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Pro/ENGINEER: Sheet Metal DesignWildfire

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ASCENT - Center for Technical KnowledgeTM

Pro/ENGINEER: Sheet Metal DesignWildfire

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ASCENT - Center for Technical Knowledge

Pro/ENGINEER: Sheet Metal Design

Table of Contents

Table of Contents ..............................................................................

Chapter 1 Introduction to Sheet Metal Modeling.......................1-1

1.1 The Sheet Metal Environment...................................... 1-1

1.2 Display of Sheet Metal Parts ........................................ 1-3

1.3 Orienting a Sheet Metal Part ........................................ 1-4

1.4 Developed Length of Sheet Metal Bends....................1-5

1.5 Designing in Sheet Metal Mode ................................... 1-6Sheet metal mode ...........................................................1-6

Assembly mode.............................................................1-10Convert parts................................................................. 1-11

Chapter 2 Primary Walls .............................................................. 2-1

2.1 Primary Wall Options....................................................2-1Extruded.......................................................................... 2-2Flat .................................................................................. 2-3Revolved .........................................................................2-3Blended...........................................................................2-4Offset............................................................................... 2-4

2.2 Capturing Design Intent in Sketcher ...........................2-5

2.3 Creating a Primary Wall................................................ 2-7

Exercise 2a Extruded Primary Wall...................................... 2-9

Exercise 2b Flat Primary Wall............................................. 2-13

Exercise 2c Creating the Project Part ................................ 2-17

Chapter 3 Secondary Walls ......................................................... 3-1

3.1 Selecting an Attachment Edge .................................... 3-1

3.2 Secondary Wall Options............................................... 3-2Flat Wall - Without Radius............................................... 3-2Extruded Wall - Without Radius ...................................... 3-3

Swept Wall - Without Radius...........................................3-4Flat Wall - With Radius....................................................3-5Extruded Wall- With Radius ............................................3-6Swept Wall - With Radius................................................3-7Options for Walls With Radius ........................................3-8Twisted Wall.................................................................... 3-9Extended Wall ............................................................... 3-10


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ii Pro/ENGINEER: Sheet Metal Design

3.3 Unattached Walls........................................................ 3-11

3.4 Bend Relief .................................................................. 3-13No Relief ....................................................................... 3-13Stretch Relief ................................................................ 3-13Rip Relief ...................................................................... 3-14Rectangular Relief ........................................................ 3-15

Obround Relief.............................................................. 3-163.5 Hems ............................................................................ 3-17

Keep Wall Height .......................................................... 3-20

3.6 Creating a Secondary Wall......................................... 3-22

Exercise 3a Secondary Walls ............................................. 3-25

Exercise 3b Unattached Wall.............................................. 3-33

Exercise 3c Hems................................................................ 3-39

Exercise 3d Adding Walls to the Project Part ................... 3-43

Chapter 4 Regular Unbends, Bend Backs, and Cuts................ 4-1

4.1 Unbending Sheet Metal Geometry .............................. 4-1

4.2 Bending Back Unbent Geometry................................. 4-3

4.3 Sheet Metal Cuts........................................................... 4-5Dimension Scheme and Feature Order .......................... 4-7Cuts Using Datum Curves .............................................. 4-9

4.4 Creating Unbend and BendBack Features............... 4-10

Exercise 4a Creating a Sheet metal Cut ............................ 4-13

Exercise 4b Projected Curve and a Cut............................. 4-19

Exercise 4c Create a Cut on the Project Part.................... 4-25

Chapter 5 Notches and Punches................................................ 5-1

5.1 Introduction to Notches and Punches........................ 5-1

5.2 Creating Notch and Punch UDFs ................................ 5-3

5.3 Placing Notch or Punch UDFs..................................... 5-6

Exercise 5a Creating a Notch for Bend Relief..................... 5-9

Exercise 5b Creating a Punch Feature .............................. 5-19

Chapter 6 Bend Features............................................................. 6-1

6.1 Types of Bend Features ............................................... 6-1Angle............................................................................... 6-1Roll.................................................................................. 6-2Regular ........................................................................... 6-2With Transition................................................................ 6-2


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Pro/ENGINEER: Sheet Metal Design ii

Planar.............................................................................. 6-3Bend Relief......................................................................6-3

6.2 Position of the Bend Line............................................. 6-4

6.3 Bend Line Adjustment ..................................................6-7

6.4 Creating a Bend Feature............................................. 6-10

Exercise 6a Bending Flat Geometry................................... 6-13

Exercise 6b Create a Bend Line Adjustment..................... 6-29

Chapter 7 Unbending Complex Geometry ................................. 7-1

7.1 Unbending Ruled and Non-Ruled Geometry..............7-1Unbend feature ...............................................................7-1Deform area feature ........................................................ 7-4

7.2 Cross-Section Driven Unbends ................................... 7-5

7.3 Rip Features ..................................................................7-7

Regular Rip ..................................................................... 7-7Edge Rip .........................................................................7-8Surface Rip ..................................................................... 7-9

Exercise 7a Deform Surfaces ............................................. 7-11

Exercise 7b Cross-Section Driven Unbend....................... 7-15

Exercise 7c Rip Features and Deformation Control ......... 7-19

Exercise 7d Deform Area Feature ...................................... 7-23

Chapter 8 Sheet Metal Forms...................................................... 8-1

8.1 Introduction to Form Features..................................... 8-1Die................................................................................... 8-1Punch.............................................................................. 8-1

8.2 Placing Form Features ................................................. 8-3Reference........................................................................ 8-3Copy................................................................................ 8-3

Assembly Considerations................................................ 8-4Radius Considerations.................................................... 8-5Openings.........................................................................8-6Bending...........................................................................8-7

Restrictions ..................................................................... 8-78.3 Flattening Form Geometry ........................................... 8-8

Flatten Form.................................................................... 8-8Edge Treatments............................................................. 8-9

8.4 Creating a Form Feature............................................. 8-10

Exercise 8a Die Form........................................................... 8-13

Exercise 8b Flattening Form Geometry............................. 8-23


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iv Pro/ENGINEER: Sheet Metal Design

Chapter 9 Documenting a Sheet Metal Part............................... 9-1

9.1 Creating Flat States ...................................................... 9-1

9.2 Opening Flat State Instances....................................... 9-5

9.3 Sheet Metal Drawings................................................... 9-6Using Flat State in Drawings........................................... 9-6Ordinate Dimension for Sheet Metal............................... 9-7

9.4 Documenting the Bend Order...................................... 9-9

Exercise 9a Sheet Metal Drawing....................................... 9-11

Exercise 9b Project Drawing .............................................. 9-23

Chapter 10 Converting Solid Parts........................................... 10-1

10.1 Converting Solid Parts ............................................... 10-1Driving Srf ..................................................................... 10-1Shell .............................................................................. 10-2

10.2 Conversion Feature .................................................... 10-3Point Relief.................................................................... 10-3Edge Rip ....................................................................... 10-4Rip Connect .................................................................. 10-5Bends............................................................................ 10-6Corner Relief................................................................. 10-7

