Sheetmetal part with Unfod, make Face, Refold

[brendan.henderson]

Looking for some assistance on getting this part feature modelled better. It Flat Patterns fine and the resultant DXF is okay (most important for our plasma cutter).

My workflow : I used Contour flange for the main body, added some flanges for some alignment/assembly tabs on the flat faces, then did an Unfold and created a sketch on the flat of the curved section. I used Face to turn these into more tabs. I then used Refold to obviously refold the part and this is where I got an error shown in the next picture.

I can progress past the error and Flat Pattern the part but the Refold node shows there is a problem. I don't like leaving models with issues like this.

In the next picture you can see that there is a line where the new Face joins with the Contour Flange. It looks strange but Flat Patterns okay and without the line. Still, I don't like it.

Can anybody share some insight into where I have gone wrong or into another method to make these tabs on the curve? The part file is attached incase someone takes up the challenge. Just move the EOP marker. Cheers.

[BeKirra]

Sorry, your part "36380-06100_FRAME_BLOCK.ipt" is missing.

[brendan.henderson]

Bugger! Can't believe I made that mistake. Attached is a zip of the parent and Frame_Block.

[BeKirra]

It is most likely a logical problem.

You "flatten"ed the sheet from a fold model then add tabs to it. Then you try to refold the model with the tabs.

It would work if you built the tabs to the other parts.

It may confuse Inventor. Inventor is not smart enough.

The way to get it done is that create tabs to the flat sheet then fold the model.

This only works if the thickness of the tabs is same as the sheet's.

HTH.

[pcrawley]

Rewind the model back to Mirror 5.

When picking the stationary face for the Unfold, pick a flat face - but remember which one!

Now pick that exact same face again to start your sketch for the tabs.

If you have the auto-project edges thing turned on, notice how it doesn't include the edges of the unfolded section...

Use Projected geometry to bring those edges into the current sketch.

Draw the tabs (just try one to make sure this works!)

Create the Face

Refold - picking the same stationary face again.

Nice?

[brendan.henderson]

Hi Peter.

Your workflow is pretty much exactly what I did, except for creating the sketch on the exact same Face used for the unfold.

So I tried it again, following your instructions (I don't use auto-profect edges) and I got the same result. Same error message, same lines showing an apparent divide between the new Face and the previous Thicken.

I appreciate your input. If you have the time here is a link to a short video showing my workflow which is as you detailed. Maybe you can see something I did wrong. https://drive.google.com/file/d/0B-gsQtdmsZzzSjlwWGFrZW9tRWM/edit?usp=sharing

[JDMather]

What is the purpose of WorkPlane1?
Isn't it the same as the XY Plane?

(back in a bit with my "solution")

[JDMather · Accepted solution]

This is a bit of a quick and dirty fudge - but should give you some ideas.  (just my dimensions - the process itself is rock solid)

Use the Project Flat Pattern and Cut Across bend functionality (that existed before we had Unfold/Refold).

[brendan.henderson]

Thanks JDMather. That solved it. Not as intuitive as the previous attemps but usable.

The extra Workplane was for 'buggered if I know'. Gone now.

[cadman777]

Making sure I used the same face for unfold/refold worked for me. Thanx!!