled part, extruded – add flange




                                     22
Angled part, extruded – mirror flange




                                        23
Angled part, extruded – insert bends




                                       24
Advantages of using SW sheet metal methods



  So why use the sheet metal features?



    Guides you through the process, but not bullet-proof
      (inside corner flanges)
    Link to thickness option
    Closed corners
    Sometimes easier to change complex geometry
    Allows you to check the flat pattern often
    Maybe fewer features
                                                           25
Angled part with flanges – sheet metal features




                                                  26
Angled part with flanges – sheet metal - base




                                                27
Angled part with flanges – sheet metal - edge




                                                28
Angled part with flanges – sheet metal - cut




                                               29
Angled part with flanges – sheet metal - mirror




                                                  30
Angled part with flanges – sheet metal – edge




                                                31
Angled part with flanges – sheet metal – Tear/Extend




                                                       32
Angled part with flanges – compare reliefs




                                 Rip         Extend




                                                      33
Angled part with flanges – comparison




                                        34
 Drip pan – take a look




Four sides
Three sides 90°
One side 60°




                          35
   Drip pan – Base flange




Open sketch - thin extrude
Bottom & two sides
Midplane extrude - symmetry
                              36
Drip pan – 90° edge flange




                             37
Drip pan – 60° edge flange




                             38
   Drip pan – Closed corner 90° flanges




Bends were outside the base flange area,
  so the corners are open
Can set to corner-corner, or overlap
Leave Open bend region unchecked to
  close the corner
                                           39
   Drip pan – Closed corner 60° flange




Bends were outside the base flange area,
  so the corners are open
Can set to corner-corner, or overlap
Leave Open bend region unchecked to
  close the corner
                                           40
Drip pan – material inside




                             41
Drip pan – flange placement



 Bend outside       Material outside   Material inside




                                                         42
Drip pan – trim side bends




   Trim side bends           Trim side bends box
    box checked                  unchecked


                                                   43
Flange placement - virtual sharp



                                   Material outside
        Material inside




                                      Bend from
        Bend outside                 virtual sharp




                                                      44
Light brkt – normal cut




                          45
Light brkt – normal cut sketch

                                 VERTICAL CUT




                                                46
Light brkt – start




                     47
     Light brkt – miter flange sketch

Miter flange – special sweep
Sketch plane must be normal to the first edge
Edges must be coincident – can’t jump a gap




        Sketch plane

                       Sketch line

                                                48
Miter flanges – sketch position




                          Sketch position
                          No virtual sharp
                              option



                                             49
Miter flanges – all, or one at a time?




                                         50
Miter flanges – base flange




                              51
Miter flanges – two edges selected




                                     52
Miter flanges – one edge selected




                                    53
Miter flanges – close the corner



          Won’t do all of it




                                   54
Miter flanges – flat




                       55
Miter flanges – statistics




                             56
Edge flanges – statistics




                            57
Miter pan – curled edges - statistics




                                        58
Miter pan – straight edges - statistics




                                          59
Edge flange pan – full




                         60
Edge flange pan – first flanges




                                  61
Edge flange pan – close corners




                                  62
Edge flange pan – second flanges




                                   63
Edge flange pan – can’t close second corners




                                               64
Edge flange pan – manually close second corners




                                                  65
Edge flange pan – statistics


                          (Remember, miter
                        flange pan was 1.49)




                                               66
Edge flange - one feature - modify sketches




                                              67
Edge flange – modify sketches




                                68
Edge flange – modify one – now or later


                    Choose your flange
                    Click the button




                                          69
Miter flanges – main points

  Pros:
  All flanges will be the same angle and shape if multi-
     selected
  Will handle the full corners well
  Can create more than just a straight flange

  Cons:
  Can’t change the bend angle for individual bends
  Can’t jump a gap
  No virtual sharp bend option


                                                           70
Edge flanges – main points
 Pros:
 All flanges will be the same angle if multi-selected
 Will handle the related corners well
 Virtual sharp bend option
 Can modify the individual flange sketches of a multiple
   selection set
 Cons:
 Can’t change the bend angle for individual bends
 Edge flanges are just a straight flange
 If you choose multiple edges, you can’t suppress a
     bend for configurations
 Can’t remove the first edge selected from the
   selection set                                           71
Large radius part – first look




                                 72
Large radius part – with radius dimension




                                            Why this gap?