10.3 Converting a Solid Part .............................................. 10-8

Exercise 10a Converting a Solid Part .............................. 10-11

Exercise 10b Conversion Feature................................... 10-17

Chapter 11 Sheet Metal Setup................................................... 11-1

11.1 Calculating the Developed Length ............................ 11-1

11.2 Y-Factor and the Default Formula............................. 11-2

11.3 Bend Tables................................................................. 11-4

11.4 Sheet Metal Parameters ............................................. 11-8

11.5 Default Fixed Geometry............................................ 11-12

Exercise 11a Calculating Developed Length .................. 11-13

Exercise 11b Sheet Metal Parameters............................. 11-19

Chapter 12 Investigating a Sheet Metal Part ........................... 12-1

12.1 Investigation Tools ..................................................... 12-1

12.2 Sheet Metal Reports ................................................... 12-3Bend Reports................................................................ 12-3Radii Reports ................................................................ 12-4


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Pro/ENGINEER: Sheet Metal Design v

12.3 Design Rules ............................................................... 12-5Design Check................................................................12-6

Exercise 12a Using Information Tools............................... 12-7

Appendix A Additional Exercises ............................................. A-1

Exercise A1 Creating a Revolved Wall................................ A-2

Exercise A2 Creating an Offset Wall ................................... A-4

Exercise A3 Form with Non-Constant Wall Thickness...... A-6


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vi Pro/ENGINEER: Sheet Metal Design


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Pro/ENGINEER: Sheet Metal Design 11

Chapter 1 Introduction to Sheet Metal

Modeling

Objective This chapter introduces:

The Sheet Metal Modeling Environment

Display Characteristics of Sheet Metal Parts

Orienting a Sheet Metal Part

Sheet Metal Bends

Designing in Sheet Metal Mode

1.1The Sheet Metal

Environment

Working in Sheet Metal mode to design your sheet metal partsenables you to effectively capture design intent. Sheet Metal modealso enables you to design components for multiple uses, includingthe following:

Design a model within the context of an assembly so that all 3Dinformation is present.

Create features that are specific to the sheet metal modelingprocess.

Create different instances of the model to use at different times,such as for design and documentation.

Extract information and establish controls that are beneficial to themanufacturing process.

Generate reports and other information to document the design ofthe sheet metal part.


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12 Pro/ENGINEER: Sheet Metal Design

The process of creating a sheet metal model is similar to the processof creating a solid part. Individual features are created in sequenceand reference one another, resulting in parent/child relationships. TheInsert menus in Part mode and Sheet Metal mode are shown inFigure 11.

Figure 11

The creation of a sheet metal model is similar to the creation of a solidpart in the following ways:

It is important to considerdesign intent whenmodeling in Sheet Metalmode and not necessarilythe order in which the partwould be bent duringmanufacturing.

Features are used to create your models (e.g., walls, bends,notches, bend back, and forms).

Sketching references are established when creating certain typesof walls, just as they are for protrusions and cuts.

Depth options are specified in Sheet Metal mode. Parent/childreferences and design intent are equally important in Sheet Metalmode and solid part creation. Remember to carefully considerfeature type and order of creation.

Insert Menu for Part Mode

Insert Menu for Sheet Metal Mode


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1.2Display of Sheet Metal Parts

Geometry created in Sheet Metal mode has a specific color scheme.One side of the model is green and the other side is white, as shownin Figure 12.

Figure 12

When modeling a sheet metal part, remember that the part alwayshas a constant wall thickness. The green side of the model is used thedriving side. The white surface is then offset by a distance that isequal to the material thickness. Typically, references and geometryare created on the green side of the model.

Green side of the model

White side of model


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1.3Orienting a Sheet Metal Part

Models are oriented in Sheet Metal mode similar to how parts areoriented in Part mode. You can pan, zoom, and spin a model usingthe same options. You can also display the model in a two-dimensional orientation by selecting two planar surfaces to face Front,Back, Top, Bottom, Left, or Right. When displaying a 2D orientation inSheet Metal mode, the first viewing reference selected must be aplanar face or datum plane, as shown in Figure 13. The secondreference can be a planar surface or an edge.

Use Pick From List(rightmouse button pop-upmenu) when selectingedges and surfaces fororientation to ensure thatthe intended reference isselected.

Figure 13

Bottom

(select edge)

Front (select

surface)


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1.4Developed Length of Sheet

Metal Bends

One of the primary ways that sheet metal is manipulated to create apart is by bending it. Stretching and compression occur in certainareas of the metal when a part, particularly in the areas where bendsare located. As a result, material thickness on the part might vary.Pro/ENGINEER compensates for this by using a formula thatconsiders material thickness, bend radius, bend angle, and otherproperties. This formula locates a neutral bend line and measures itslength to determine the developed length of the bend. With thistechnique, Sheet Metal mode captures your design intent whencreating the model in the bent (formed) condition. You can then createa flat instance of the model to be used for manufacturing, as shown in

Figure 14.

The calculation of thedeveloped length can alsobe defined in a bend table.

A bend table includesinformation about the bendradius, sequence andangle. Bend tables arediscussed later in thiscourse.

Figure 14


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1.5Designing in Sheet Metal

Mode

Sheet metalmode

A common way of creating sheet metal parts in Pro/ENGINEER is tobuild them using feature-based techniques similar to those used whenbuilding a solid part.

Use the following steps to create a sheet metal part in Sheet metalmode:

1. Open a template file or create default datum planes, as shown inFigure 15.

Figure 15

2. Create any required reference geometry.

3. Create the primary wall feature, as shown in Figure 16.


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Figure 16

4. Create additional walls, as shown in Figure 17.

Figure 17


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5. Apply bend relief, as shown in Figure 18.

Figure 18

6. Create notches, punches, and cuts, such as those shown inFigure 19.

Figure 19

7. Create forms, such as those shown in Figure 110, which areused to stiffen the opening in the part.

Bend relief added to wall

Sheet metal cuts added to model


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Figure 110

8. Create a flat state to facilitate documentation, as shown inFigure 111.

Figure 111

Form added to rear wall


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9. Create a detail drawing, including bend information, to documentthe design, as shown in Figure 112.

Figure 112

Assembly mode If you use top-down design principles, working with an assembly maybe more beneficial. Sheet metal parts created within the context of an

assembly model often act as supporting structures for principlecomponents in the larger assembly.

Use the following general steps to create a sheet metal part inAssembly mode:

1. Assemble all of the required components relative to each otheror to a default reference.

2. Create the required sheet metal components with appropriateparent/child references.

3. Add any remaining components.

4. Apply an appropriate bend table to the sheet metal part so that ithas proper clearance with the surrounding components.

5. Define a bend order table in Sheet Metal mode to generate thebend sequence for the part.


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6. Create a flat state in the model to enable multiple part instancesto aid documentation.

