solid works sheet metal

7/30/2019 Solid Works Sheet Metal

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Presented By Jeff Parker for Yakima SolidWorks User Group


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Part One Theory & Basics Part Two Adv. Topics

Sheet Metal Theory

Definitions & Formulas Bending Theory

Tools Overview

What tools are available?

Special Tool Options

How to Start Part

Start with SM Features

Model Part then add SMFeatures

Bend Tables

Advanced Shapes

Forming Tools

Using & Creating

Sheet Metal Configurations

Drawing Creation

Using Imported Bodies

Best Practices Compilation


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Examples
http://localhost/var/www/apps/conversion/tmp/scratch_9/Sample%20Files/special_corner_sample.SLDPRT


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Examples
http://localhost/var/www/apps/conversion/tmp/scratch_9/Sample%20Files/Sheet%20Metal%20Plane%202K9%20v2.SLDPRT


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Examples


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Examples
http://www.parallax.com/http://localhost/var/www/apps/conversion/tmp/scratch_9/Parallax%20SolidWorks%20Example/Stingray%20Robot/Parallax%20Stingray%20Robot%20Full%20Assembly/28980%20-%20Mid-size%20Robot%20Full%20Assembly%20(Rev%20A%20-%2020090123)%20[RefModel].SLDASM


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Sheet Metal Theory

Definitions:

Bend Allowance Length of the arc through the bend area at the neutral axis.

Bend Angle

Angle of the arc formed by the bending operation.

Bend Compensation Amount by which the material is stretched or compressed by bending.

Bend Lines The straight lines where the flange boundary meets the bend area.

Inside Bend Radius Radius of the arc on the inside surface of the bend area.

K-factor Defines the location of the neutral axis. (distance from the inside of the material to theneutral axis divided by the material thickness).

Mold Lines For bends of less than 180 degrees, the mold lines are the straight lines where the surfacesof the flange bounding the bend area intersect.

Neutral Axis Looking at the cross section of the bend, the neutral axis is the theoretical location atwhich the material is neither compressed nor stretched.

Set Back - For bends of less than 180 degrees, the set back is the distance from the bend lines to themold line.


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Sheet Metal Theory

Formulas:

Bend Allowance = Angle * (PI / 180) * (Radius + K-factor * Thickness)

Bend Deduction = Bend Allowance (2 * Set Back)

Inside Set Back = tan (Angle / 2) * Radius

Outside Set Back = tan (Angle / 2) * (Radius + Thickness)


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Calculating Bends for Your Equipment

Calculating the correct flat pattern layout is crucial. Lets start with a simple L bracket. The picture shows that thelegs of the bracket are 2 and 3. The material thickness is 0.036, the inside radius is 0.125, and the angle ofbend is 90 degrees. The flat length is the total of the flat portion of both flanges plus the length through thearc of the bend area. Do you calculate that on the inside of the material or the outside? Neither! This iswhere the K-factor comes into play. The K-factor is the percentage of the material thickness where there isno stretching or compressing of the material, for example, the neutral axis. For this simple L bracket, I willuse a K-factor of 0.42. The formula is: Bend Allowance = Angle * (PI / 180) * (Radius + K-factor * Thickness).Plugging in our numbers, we get: Bend Allowance = 90 * (PI / 180) * (0.125 + 0.42 * 0.036) =0.2200999813105009.

So the flat pattern length is 2 + 3 + 0.2201 which is equal to 5.2201. So if you add up the flat length of all theflanges and add one Bend Allowance for each bend area you have the correct flat length of the part. Now wehave to subtract two times the material thickness plus the bend radius (also known as the Setback) for eachbend area.


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Sample 1 Converting to Sheet Metal

Insert Bends vs. Convert to Sheet Metal Tools

Insert Bends Convert to Sheet Metal

Add Bends X X

Select Edges for Bends X

Rip Edges X XUse Rip Sketches X

Inside Radius X X

Auto Relief X X

Control Thickness & Direction X

Bend Allowance X

New for2009
http://localhost/var/www/apps/conversion/tmp/scratch_9/Sample%20Files/Base1.SLDPRThttp://localhost/var/www/apps/conversion/tmp/scratch_9/Sample%20Files/Insert%20Bends.SLDPRT


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Sample 2 Ground Up Tools Review

Overview of Sheet Metal Tools while building a part.

With this we are going to go over the basic Sheet Metal toolsSolidWorks offers, while also introducing some BestPractices for creating sheet metal parts.


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Base Flange/Tab

Insert Bends

Convert to Sheet Metal

Unfold

Closed Corner

Welded Corner

Break-Corner/Corner-Trim

Corner-Trim

Forming ToolSketched Bend

Lofted-Bend

Jog

Edge Flange

Miter Flange

No Bends

Rip

Flatten

Fold

Cross-Break

Hem


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Sheet Metal Notable Tool Options


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Bend & Gauge Tables

Sheet metal tables allow you to select frompre setup lists of material types,thicknesses, and inside radii. There arethree types of tables, they are bend, gauge,and gauge/bend.

