I'm trying to model a complex sheet metal object. It isn't your standard "square" part. It's base is bent into a cylindrical shape, then merges into a semi-circular shape which is then extruded along the X axis.
I've managed to "hack" the blend by using flange + extrude + loft, but as you can see it looks ugly and has way too many steps.
Is there a better way to achieve this?
If it's not clear which area I'm having trouble with, it's where the cylinder merges into a straight line:
Also, it's an IKEA TERTIAL Work lamp - in case anyone has one at home they can reference.
I just made a quick basic transition from flat to round. Here are images of flat pattern and formed views. Attached is a file if you want to open and modify to the cuts you need.
Hope this helps.
In your image "Original part - from IKEA Lamp", half of the part has about 180 degree bend and another half has close to 360 degree bend, so there might not be a direct way to create that in Fusion 360 Sheet Metal and seems some hack has to be used (yours is one such hack and another one suggested by @bryan5 ). Although practically you can bend the model 180 degree first and then bend only selective region more to make it almost full circle. In that case, unless enough relief is available, some distortion will be seen, like you see with the original part.
Please check if this method gives you more control or better result -
Start with a U shaped Contour Flange, unfold it cut some regions, refold it. Then create a separate contour flange to add the remaining 'almost full circle' region.
something like this (see the f3d attached to get rough idea) -
You can use combine command to keep only one body, but then it will not unfold & refold.
@laughingcreek - Whenever user adds extra material to the bend region, such that bend is affected, unfold & refold are likely to face problems (because the commands then cannot easily identify original bends to unfold/refold, more so for refold). That is why the 'test_piece' file uploaded by @bryan5 fails to refold.
Notice that it has modified the bend region by attaching extrude to it, so it fails to refold the tampered bend.