7. Create a detail drawing, including bend information, to documentthe design.

Convert partsYou can also create a sheet metal model by converting a solid part toa sheet metal part. Use the following general steps to convert a solidpart to a sheet metal part:

1. Before opening the part in Sheet Metal mode, remember tocarefully consider your design intent (e.g., driving geometry).

2. Add relief where necessary.

3. Add any necessary additional features.

You can work with the part in Sheet Metal mode once the solid part

has been converted to a sheet metal part. An example of a convertedpart is shown in Figure 113.

Figure 113

Top, front, and bottom surfaces

removed with a shell feature toachieve constant wall thickness


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Chapter 2 Primary Walls


Primary Wall Options

Capturing Design in Sketcher

Sheet Metal mode contains two types of walls: primary andsecondary. The primary wall is the first wall that is created in the sheetmetal model. It references only default datum planes or otherreference geometry, and forms the foundation on which all other wallfeatures are built.

The primary wall is similar to the base feature in a solid part. Both thebase feature of a solid model and the primary wall of a sheet metalmodel contain the basic shape of the object.

2.1Primary Wall Options

In Sheet Metal mode (as in other modes of Pro/ENGINEER), it isgood practice to begin the creation of a model with three defaultdatum planes. The next feature is generally the primary wall feature.The following types of walls are the most common:

Extruded Flat

Blended

Revolved

Offset


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Extruded For an extruded wall, the cross-section is sketched and then the depthis defined, as shown in Figure 21. Extruded walls are generallysketched with open sections.

Figure 21

When you sketch an extruded wall, you can include bends in thesection, or you can leave these bends as sharp corners and havethem automatically converted to bends.

An element called Sharps to Bend is included in the feature dialog boxfor extruded walls. Setting this option toYescauses one radius to be

applied to all sharp corners in the section. You can apply this radiusbetween inside radius and outside radius. The automatic conversionof sharps to bends does not include sharp edges connected toexisting geometry.

unattached,extruded wall


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Flat The outline shape of a flat wall is sketched, as shown in Figure 22. Amaterial thickness is applied to the wall as the final step.

Figure 22

Revolved The cross-section of a revolved wall is sketched and rotated about acenterline, as shown in Figure 23.

Figure 23

unattached,

flat wall

unattached,

revolved wall


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Blended The cross-sections of a blended wall are sketched, as shown inFigure 24. Parallel, rotational, and general blend characteristics areall options when creating this type of wall.

Figure 24

Offset An offset sheet metal wall is created by offsetting from an existingsurface, as shown in Figure 25.

Figure 25

unattached,blended wall

A rip feature would be

required to unbend this part.

unattached,

offset wall

Surface quilt Offset sheet

metal wall


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2.2Capturing Design Intent in

Sketcher

Bend geometry may be included when extruded and revolved wallsare sketched. This enables you to accurately describe the profile ofthe wall; however, this also means that you must account for thematerial thickness inside the sketch. Sheet metal bends are generallydimensioned according to the inside bend radius in the part, as shownin Figure 26.

Figure 26

The Thickenoption in Sketcher enables you to offset the materialthickness and dimension the inside radii on the wall.


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When modeling in Sheet Metal mode, you may need to dimension awall to the mold line. The mold line is the theoretical intersection of theflat wall extensions. Use Sketcher centerlines and points to define theintersection of the flat wall extensions to create this dimensioningscheme. Instead of dimensioning to the tangency points on the wall,add dimensions from the endpoints of the wall profile to the Sketcherpoints. An example of how you can dimension to the mold line is

shown in Figure 27. Notice the application of material thickness andthe resulting dimensioning scheme.

Figure 27

A Sketcher point is placed at theintersection of the two centerlines.


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2.3Creating a Primary Wall

Use the following example as a guide to creating extruded primarywall:

1. Create a new part file using the Sheetmetaloption in the Newdialog box. Use the default sheet metal template.

You can also clickInsert >Sheetmetal Wall >Unattached > Extrude.

2. Start the creation of the wall. Select the button from the

flyout toolbar.

3. Specify the wall attributes and select sketching references fromthe default datum planes, as shown in Figure 28.

Figure 28

4. Sketch the section for the wall and add the required dimensions,as shown in Figure 29.

Figure 29


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5. Select a depth option, such as Blind, as shown in Figure 210.

Figure 210

6. Complete the extruded wall, as shown in Figure 211.

Figure 211


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Exercise 2a Extruded Primary Wall

Goal After you complete this exercise, you will be able to:

Create an extruded primary wall

In this exercise, you create the extruded primary wall shown inFigure 212.

Figure 212

Task 1: Create a new sheet metal part.

1. Create a new part file and select the Sheetmetaloption in theNew dialog box. Select the Use default templateoption.


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2. Enter [support] as the part name, as shown in Figure 213, and

select the button.

Figure 213

Task 2: Create an extruded wall on datum plane FRONT.


1. Select the button from the flyouttoolbar.

2. ClickOne Side>Done.

3. Select datum plane FRONT as the sketching plane. Use thedefault direction of feature creation.

4. Select datum plane TOP as the sketcher orientation reference toface the Topdirection.


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5. Sketch the section shown in Figure 214. Modify the dimensionsto the values shown.

Figure 214

Task 3: Add the material thickness to the profile.

You can also use your rightmouse button to accessthe Thickenoption.

1. Click Sketch > Feature Tools > Thicken.

2. Make sure the arrow points toward the interior of the section.Click Flipor Okay.

3. Enter [.10] for the material thickness.

4. Delete the dimension that currently exists for the radius of thearc.

5. Re-dimension the radius by selecting the dotted arc created bythe Thickenoption. Set the value to [0.5]. The radius appears asshown in Figure 215.

Figure 215


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6. Extrude to a Blinddepth of [6]. The completed wall featureappears as shown in Figure 216.

The green side should beon the outside of the modelwhen finished.

Figure 216

7. Save the part and erase it from memory.


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Exercise 2b Flat Primary Wall


Create a flat primary wall

In this exercise, you create the flat primary wall for the bracket partshown in Figure 217.

Figure 217

The remaining features of this part are created in exercises later inthis course.


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Task 1: Create a new sheet metal part.

1. Create a new part file and select the Sheetmetaloption in theNew dialog box, as shown in Figure 218. Select the Usedefault templateoption.

oFigure 218

2. Enter [bracket] as the part name and select the button.

Task 2: Create a flat wall on datum plane FRONT.

You can also clickInsert >Sheetmetal Wall >Unattached > Flat.

1. Select the button from the flyouttoolbar.

2. Select datum plane TOP as the sketching plane. Use the defaultdirection of viewing the sketching plane

3. Select datum plane FRONT to face Bottom as the Sketcherorientation reference.


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4. Sketch the section as shown in Figure 219.

Use centerlines andsymmetry to aid in thesketching process.

Figure 219

Task 3: Enter a material thickness of [.04] and finish the wallfeature.

1. Modify the dimensions accordingly and exit Sketcher.

2. Enter [.04] as the material thickness.


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3. Select the button in the dialog box. The completed wallappears as shown in Figure 220.

