Flange tool question

[dwoodville]

I'm looking to create flanges to fill in the corners on my attached drawing. I have not been able to find a suitable way of doing this. I've attached my working file along with a .jpg of what I'm trying to achieve (disregard the angles written in on the drawing). Any tips out there? 

[jhackney1972]

You screen capture or image attached but your model did not.

[dwoodville]

Whoops, here is the file. 

[dwoodville]

Thank you! I got it uploaded now. 

[jhackney1972]

Where is your Fusion 360 (F3D) file?  This is an raw DWG file.  The base plate of this file is not square, it has multiple sides.  You will have to define how you want sheet metal to work with this.

[dwoodville]

Sorry here is the fusion 360 file.

[jhackney1972]

Well if you want this cover to completely enclose the flange to some height, I used 4", then it cannot be sheet metal.  Sheet metal cannot unfold because of the corners.  So I made a cover but it is solid, 0.125" thick.  I am sure it is not what you want but what you have defined, by your photo, is impossible to create in sheet metal, at least in Fusion 360.  by the way, your flange is not symmetrical.  Different sides measure different lengths and the inside radii are different.  Model is attached.

[dwoodville]

I should have noted that the cover is bent and welded in real life. The flange is not symmetrical by design however I'm not as concerned about that. I'd like the corners on my design to be bent/flanges and not a solid cover. The plan is to weld it in real life. 

[jhackney1972]

So the angled corners and the fillet edges are not covered?  The sheet metal only welds to the flat sides of the flange? If so, inside the flange, on the top face of the flange to the inside edge, or some distance on top of the flange.

[dwoodville]

I'm not following your questions. I attached another photo in hopes to help. 

[jhackney1972]

I do not know of any way to close the corners of this shape using the sheet metal tools included in Fusion 360.  So I will call an end to my trail and error to try and answer your question.  Good luck with your design.

[dwoodville]

Thanks for your time and trying to help!

[dwoodville]

I've now tried using the loft tool, creating a path and then a flange from that path etc and have spent about 5 hours trying to make it work. There is a way to do this and it should be so much easier than what I've done so far. All I want is a piece of sheet metal with a few flanges that will allow me to bend and weld up when done. 

[dwoodville]

Heres another example of what I would be OK with if I could draw it. 

[davebYYPCU]

See if this works for you, I did try to mirror the body, then flat pattern, but that failed, so mirror the flat pattern, in the dxf.  closing the gaps for welding with press pull, not my area of expertise...

With thanks to JD, 

Might help....

[davebYYPCU]

Got the mirror to work, was workflow ordering thing...

[TheCADWhisperer]

Pretty sure we can get this done with very simple technique.

Check back later today when I have had a chance to tackle the problem.

[dwoodville]

Sorry for the delay in response. This looks great and I will have to give it a shot! Thank you. 

[dwoodville]

Any chance you can screen cast how you did that? I'm not sure how to press/pull the flat component but still have bend lines or create new bend lines. 

[davebYYPCU]

I sent my file back to you, stepping up the timeline, using edit feature, will give you my settings.

In summary - I lofted Surfaces, stitched them, filleted the seams and then deleted the fillet faces not required, and then thickened the base surface.  I then converted it to sheet metal, mirrored the finished body, and flat pattern was extracted.

Let me know - my screencasts have terrible sound qualities, and can answer questions, in here.

Might help...