                                                            73
Large radius part – base flange




                                  74
Large radius part – unfold & cut




                                   75
Large radius part – add holes




                                76
Large radius part – fold

         The original unfold edge
         is gone – must have a
         linear edge or face to fold
         that is parallel to the
         original edge. Flatten this
         part by suppressing the
         Fold1 feature.




                                       77
Large radius / small radius




                              78
  Large radius / small radius - sketch




The whole part is the
base flange.


                                         79
Large radius / small radius – Base-Flange1




                                             80
Large radius / small radius – BaseBend1




                                          81
Large radius / small radius – BaseBend2




                                          82
   Large radius – Custom Bend Allowance




Right-click on BaseBend2
and Edit Feature.



                                          83
Cut across bend




                  84
   Cut across bend – use Unfold/Fold




Use Unfold/Fold, not the flatten button
to make features desired in the flat.
                                          85
   Cut across bend – not the flatten button




This way they end up AFTER the
Flat-pattern1 feature and therefore
only show up in the flat pattern view.
                                              86
Flat pattern corners




                       87
Bend calculations - names

   K-factor (my preference)
   Bend allowance (addition)
   Bend deduction
   Setback




                               88
Bend calculations – allowance (addition)




                                           89
Bend calculations - deduction




                                90
Setback / Bend deduction




                           91
             K-factor study
 Line      Part  Sample Location    Bend   Material    Flat   Top formed  Side   Bottom   Neutral   Bend arc  Radius of    Depth into
Number   Number Number Number      radius thickness dimension dimension formed   formed   axis %     length  neutral axis the material
   1     SAMPLE    1       1         0.25    0.25     10.999     2.476   7.000    2.476   0.3331     0.5235    0.3333        0.0833
   2     SAMPLE    1       1         0.25    0.25     11.073     2.476   7.000    2.476   0.4276     0.5606    0.3569        0.1069                                   Calculated K-Factor
   3     SAMPLE    1       1         0.25    0.25     11.130     2.476   7.000    2.476   0.5000     0.5891    0.3750        0.1250
   4      11' 6"   1       1         0.25   0.247     10.995     2.427   6.996    2.487   0.3706     0.5365    0.3415        0.0915
                                                                                                                                                    0.8000
   5      11' 6"   1       2         0.25   0.247     10.983     2.403   6.966    2.555   0.3371     0.5235    0.3333        0.0833
   6      11' 6"   1       3         0.25   0.247     10.993     2.392   6.968    2.568   0.3449     0.5265    0.3352        0.0852                 0.7000
   7      11' 6"   1       4         0.25   0.247     10.987     2.428   6.977    2.539   0.3165     0.5155    0.3282        0.0782
   8      11' 6"   1       5         0.25   0.247     10.991     2.472   6.962    2.425   0.4312     0.5600    0.3565        0.1065                 0.6000
   9      11' 6"   2       1         0.25   0.247     10.985     2.392   6.997    2.522   0.3565     0.5310    0.3380        0.0880
  10      11' 6"   2       2         0.25   0.247     10.989     2.568   6.984    2.562   0.1000     0.4315    0.2747        0.0247                 0.5000