Figure 220



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Exercise 2c Creating the Project Part


Create a sheet metal part for use with other parts

In this exercise, you create a primary wall with the dimensions shownin Figure 221. It is used in several exercises later in this course asyou learn additional sheet metal features.

Task 1: Create a new part.

1. Create a new sheet metal part called [project] using the defaulttemplate.

2. Create the first wall feature using the Extrudeoption, as shownin Figure 221.

Make sure that the insideradii of the two bends areequal.

Figure 221



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Chapter 3 Secondary Walls


Selecting an Attachment Edge

Secondary Wall Options

Unattached Walls

Bend Relief

3.1Selecting an Attachment

Edge

Remember to use PickFrom Listto ensure thatyou are selecting thedesired attachment edge.

Just as secondary solid features are built by referencing the basefeature, secondary walls are built by attaching them to the primarywall. By selecting an existing edge to which to attach the wall, youestablish a parent/child relationship between the primary wall and thewall you are creating. Carefully consider the edge references to avoidhaving to redefine them later.

The type of wall being created determines the sketching orientation.In some models, you view the attachment edge parallel to the screen;in other cases, the edge is viewed normal to the screen (i.e., as a

point in the sketching plane).


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3.2Secondary Wall Options

Many of the options used to create primary walls are also available tocreate secondary walls along an attachment edge. With somesecondary walls, you can also have the system automatically apply abend radius where the walls meet.

The following sections describe are some common types ofsecondary walls.

Flat Wall -

Without Radius

To create a flat wall without a radius, sketch the outline of the wall sothat the endpoints are coincident with the linear attachment edge. Theoutline of the wall can include the entire attachment edge or asegment of it. The flat wall sketch in the following figures has a singleopen section. The resulting wall is created coplanar with the existing

wall, as shown in Figure 31and Figure 32.

Figure 31

Figure 32

attached, flat wall

without radius

Open sketch

The endpoints of the attachment edge are

automatically selected as Sketcher references. In this

case, no additional references are required.

Open sketch

The attachment edge must be selected as asketcher reference in this case.


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Extruded Wall -

Without Radius

To create an extruded wall without a bend radius, select the straightattachment edge. After selecting a sketching plane, Pro/ENGINEERorients you normal to the attachment edge.

Sketch the section of the extruded wall so that one of the endpoints ofthe section touches the attachment edge. A bend radius can besketched as an arc in the section, as shown in Figure 33.

Figure 33

A tangency constraint can be applied to the arc to ensure it is tangentto the existing wall. The wall is extruded the entire length of theattachment edge unless you define the optional Depth element.

In addition, you can vary the results of the wall using any of thefollowing techniques:

A datum plane can becreated on the fly using theMake Datumoption.

Create a partial extruded wall using only a portion of theattachment edge.

Create a datum plane normal to the edge at any point to use asthe sketching plane.

Define a blind depth instead of extruding along the entire edge.

attached, extruded

wall without radius

Apply a tangency constraint to

ensure the arc is tangent to the

existing wall.


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Swept Wall -

Without Radius

To create a swept wall without a bend radius, sketch an open section,as shown in Figure 34.

Figure 34

This option creates a wall swept along a tangent chain of non-linearedges. The surfaces containing the attachment edge(s) do not needto be planar.

attached, swept

wall without radius


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Flat Wall - With

Radius

To create a flat wall with a radius, select the linear attachment edge.The system prompts you for the angle. Select a bend angle from theDEF BEND ANGLE (default bend angle) menu. A sketching plane isautomatically selected through the attachment edge and is at anangle to the adjacent surface. Sketch the outline of the wall, as shownin Figure 35.

Figure 35

This option creates a flat wall at an angle to an existing planar wall. Abend is automatically created between the new wall and the adjacentwall.

attached, flat wall

with radius

Depending on the

attachment edge, some of the

adjacent existing wall maybe consumed by the bend.


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Extruded Wall-

With Radius

To create an extruded wall with a radius, you must sketch the bendangle in the profile of the wall and specify a radius for it. Note that aportion of the adjacent wall may be consumed depending on theattachment edge selected.

You can also establish the sketching plane at a location along theattachment edge other than the end point to define a partial wall. To

do this, you must provide a blind depth and bend relief. Figure 36and Figure 37show examples of an extruded wall with a radius.

Figure 36

Figure 37

attached, extruded

wall with radius

No arc is sketched to form the bend


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Swept Wall -

With Radius

To create a swept wall with a radius, sketch the section normal to theattachment edge at its endpoint, as shown in Figure 38.

Figure 38

When creating a swept wall with radius, the angle between theadjacent surface and the swept wall cannot be greater than 180.

attached, swept

wall with radius

No arc is sketched to form the bend


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Options for

Walls With

Radius

Creating a wall with radius can affect on the length of the walls.Consider the example shown in Figure 39. The overall length of thepart may increase depending on the selection of the attachment edge.In either case, the length of the original wall decreases by the value ofthe bend radius or by the sum of the bend radius and the materialthickness.

Figure 39

Four options are available to determine the radius of the bend whencreating walls with radius, described in Table 31.

Table 31

Option Result

Thickness The bend radius is made equal to the materialthickness.

Thickness*2 The bend radius is made equal to two times the value

of the material thickness.

Enter Value A value must be specified to define the bend radius.

From Table The appropriate radius value is selected from the listand the radii values are defined in the bend tableassigned to the part. This option is unavailable if abend table is not assigned to the part.

L L

L - R

L

L + TL

L - T

Direction of material

L - (T + R)


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In Pro/ENGINEER, bendtables are used to controlthe developed length of thebend based on the bendradius and materialthickness. By applying abend table, you can

capture design intent inyour models. Bend tablesare covered in more detaillater in this course.

You must choose whether to apply the defined radius value to theinside or outside radius. Since Pro/ENGINEER generates the bendarea geometry when a wall with a radius is created, you must specifywhich bend table should be used to create the resulting wallgeometry. You can choose Feat Bend Tblor Part Bend Tbl. Byusing the Part Bend Tbloption you can control all bends in the partwith the same table, or you can apply the Feat Bend Tblcommand so

that each feature can be driven by its own table.

Twisted Wall A twisted wall acts as an extension to a straight edge on an existingplanar wall. The twisted wall can be rectangular or trapezoidal inshape. Once you complete the wall, an axis is created through thecenter of the twist, perpendicular to the attachment edge. Figure 310shows a twisted wall and the resulting dimensions.

To create a twisted wall,click Insert > SheetmetalWall > Twist.

Figure 310

You cannot apply a radius to this type of wall; however, you canunbend the wall. You can also add additional walls to the free end ofthe twisted wall.

To create a twisted wall, you must define the following geometry:

Specifying different widthsat the start and the end of

the wall results in atrapezoidal twisted wall.