Bend Gauge Gauge/Bend

Thickness X X X

Radius X X X

Different BendAllowance Values

X

Bend Allowance Type X X

New for2009


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Bend & Gauge Tables


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Advanced Forming Shapes

Can you model this formed edge? How about as a mitered edge?

This is probably one of the most complex bend profiles that Ihave seen. It is a prime example of a little knowledge ofSolidWorks and some planning ahead before starting tomodel the part.


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Forming Tools Using & Creating

Using forming tools


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Forming Tools Using & Creating

Items to consider:

Positioning sketch

Material to cut

Stopping faces Minimum Radius of Curvature

Creating forming tools

1. Start with base sizedlarger than thefinished tool.

2. Sketch the layoutsketch of tool.

3. Start modeling thetool body of the

louver.

4. Add all featureswanted for the tool.

5. Add fillet that has thesame >= radius thanthe material.

6. Cut the base fromthe newly createdtool.

7. Create a positioning

sketch at the base ofthe tool.

8. Color all cutting facesred and stopping faceRGB(202,209,238)


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Sheet Metal Configurations

Configurations are the same with sheet metal parts as withother parts with the exception that when you add a flat-pattern view onto a drawing, SolidWorks automaticallycreates a derived configuration. By default the derived

configuration is called Name of Configuration & SM-FLAT-PATTERN.

Tip:Use configurations to show the steps toform parts. You can use progressiveconfigurations as a How To referencefor forming.


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Sheet Metal Drawings

Adding the flat pattern view Legacy vs. View Palette

Using Model View must select Flat Pattern toimport view onto sheet.

View Palette allows the user to see preview andquickly add all needed views onto sheet. Alsoimporting of annotations is built into the

palette. Use of either technique will produce the same

view. The flat pattern view has also beenimproved over the last couple releases as it nowautomatically adds the bend notes.


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Using Imported Bodies

Importing Options

There are two main methods to convert imported geometryto sheet metal.

Importing the model and then converting to sheet metal.

Using FeatureWorks to automatically read the sheet metal featuresinto SolidWorks.

Tip: To be able to define the radii of the part, first import as a normalpart file not a sheet metal part. Then use FeatureWorks to identifythe radii. Now remove the radii and then use the Convert to Sheet

Metal tool, this will allow you to define your own radii and not beconfined by the import model radii.


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Start with a sheet metal part.

On existing parts define sheet metal early, this way you can take advantage of theLink to Thickness option.

Name Features..ALWAYS!!!

Edit flange profiles to add features like holes and cutouts. When using the legacy

method, take advantage of being able to create multiple flanges with one sketch. LetSolidWorks model the radii, do not model it manually.

You can model your own reliefs to add further control over their profile and size.

Take manufacturing processes into consideration when modeling the part.

Minimize any reference to bend lines, this is a bad practice as they are volatile andable to change based on sheet metal options.

Use Bend/Gauge tables to centralize forming information within the company. Forming tools do not show on flat patterns.

Understand the Normal Cut option.

Use PEM fasteners as Smart Components

Use tangent edges set to a non-solid line type to helpvisualize the bends in ISO views.

Do not use tangent edges on orthographic or flat patternviews.

Be aware of the Flip View button on flat pattern views, thishelps you orient the flat pattern to match the manufacturingpractice for the given material.

You can hide/show bend notes and lines. Also you can edit

the format of the bend note in the file bendnoteformat.txt(see Help).

Showing both X & Y dimensions in the BOM for sheet metalparts (example if time allows, if not please contact me forexample files).

Sheet Metal Drawing Modeling

Best Practices Compilation

Sheet Metal Part Modeling


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SolidWorks Sheet Metal Links

http://www.theswgeek.com/category/tutorials/sheet-metal-tutorials/ http://www.sheetmetaldesign.com/

http://video.google.com/videosearch?hl=en&safe=off&num=20&q=solidworks+sheet+metal#
http://www.theswgeek.com/category/tutorials/sheet-metal-tutorials/http://www.sheetmetaldesign.com/http://video.google.com/videosearch?hl=en&safe=off&num=20&q=solidworks+sheet+metalhttp://video.google.com/videosearch?hl=en&safe=off&num=20&q=solidworks+sheet+metalhttp://www.sheetmetaldesign.com/http://www.theswgeek.com/category/tutorials/sheet-metal-tutorials/http://www.theswgeek.com/category/tutorials/sheet-metal-tutorials/http://www.theswgeek.com/category/tutorials/sheet-metal-tutorials/http://www.theswgeek.com/category/tutorials/sheet-metal-tutorials/http://www.theswgeek.com/category/tutorials/sheet-metal-tutorials/

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