                                                                                                                                         k-Factor
  11      11' 6"   2       3         0.25   0.247     11.010     2.537   6.983    2.414   0.3590     0.5320    0.3387        0.0887
  12      11' 6"   2       4         0.25   0.247     10.997     2.436   6.988    2.442   0.4299     0.5595    0.3562        0.1062                 0.4000
  13      11' 6"   2       5         0.25   0.247     10.996     2.416   6.964    2.519   0.3861     0.5425    0.3454        0.0954
                                                                                                                                                    0.3000
  14      11' 6"   3       1         0.25   0.247     10.993     2.407   6.998    2.540   0.3230     0.5180    0.3298        0.0798
  15      11' 6"   3       2         0.25   0.247     11.001     2.400   6.984    2.520   0.3861     0.5425    0.3454        0.0954
                                                                                                                                                    0.2000
  16      11' 6"   3       3         0.25   0.247     11.006     2.400   6.978    2.527   0.3913     0.5445    0.3466        0.0966
  17      11' 6"   3       4         0.25   0.247     10.989     2.438   6.976    2.488   0.3732     0.5375    0.3422        0.0922                 0.1000
  18      11' 6"   3       5         0.25   0.247     10.996     2.434   6.965    2.458   0.4402     0.5635    0.3587        0.1087
  19      11' 6"   4       1         0.25   0.247     10.987     2.524   6.965    2.400   0.3874     0.5430    0.3457        0.0957
  20      11' 6"   4       2         0.25   0.247     10.990     2.550   6.972    2.398   0.3513     0.5290    0.3368        0.0868                          0   20    40             60      80   100   120
  21      11' 6"   4       3         0.25   0.247     10.989     2.576   6.979    2.330   0.3951     0.5460    0.3476        0.0976
                                                                                                                                                                                   Sample #
  22      11' 6"   4       4         0.25   0.247     10.990     2.598   6.974    2.338   0.3642     0.5340    0.3400        0.0900
  23      11' 6"   4       5         0.25   0.247     11.004     2.464   6.995    2.386   0.4660     0.5735    0.3651        0.1151
  24      11' 6"   5       1         0.25   0.248     10.970     2.475   6.968    2.445   0.3704     0.5370    0.3419        0.0919
  25      11' 6"   5       2         0.25   0.2485    10.988     2.510   6.946    2.445   0.3786     0.5405    0.3441        0.0941                                         Mean     0.3693
  26      11' 6"   5       3         0.25   0.2485    10.973     2.525   6.925    2.460   0.3479     0.5285    0.3365        0.0865
  27      11' 6"   5       4         0.25   0.2485    10.974     2.520   6.920    2.480   0.3364     0.5240    0.3336        0.0836
  28      11' 6"   5       5         0.25   0.249     10.985     2.488   6.918    2.478   0.3983     0.5485    0.3492        0.0992
  29      11' 6"   6       1         0.25   0.255     11.007     2.425   6.991    2.427   0.4976     0.5920    0.3769        0.1269
  30      11' 6"   6       2         0.25   0.2525    10.992     2.452   6.984    2.422   0.4521     0.5720    0.3641        0.1141
  31
  32
  33
          11' 6"
          11' 6"
          11' 6"
                   6
                   6
                   6
                           3
                           4
                           5
                                     0.25
                                     0.25
                                     0.25
                                            0.2525
                                            0.2525
                                             0.25
                                                      11.001
                                                      10.990
                                                      10.986
                                                                 2.431
                                                                 2.430
                                                                 2.455
                                                                         6.984
                                                                         6.978
                                                                         6.964
                                                                                  2.425
                                                                                  2.428
                                                                                  2.490
                                                                                          0.4861
                                                                                          0.4773
                                                                                          0.3713
                                                                                                     0.5855
                                                                                                     0.5820
                                                                                                     0.5385
                                                                                                               0.3727
                                                                                                               0.3705
                                                                                                               0.3428
                                                                                                                             0.1227
                                                                                                                             0.1205
                                                                                                                             0.0928
                                                                                                                                                        Notice the pattern of the
  34
  35
  36
          11' 6"
          11' 6"
          11' 6"
                   7
                   7
                   7
                           1
                           2
                           3
                                     0.25
                                     0.25
                                     0.25
                                            0.252
                                            0.2505
                                            0.2505
                                                      11.012
                                                      10.992
                                                      11.004
                                                                 2.500