The attachment edge

The datum point on the attachment edge to locate the twist axis

The width of the twist wall at the start

The width of the twist wall at the end

The length of the twisted wall

The twist angle

The developed length of the twisted wall

attachment edge


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Extended Wall An extended wall can be used to close gaps. The wall is extended aspecified distance or up to a planar surface.

Consider the example in Figure 311. The gap is closed by extendingthe wall on the right-hand side to the inside surface of the wall on theleft-hand side.

Figure 311

extended wallUnattached,

extruded wall

Unattached, flat

wall

Extend this wall Extended to inside of adjacent wall


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3.3Unattached Walls

Some secondary walls can be created without connecting them to thegeometry of the rest of the part, as shown in Figure 312. These wallare known as unattached walls.

Figure 312

Unattached walls can be patterned, as shown in Figure 313,whereas attached walls cannot be patterned. Unattached walls also

enable you to work on different regions of a sheet metal model.

Figure 313

Unattached walls can be patterned

Unattached patterned wall

instance should be merged to the

base walls


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If an unattached wall is separated from the rest of the model, youmust create walls to bridge the gap. The walls must then be joinedbecause operations, such as unbending, require unattached walls tobe merged. When merging the walls, keep the green side of theprimary wall adjacent to the green side of the unattached wall. If thecolors are not properly positioned, you can use the Swap Sideelement of the Unattached Wall feature to switch the colors so that

they are correct. Additionally, ensure that the walls are tangent.Figure 314shows the example with the walls merged to the basegeometry of the part.

Figure 314

merge unattached

wall Unattached wall created

to connect the first

Two Merge features are created

to attach the unattached walls to

the base walls.


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3.4Bend Relief

In certain cases, especially when creating partial flat or extrudedwalls, you need to add bend relief to the ends of the secondary wall.This enables Pro/ENGINEER to reshape or remove a certain portionof the primary wall so that the secondary wall can be created. You canadd bend relief to one or both ends of the wall. The following types ofbend relief can be added to a model:

No relief

Stretch relief

Rip relief

Rectangular relief

Obround relief

No Relief The No Reliefoption creates a wall that requires no relief. If relief isrequired and this option is selected, the wall will not be created.

Stretch Relief The Strtch Reliefoption creates a wall that is attached to the primarywall by stretching it at the attachment points. You must specify anoffset distance and an angle for this relief type, as shown inFigure 315.

Figure 315

Stretch relief


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Rip Relief The Rip Reliefoption creates a cut in the primary wall.This cut isapplied at the secondary wall attachment points normal to theattachment edge and back to the tangent line that defines the bendarea. This relief results in a zero-volume cut in the metal, as shown inFigure 316.

Figure 316

When sketching a flat wall, you can sketch beyond the boundaries ofthe attachment edge and align them to an existing wall. When usingthis technique, you must apply rip relief along the attachment edge atone or both of the endpoints of the flat wall. Pro/ENGINEERautomatically miters the corner, as shown in Figure 317.

Figure 317

Rip relief

Rip relief


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Rectangular

Relief

The Rec Reliefoption creates a rectangular-shaped cut using aspecified depth and width, as shown in Figure 318.

Figure 318

The width is defined by selecting Thickness, Thickness * 2, or Enter

Value. The depth of rectangular relief is defined by selecting Up toBend (creates the bend relief up to the bend boundary) or Entervalue, as shown in Figure 319.

Figure 319

Rectangular relief

Up to Bend Enter Value


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Obround Relief The Obrnd Reliefoption creates an obround cut at the attachmentpoints of the secondary wall. You must define the width and depth ofthe cut, as shown if Figure 320.

Figure 320

The depth of obround relief is defined by selecting Up to Bend

(creates the bend relief up to the bend boundary), Tan to Bend(creates the bend relief tangent to the side of the bend boundary), orEnter value, as shown in Figure 321.

Figure 321

obround relief

Up to Bend

Enter ValueTan to Bend


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3.5Hems

The sheet metal hem feature enables you to create hems on straight,circular, and swept sheet metal edges. The following types of hemscan be created:

Open Hem

Figure 322

Flushed Hem

Figure 323

hem

Open Hem

Flushed Hem


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Duck Hem

Figure 324

C Hem

Figure 325

Duck Hem

C Hem


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Z Hem

Figure 326

Use the following steps to create hem:

1. Select the hem type you want to create from the Type pull-downmenu of the Wall: Hem dialog box.

You can also select theedge first and select thehem type second.

2. Select the edge you want to hem and click Donein the MenuManager.

3. Enter the parameters for the hem in the Wall: Hem dialog box.

4. Select the button to create the hem.

The new, predefined hem feature eliminates the need to create thistype of geometry as a swept wall.

Z Hem


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Keep Wall

Height

Hem walls change the height of your wall. If your hem design requiresa specific wall height, you can set your hem walls to maintain theoverall length of the wall. To set the hem wall to maintain the wallheight, select the Keep wall heightoption to maintain the overalllength of the wall, as shown in Figure 327.

Figure 327

The resulting hem wall maintains the wall height, as shown inFigure 328.

Figure 328

Relief is only available ifyou set the hem to Keepwall height.

To define how to relieve the hem wall, select the Relief tab, as shownin Figure 329.

L L LL+R

L-R

RR

Hem Wall: Standard Hem Wall: Keep wall

height


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Figure 329

You may need to add bend relief depending on where you position the

hem wall. The bend relief helps control the sheet metal material andprevent unwanted deformation. You can automatically set the reliefattributes (type, width, depth, and angle) by defining bend reliefdefaults and parameters. If the defaults and parameters are notapplicable they are ignored. Relief is only available if you set the hemto Keep wall height.

You can assign different relief

types to each side of the bend

relief by selecting this option.

Otherwise, bend relief is applied

to both sides.


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3.6Creating a Secondary Wall

Use the following example as guide to creating a flat secondary wallwith obround relief:

You can also clickInsert >Sheetmetal Wall > Flatwith Radius.

1. Start the creation of wall Select the button from the

flyout toolbar.

2. Select the appropriate bend table and radius options. Click PartBnd Table > Inside Rad.

3. Select the appropriate attachment edge, as shown inFigure 330.

Figure 330

4. If the wall is being created with a radius, specify a bend angle

and select the direction for the new wall.

Select the attachment edge


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5. Specify the desired viewing direction for the sketching plane, asshown in Figure 331.

Figure 331

6. Select the required sketching references and sketch the profileof the wall, as shown in Figure 332.

Figure 332

The attachment edge was selected

as a reference for the open section.


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7. If necessary, apply bend relief to each end of the new wall (e.g.,Click w/Relief > ObrndRelief.).

8. Enter the required values for any applied bend relief.

9. Select the and buttons in the Wall Creationdialog box to complete creating the wall. The completed wall

appears as shown in Figure 333.

Figure 333


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Exercise 3a Secondary Walls


Create a secondary extruded wall

Create a secondary flat wall

Create walls with radius

Create obround relief

In this exercise, you create several secondary walls on the supportpart, as shown in Figure 334.

Figure 334

Task 1: Open a part and create an extruded wall with radius .

