Adding flanges to a contour roll

[shight]

I've been having some issues recently with Sheet Metal parts. I am attempting to make a part that looks like this:

The only way I have been able to do this so far is by doing a contour roll to get the rounded part and then add the flanges on as part of an assembly. 

I have attempted to do it as one Sheet Metal piece but I continually run into the problem where I cannot refold the part once I have the flanges.

Here are the steps I have gone through:

1. Created a contour roll to the necessary angle to get my desired dimensions

2. Unfolded the roll

3. Created my hole pattern

4. Folded back the flanges

This is where I got stuck. I attempted to refold the part between the bends but it will not let me do this. If I have one flange, I am able to refold but not when I have 2.

Another problem I have encountered is when I get one flange done, the thickness of it is larger than the rest of the part. 

If there is any help you can give me, I would appreciate it.

-S. Hight

[CAD-One]

Just curious hou did you make those holes?

[shight]

I made a sketch on the face after it had been unfolded and was flat. I made one hole and then did a rectangular patterm. Then I did an offset hole and another rectangular pattern. 

[blair · Accepted solution]

The other way is to create your flat sheet metal piece,do your holes and pattern them on the flat, then place a sketch line in the middle and fold the one side up 90 deg, then create another sketch on the middle (edge of the first fold) and fold the other side. The trick is to use a radius that doesn't consume the one half of the flat, this will allow you to create the flange on each side with the Flange tool.

[blair]

And yes it does Flatten as well within the Sheet-Metal module.

[blair]

Here is the part to see how I did it. Just drag the EOM down to the end of the features.

[shight]

I can't open your part because I'm running IV2011, any way you can put it in a compatible format?

[shight]

Nevermind, I don't need to be able to open it, I was able to sort my problem out. Thanks for your help blair

[SBix26]

Here's a 2011 version with a contour flange, unfold, hole pattern, refold.