                                                                 2.475
                                                                 2.595
                                                                         6.996
                                                                         6.991
                                                                         6.986
                                                                                  2.407
                                                                                  2.362
                                                                                  2.345
                                                                                          0.4189
                                                                                          0.4836
                                                                                          0.3744
                                                                                                     0.5585
                                                                                                     0.5830
                                                                                                     0.5400
                                                                                                               0.3556
                                                                                                               0.3711
                                                                                                               0.3438
                                                                                                                             0.1056
                                                                                                                             0.1211
                                                                                                                             0.0938
                                                                                                                                                        points – why?
  37      11' 6"   7       4         0.25   0.2505    10.970     2.563   6.698    2.400   0.6679     0.6555    0.4173        0.1673
  38      11' 6"   7       5         0.25   0.249     11.005     2.480   6.955    2.496   0.3638     0.5350    0.3406        0.0906
  39      11' 6"   8       1         0.25   0.247     10.993     2.453   6.974    2.463   0.3938     0.5455    0.3473        0.0973
  40      11' 6"   8       2         0.25   0.2465    10.995     2.438   6.939    2.533   0.3688     0.5355    0.3409        0.0909
  41      11' 6"   8       3         0.25   0.2465    10.998     2.446   6.904    2.582   0.3443     0.5260    0.3349        0.0849
  42      11' 6"   8       4         0.25   0.2465    10.991     2.448   6.971    2.596   0.2280     0.4810    0.3062        0.0562
  43      11' 6"   8       5         0.25   0.246     11.002     2.451   6.858    2.558   0.4317     0.5595    0.3562        0.1062
  44       6' 0"   1       1         0.25   0.247     11.000     2.429   7.010    2.500   0.3397     0.5245    0.3339        0.0839
  45       6' 0"   1       2         0.25   0.247     10.990     2.493   6.996    2.486   0.2804     0.5015    0.3193        0.0693
  46       6' 0"   1       3         0.25   0.247     10.993     2.484   6.994    2.438   0.3603     0.5325    0.3390        0.0890
  47       6' 0"   1       4         0.25   0.247     11.005     2.487   7.004    2.440   0.3565     0.5310    0.3380        0.0880
  48       6' 0"   1       5         0.25   0.247     10.985     2.465   7.017    2.456   0.3217     0.5175    0.3295        0.0795
  49       6' 0"   2       1         0.25   0.247     10.999     2.460   7.025    2.485   0.2985     0.5085    0.3237        0.0737
  50       6' 0"   2       2         0.25   0.247     10.978     2.487   6.975    2.432   0.3693     0.5360    0.3412        0.0912
  51       6' 0"   2       3         0.25   0.247     10.989     2.498   6.945    2.438   0.4003     0.5480    0.3489        0.0989
  52       6' 0"   2       4         0.25   0.247     10.994     2.520   6.930    2.441   0.3938     0.5455    0.3473        0.0973
  53       6' 0"   2       5         0.25   0.247     10.985     2.526   6.940    2.455   0.3436     0.5260    0.3349        0.0849
  54       6' 0"   3       1         0.25    0.25     11.000     2.481   7.005    2.432   0.3776     0.5410    0.3444        0.0944
  55       6' 0"   3       2         0.25   0.2495    11.005     2.460   6.976    2.466   0.4026     0.5505    0.3505        0.1005
  56       6' 0"   3       3         0.25   0.2495    11.004     2.452   6.983    2.475   0.3912     0.5460    0.3476        0.0976
  57       6' 0"   3       4         0.25   0.2495    10.989     2.457   6.986    2.481   0.3542     0.5315    0.3384        0.0884
  58       6' 0"   3       5         0.25   0.249     11.002     2.466   7.004    2.470   0.3485     0.5290    0.3368        0.0868
  59
  60
           6' 0"
           6' 0"
                   4
                   4
                           1
                           2
                                     0.25
                                     0.25
                                            0.251
                                            0.2505
                                                      11.000
                                                      10.996
                                                                 2.445
                                                                 2.465
                                                                         7.058
                                                                         7.000
                                                                                  2.430
                                                                                  2.470
                                                                                          0.3622
                                                                                          0.3527
                                                                                                     0.5355
                                                                                                     0.5315
                                                                                                               0.3409
                                                                                                               0.3384
                                                                                                                             0.0909
                                                                                                                             0.0884
                                                                                                                                                                                                               92
   Hem & Simple hole