1. Open support.prt you created in Exercise 2a. If you did notcomplete the part, open 02_support.prt.

You can also clickInsert >Sheetmetal Wall >

Extrude with Radius.2. Select the button from the flyout toolbar.

3. Click Part Bend Tbl > Done/Return. The part bend table isselected so that all bend radii will have their developed lengths

calculated consistently within the part.4. Click Inside Rad > Done/Return. When the system creates the

bend at the attachment edge, the radius value is applied to theinside of the bend.

5. Click One Side > Done.


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6. Select the outside green edge as the attachment edge, as shownin Figure 335.

Figure 335

7. Click Defaultas the sketching plane option and Okayto acceptthe viewing direction.The sketching plane is automatically placedat one endpoint of the attachment edge. For a partial wall, youcould select or create a sketching plane anywhere along theattachment edge.

8. Sketch the section, as shown in Figure 336.

Figure 336

9. Exit Sketcher when the section is complete and return to thedefault view of the model.

Select the green edge.

The endpoint of the attachment edge is

automatically selected as a Sketcher reference.


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10. Click No Relief > Donesince the wall does not require bendrelief.

11. Click Enter Valueto specify the bend radius.

12. Enter [.5] for the bend radius value.

13. Select the button in the Wall Options dialog box tocomplete the feature. The part appears as shown in Figure 337.

By selecting the green

edge as the attachmentedge, you are able to usethe Inside Radoption.

Figure 337


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14. Create a similar wall on the opposite side of the part, as shown inFigure 338.

The two secondary wallscould have been createdas part of the original

primary wall. They are

created separately toaccommodate a possiblefuture design change.

Figure 338

Task 2: Create a flat wall with radius and bend relief.

You can also clickInsert >Sheetmetal Wall > Flatwith Radius.

1. Select the button from the flyout toolbar.

Select the green edge.


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8. In Sketcher mode, select the top and the left-hand surfaces asreferences for sketching, as shown in Figure 341.

9. Sketch the outline shown in Figure 341.

Figure 341

10. When you are finished in Sketcher, return to the default view ofthe model.

11. Click w/Relief > Done. A red X appears on the model toindicate the end of the attachment edge for which bend relief iscurrently being defined. Relief for the other end of theattachment edge is specified separately.

12. Click ObrndRelief > Done.

13. Click Enter Valuefor the relief's width and enter [.25].

14. Click Enter Valuefor the relief's depth and enter [1.00].

15. Enter the same values for the opposite end of the wall.

16. Click Enter Valueand enter [.5] for the bend radius.

Select the top and left surfaces of the part

as additional sketching references.Open section


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17. Select the button from the Wall Options dialog box. Thecompleted part is shown in Figure 342.

Figure 342



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Task 2: Create an unattached wall.


1. Select the button from the flyouttoolbar. Notice that you cannot create an unattached wall with aradius.

2. ClickOne Side > Done.

3. Select datum plane TOP as the sketching plane. Flip the arrowfor feature creation direction, and click Okay.

4. Select datum plane FRONT as the Bottom reference forsketching.

5. In Sketcher mode, select the necessary references and sketchthe section shown in Figure 345. Sketch the arcs tangent to theadjacent walls.

Figure 345


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6. Thicken the section, as shown in Figure 346. Pro/ENGINEERthickens this wall to the same value as the existing walls.

Figure 346

7. Complete the sketch and select the UpTo Surfacedepth option.Select the surface shown in Figure 347.

Figure 347

Select this thin

edge surface to

extrude up to.


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8. Select the button in the Unattached Wall dialog box. TheCOVER appears as shown in Figure 348.

Figure 348

Task 3: Merge the walls to make one continuous part.

You can also click Insert >Merge Walls. 1. Select the button from the flyout

toolbar.

2. Pro/ENGINEER prompts you to Select the surfaces to whichunattached wall will be merged. Select the surface on theprimary wall, as shown in Figure 349. Click Done Refs.

Pro/ENGINEER prompts you to Select the surfaces which willbe merged with the base surfaces. Select the bend surface onthe unattached wall, as shown in Figure 349. ClickDone Refs.

Only two walls can bejoined at one time so youmust to repeat the merge

process for the remainingunattached wall.

Figure 349

Select this surface first.

Select this

surface second.


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Remember to selectadjacent green or whitesurfaces.

3. Select the button in the WALL Options Merge dialog box

4. Create another merge feature for the original unattached wall.

You can also click Insert >Bend Operation >

Unbend.

5. Check to see if the merge commands were successful byunbending the part. If the part flattens successfully, then the

merge has been created correctly. Select the button from

the flyout toolbar. Click Insert > Bend Operation> Unbend.

6. Click Regular > Done.

7. Select a flat, planar surface to remain fixed, as shown inFigure 350.

Figure 350

8. Click UnbendSelect > Done.

9. Select the bend surfaces on the two merged walls as thesurfaces to unbend. ClickDone Refs.

Select this surface

to remain fixed.

Select these five bends.


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10. Select the button in the Regular Type dialog box. Themodel appears as shown in Figure 351.

Figure 351

11. Delete the unbend feature.



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Exercise 3c Hems


Create a Z hem

In this exercise you create a Z hem feature on an existing part.

Task 1: Open a part and create a Z hem.

1. Open clip.prt.

You can also click Insert >Sheetmetal Wall > Hem. 2. Select the button from the flyout toolbar.

The WALL: Hem dialog box appears.

3. Click Z_HEMin the Type pull-down menu.

4. Select the green edge shown in Figure 352as the attachmentedge. Click Done.

Figure 352

Select this green

edge as the

attachment edge.


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5. Enter the dimensions for the Z hem, as shown in Figure 353.Notice the orientation of the Z hem.

Figure 353

6. Select the button to flip the orientation of the hem. Thepreviews appear as shown in Figure 354.


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Figure 354

7. Select the button to complete the feature. Thecompleted feature appears as shown in Figure 355.

Dimensions can bemodified, as with any otherfeature.

Figure 355



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Exercise 3d Adding Walls to the Project Part


Add secondary walls

In this exercise you create additional walls on the project part, asshown in Figure 356.

Figure 356

Task 1: Open a part and create secondary walls.

1. Open project.prt.

2. Create an extruded wall. Use the green edge as the attachmentedge and create the wall with radius. Use Inside Radfor theradius dimension. The model appears as shown in Figure 357.

Figure 357


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3. Create a flat wall. Use the green edge as the attachment edgeand create the wall with radius. Use Inside Radfor the radiusdimension. You may have to flip the bend angle dimension. Themodel appears as shown in Figure 358.

Figure 358

4. Create an extruded partial wall on the green edge of the part.Create the wall with a radius, using the Inside Radoption. ClickSetup New > Make Datumto create the sketching planeaccording to the given dimensions. Apply obround bend reliefand specify a Blinddepth option for the wall. The dimensionsare shown in Figure 359.

Depth is an optionalelement for an attached,extruded wall.

Figure 359


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5. Create a similar wall on the opposite side of the part using thesame dimension scheme. The completed part is shown inFigure 360.

Figure 360



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Chapter 4 Regular Unbends, Bend Backs,

and Cuts


Unbending Sheet Metal Geometry

Bending Back Unbent Geometry

Sheet Metal Cuts

4.1Unbending Sheet Metal

Geometry

It is often necessary to unbend sheet metal geometry in order tocreate other features or to test whether or not geometry can bedeveloped (i.e., flattened). The simplest form of unbend feature is theregular unbend. It enables you to flatten ruled bends, as shown inFigure 41.

Figure 41

unbend

Ruled geometry exhibits

curvature in only one

direction.


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When creating a regular unbend feature, you can flatten all bendsusing the Unbend All option, or you can flatten individual bends withthe UnbendSelectoption, as shown in Figure 42

In a later chapter, youlearn how to set up defaultfixed geometry.

Figure 42

With both options, you are prompted to select an edge or a surface toremain fixed during the unbend. Try to select the same edge orsurface for every unbend to maintain a consistent default orientation.

Unbend allUnbend select


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4.2Bending Back Unbent

Geometry

To return unbent sheet metal geometry to the bent condition, you cancreate a bend back feature. As with the unbend feature, you areprompted to select a surface or edge to remain fixed. You can bendback all unbent geometry using the BendBack All option or bendback selected unbent geometry using the BendBack Sel.

Contours that intersect a bend area can be left unbent. Consider theexample in Figure 43.

Figure 43

bend back contour


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A cut has left an isolated contour in one of the bends. When theflattened bend is bent back, you are prompted to select thosecontours you wish to have remain unbent. If this isolated contour isselected, the resulting bend appears as shown on the bottom ofFigure 44.

Figure 44

Avoid having an unbend feature followed by a bend back feature inyour model tree. If you create an unbend feature to simply view the

flattened geometry, delete the feature when you are finished.Consecutive unbend and bend back features result in unnecessaryincreased regeneration times.

unbent

contour


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4.3Sheet Metal Cuts

When you create a cut in Sheet Metal mode, you can create a solidcut or a sheet metal cut. A solid cut is created the same as a cutcreated in Part mode. A sheet metal cut can only be extruded andhave a blind, through all, or through untildepth. Additionally, asheet metal cut can be created as a Thinor Solid. Click Insert >Sheetmetal Cut > Thinto create a thin sheet metal cut.

An extruded solid cut is extruded through the material in a directionnormal to the sketching plane.An extruded sheet metal cut is firstprojected onto the surface (green or white) selected as the drivingsurface, and extruded normal to that surface.

Consider the part shown in Figure 45. It shows the section of a cutabout to be extruded on a sheet metal part.

Figure 45

sheet metal cut - solid

Cut section

The shaded surface

represents the green surface

of a sheet metal part.


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If the cut is a solid extrudedThru Allcut, the result appears as shownin Figure 46. The cut is extruded normal to the sketching plane.

Figure 46

If the cut is a sheet metal extruded cut with the green surface selected

as the driving surface, the result is as shown in Figure 47. The cut isprojected onto the green surface and extruded normal to the greensurface.

The shaded surfacerepresents the greensurface of a sheet metal

part.

Figure 47

If the cut is a sheet metal extruded cut with the white surface selectedas the driving surface, the result is as shown in Figure 48. The cut isprojected onto the white surface and extruded normal to the whitesurface.


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Figure 48

Dimension

Scheme and

Feature Order

If you create a sheet metal cut prior to bending geometry, the locationof the dimension scheme for the cut may be different then you expect.


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Consider the example in Figure 49.

Figure 49

1. flat wall

2. sheet metal cut

3. bend

1. flat wall

2. bend

3. unbend

4. sheet metal cut

5. bend back

On this side, an extruded sheet metal cut is

created on a flat wall and then a bend is

created. When the cut is modified in the

bent condition, the dimension scheme

appears in the original location.

On this side, the bend and a bend back

feature are created prior to the cut. The cut

is still created in the unbent condition, but

when the part is bent back, the dimension

scheme for the cut follows the geometry.


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4.4Creating Unbend and

BendBack Features

Use the following example as a guide to creating a sheet metal cutrequiring the use of unbend and bend back features.

You can also click Insert >Bend Operation >Unbend.

1. Start the creation of the unbend feature. Select the button

from the flyout toolbar.

2. Select a surface to remain fixed, as shown in Figure 412, andclick UnbendAll.

Figure 412

You can also click Insert >Sheetmetal Cut > Solid. 3. Select the button.

4. Select the sketching and orientation planes to create the cut, asshown in Figure 413.

Select this surface


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Figure 413

5. Select sketching references and sketch the profile of the cut, asshown in Figure 414.

Figure 414

6. Specify material to be removed and select the depth option.

You can also click Insert >Bend Operation > BendBack.

7. Create the bend back feature. Select the button from thetoolbar menu.

Sketching plane

Orientation plane

to face Bottom


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Exercise 4a Creating a Sheet metal Cut


Unbend a sheet metal part

Create a cut in the unbent condition

Bend back a sheet metal part

In this exercise, you create the sheet metal cut shown in Figure 417.The cut will require you to first unbend the part.

Figure 417

Task 1: Open and unbend a part.

1. Open unbend1.prt.


2. Select button.

3. Click Regular > Done.


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4. Select the surface to remain fixed, as shown in Figure 418.

Figure 418

5. Click Unbend All > Done.

6. Select the button. Select the button from theRegular Type dialog box. The finished unbent part is shown inFigure 419.

Figure 419

Task 2: Create the sheet metal cut in the unbent condition.

You can also click Insert >Sheetmetal Cut > Solid. 1. Select the button from the toolbar.

Select this

surface


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2. Select the sketching plane and the orientation plane as shown inFigure 420. Click Okayto accept the direction of viewing thesketching plane.

Figure 420

3. Select the sketcher references and sketch the section shown inFigure 421.

Figure 421

4. When finished in Sketcher, click Okayto remove the material

inside the cut section.

Sketching plane

Orientation plane to face Bottom

Sketcher references


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5. Click Thru All > Donefor the depth of the cut. The cut appearsas shown in Figure 422.

Figure 422

Task 3: Return the part to its bent condition .

You can also click Insert >Bend Operation > BendBack.

1. Select the button from the toolbar.

2. Select the surface to remain fixed, as shown in Figure 423. Theselected surface should be the same one you used to create theunbend feature.

Figure 423

Surface to remain fixed


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3. Click BendBack All > Done. Select the button. Select

the button in the Bend Back dialog box. The partappears as shown in Figure 424.

Figure 424



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Exercise 4b Projected Curve and a Cut


Project a datum curve that follows the part surfaces

during unbending and bending back

Create a sheet metal cut that references a projected

datum curve

In this exercise, you project a curve onto the model in the bentcondition and unbend the part. You will then use the projected datumcurve as a reference for a cut and return the model to the bentcondition.