Hem K-factor .28, .67, ? – best to
determine your own
Hem will miter the corners
Simple hole – try it




                                     93
       Lofted Bend




                             (SW2007)

Lofted bends are special
   •     Both sketches must be open
   •     Alignment is important
   •     No sharp corners – radii in sketches
   •     SW2007 bend lines may show
   •     Only one lofted bend per part          94
Sheet metal lofted bend - flat




                                 95
  SW2007 Curved edge flange


Read through the Help section to learn the
  possibilities & limitations of this feature.




                                                 96
Long part – full length too long




                                   Part is too long to make as
                                   one piece, but still want to
                                   control the overall shape.
                                                                  97
Long part – add a layout sketch




                                  Add a layout sketch.


                                                         98
Long part – make individual cuts to separate




                             Make individual cuts to
                             separate the parts per desired
                             lengths. A config for each.


                                                              99
Lofted part – scallops on the top edge




                                         100
Lofted part – scallops on the top edge



          Cut the upper edge with the original
          edge as the pattern curve. The
          scallop cut fails because the cut
          doesn’t go to the edge of the part.




                                                 101
Lofted part – original edge cut



           Cut the upper edge with the original
           edge as the pattern curve. The
           scallop cut fails because the cut
           doesn’t go to the edge of the part.




                                                  102
Lofted part – arc edge cut



           Cut the upper edge with an arc
           cut and then use that edge as
           the pattern curve. The scallop
           cut is not correct.




                                            103
Lofted part – offset spline cut



            Cut the upper edge with an
            offset spline cut and then use
            that edge as the pattern curve.
            The scallop cut now works.




                                              104
Sheet metal drawings




                       105
Drawings – add flat pattern model config

What’s the easiest way to create
 a flat pattern configuration in
 the model?


Let SolidWorks do it!




                                           106
Drawings – add flat pattern model config



How?
  •   Insert other drawing views
  •   Insert a flat pattern view by
      selecting it from the list




                                           107
SW2007 View Palette – creates config




            Flat pattern box not checked

                                     Flat pattern
                                     view in
                                     palette




                                                    108
    Sheet metal drawings – flip & rotate view




Flip view – lets you flip the
    flat pattern view to set
    which side is up as you
    cut it. Example –
    coated stainless.
You can also rotate it with
  the Rotate Drawing
  View command to fit the
  space.
                                                109
   Sheet metal options - help
Set colors
Hide or display a bend note (If
you hide one, to get it back, go
to View menu, Hide/Show
annotations.)
Set note style
Watch out for leader “nearest”
not working properly on notes
that are not horizontal.
(SW2007 SP2.2)
Can modify the bend notes file
- bendnoteformat.txt (See
Help)
Set note angle precision with
the document properties

                                   110
   Sheet metal drawings – Hide & Show

Hide/Show all notes – go to View
   Properties of that drawing view -
   Display sheet metal bend line
   notes box


Hide all bend lines – right-click on a
   line and Hide, or go to the
   FeatureManager tree and Hide


Show all bend lines – go to the
  FeatureManager tree and Show


(See Help - Creating Drawings of
   Sheet Metal Parts )
                                         111
Merge faces




              Edit the Flat-Pattern feature
              View on left with it checked
              View on right with it not checked
              (I generally keep it checked)

                                                  112
 Copy drawing per model configurations

Complete the first drawing & make sure you save it
Save As the new name (not as a copy)
Change the referenced config in each formed view


Hmmm – problem – the next config doesn’t have a flat pattern
 config yet




                                                               113
 Copy drawing per model configurations

No problem – change the Reference
  Configuration and leave the Flat
  pattern view checked




                                         114
BOM property – length & width




                                115
Flat dimension for BOM property




                                  116
Two surface lofts to sheet metal – how?




                                          117
Two surface lofts to sheet metal – flat




                                          118
Two surface lofts to sheet metal – structure




                                               119
Failure if outside selected as base




                                      120
Single lofted surface sheet metal




                                    121
Sheet metal lofted bend




                          122
Sheet metal sketches to surface lofts




                                        123
All three varieties




                      124
   More information

SolidWorks Help & Tutorial sections
SolidWorks Forums
comp.cad.solidworks newsgroup
http://www.sheetmetaldesign.com/index.htm
http://www.tyharness.co.uk/sheetmetal/
http://www.appliedproduction.com/SolidWorks.htm
http://www.sheetmetalguy.com/bend-calculator.htm
http://www.solidsmack.com/solidworks-sheetmetal-tips-to-flip/
Do an internet search for “SolidWorks” and “sheet metal”


Always watch out for old info (closed corners)


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