Figure 425

Task 1: Open a part and create a projected datum curve.

1. Open curve_cut.prt. Make sure the part is in the defaultorientation.

2. Click Edit > Projectto create a datum curve. The dashboardappears.

3. Open the References slide-up panel.

4. Select the Follow Surf option and click Project a sketchin the

pop-up menu. Then select the button.


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5. Select the surface shown in Figure 426as the sketching plane.

Figure 426

6. Select datum plane FRONT to face Bottom.

7. Keep the direction of feature creation and select thebutton.

8. Select the required sketcher references and sketch the sectionshown in Figure 427.

Figure 427

9. When finished in Sketcher, select the button and orientthe model to the default view.

Sketching

plane


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10. Using the key, select the surfaces on which to project thecurve, as shown in Figure 428.

Figure 428

11. Select Along directionas the Direction item and select theplane used as sketching plane as the direction reference. Thecompleted curve is shown in Figure 429.

Figure 429

Task 2: Unbend the part and use the datum curve as a referencefor a sheet metal cut.


1. Select the button in the toolbar.

2. ClickRegular > Done.

Select these surfaces for projection


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3. Select the surface shown in Figure 430to remain fixed.

Figure 430

4. Click Unbend All > Done. Select the button in theRegular Type dialog box. Notice that the projected datum curvefollows the surfaces in the unbent condition.

You can also click Insert >Sheetmetal Cut > Solid. 5. Select the button in the toolbar.

6. Select the sketching plane shown in Figure 431and selectdatum plane FRONT to face Bottom.

Figure 431

7. Sketch the section shown in Figure 432. Use the datum curveto create entities in the sketch.

Surface to remain fixed

Sketching plane


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11. Select the surface to remain fixed. The surface should be thesame as the one that you used for the Unbend feature.

12. Click BendBack All > Done. The part appears as shown inFigure 435.

Figure 435



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Exercise 4c Create a Cut on the Project Part


Create a sheet metal cut

In this exercise, you create a thin sheet metal cut feature on theproject part created in a previous exercise. Keep in mind the methodsof unbending the model and creating cuts introduced in this chapter.

Task 1: Create a sheet metal cut on the project part.

1. Open project.prt. Make sure the part is in the default orientation.

2. Unbend the entire part.

3. Create a thin sheet metal cut using the dimension schemeshown in Figure 436.

Figure 436

4. Return the model to the bent condition. You are prompted toselect contours in unbent areas to remain flat. Since the cutintersects one of the bend regions, it can remain unbent.


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5. Click Nextuntil the geometry isolated by the cut is highlighted.Click Accept > Done. The completed part appears as shown inFigure 437.

Figure 437



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Chapter 5 Notches and Punches


Creating Notch and Punch UDFs

Placing Notch and Punch UDFs

5.1Introduction to Notches and

Punches

Notch and punch features are created in a Sheet Metal model usingsheet metal cuts and user-defined features (UDFs) to create

geometry. Notch features are often used for bend relief at corners,since obround and rectangular relief cannot cross the bend geometryof another wall. Punches tend to be closed-profile shapes that removematerial, usually in a template format. Figure 51shows an exampleof the notch and punch features.

Figure 51

notch

punch

PunchNotch


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Notches and punches are made with specific tools. Pro/ENGINEERenables you to create notch and punch UDFs with specific geometrythat can be reused on different models. When creating a notch orpunch UDF, you are prompted to define the following items:

A coordinate system to locate tooling

A specific tool ID for fabrication purposes

A single sheet metal cut feature

The part on the left-hand side of Figure 52show a sheet metal cut.This cut is used in a notch UDF and placed on the part shown on theright-hand side. Notice that the cut remains normal to the sheet metalsurface in the bend area.

Figure 52

Cut remains normal to sheet

metal surfaces in the bend area


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5.2Creating Notch and Punch

UDFs

Notches and punches are created in conjunction with UDFs. UDFsallow the geometry to be created once and then reused as needed onother models.

Use the following example as a guide to creating a notch or punchUDF:

1. Create a simple sheet metal part to act as a reference part.

2. Create a sheet metal cut feature. When sketching the profile, beaware of sketching and dimensioning references, and rememberto include a coordinate system. If the cut is used to relieve a

bend area, the reference part should contain a bend to be usedas reference, as shown in Figure 53.

Use relations whenappropriate to capturedesign intent and tominimize and controlvariability in future use.

Figure 53

3. Click Feature > UDF Library > Create.

4. Specify a name for the UDF. Pro/ENGINEER saves this file as.gph.


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When creating a UDF, youhave two options:Subordinateand Stand

Alone. The Stand Aloneoption copies the UDFgeometry from thereference part to the .gph

file. This option enablesyou to discard thereference part once youare finished. TheSubordinateoption keepsthe references for creatingthe UDF geometryembedded in the reference

part.

5. Click Stand Alone > Donein the UDF OPTIONS menu.

6. Pro/ENGINEER prompts you to include the reference part. If thereference part is simple, enter [Y]. If the reference part iscomplex, enter [N]. A complex reference part will increase the filesize; therefore, keep the reference part as simple as possible.

By including the reference part, the system saves a copy of thereference part with the name .prt. This referenceinformation is now available when you place the UDF in anotherpart.

7. Click Addin the UDF FEATS menu and select the cut featureshown in Figure 54.

Figure 54

8. Click Done > Done/Return.

9. Pro/ENGINEER asks you if you are defining the UDF for a punchor notch feature. Enter [Y].

10. Enter a name for the tool used to create the notch or punch onthe actual sheet metal part.

11. Define the symmetry for the tool relative to the coordinatesystem in the cut feature using the SYMMETRY menu. Click theappropriate option.

Select the cut feature


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5.3Placing Notch or Punch

UDFs

Use the following example as a guide to placing a notch or punchUDF:

You can also click Insert >Shape > Notch or Insert >Shape > Punch.

1. Select the button (for a notch) or the button (for a

punch) from the flyout toolbar. Use anunbend feature to flatten the model if necessary.

2. Select the appropriate UDF file from the Open dialog box.

3. Specify whether or not to retrieve the reference part. If you

retrieve the reference part, the reference part appears in asub-window, as shown in Figure 56.

Figure 56

The original references on the reference part highlight as you areprompted to select corresponding references on the placement part.This may be useful for placing the UDF on the current part.

4. Specify values for variable dimensions and features.

Corresponding references

will be selected here

Placement references

will be shown here


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5. Describe how to display non-variable dimensions using theoptions in the DISP OPTION menu. Some dimensions may havebeen specified as non-variable during the UDF definition andthey cannot be modified after the UDF has been placed.

Displaying non-variabledimensions will be

determined by designintent.

6. Select corresponding placement references similar to those inFigure 57.

Figure 57

Create your walls andbends in the bent conditionfirst. Then create thenotches in the unbent

condition. It is easier todesign in the bentcondition and then unbendthan it is to design in theflat or unbent condition.

7. Complete the feature. The mo

sheet metal design.pdf

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