Having difficulty with a bent sheet metal part

[willemwilke1]

Hello everbody!

I'm having difficulty creating this shape in 3mm stainless sheet metal. This is a mockup I made in photoshop, so this is not how it looks in fusion ATM (forget the middle part going up, that's a seperate part.):

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This is the flat part in Fusion 360, is there anyway to edit this file with flange tools to create the bends you see in the above picture? (30 degrees on both outermost sides and a collective 110 degrees on the centre bend)

And this is how far I got in Fusion with the flange tools. As you can see it's only half of the shape and it has a weird anomaly on the top. ( I made this with the flange tool) I can't copy and paste flange bodies so I couldn't make the mirror opposite side and even if I could I wouldn't know how to merge them into one flange body

Could anybody please help me??

[TheCADWhisperer]

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@willemwilke1wrote:

 And this is how far I got in Fusion with the flange tools. 

Could anybody please help me??

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Can you File>Export and then Attach your *.f3d file here?

[willemwilke1]

File 1 is the bent metal tryout

file 2 is what the definitive flat version of what must be bent into picture number one

[TheCADWhisperer]

What I am going to do when I find the time.

1. Model oversize bent flange stock.

2. Unfold.

3. Cut away excess stock with your profile.  (after correcting all of the errors and fully defining the sketch symmetrical about the origin (one dimension??))

4. Refold.

5. Flat Pattern.

[willemwilke1]

That sounds like a clever solution man!

One last bit of info though... the bend lines for the two outer bends are not parralell to the centre bend... see the image

[willemwilke1]

Thanks to your info I managed to create the shape i wanted in fusion! 
Thanks a bunch!

But now there's something weird going on in my cutting and bending program (Sophia app through https://www.247tailorsteel.com/enm)

The black spheres indicate through-holes... but somehow it's not registering one correctly. Is there something wrong with my file?

[JDMather]

Well, you have several errors in your technique and you are doing a rather astonishing amount of extra work.

Check back in couple of days and if I have time I will show how the part should have been modeled.

(I will start over from scratch - as you should have done.  Consider your initial attempt (or two or three) to only practice runs and then start over from scratch using what you have learned.)

[willemwilke1]

It's my first part ever, so I'm learning on the fly so to speak.

I managed to fix the current file for printing, but i'll make it again tommorow from scratch, will be only reusing the sketch of the flat shape and moving from there.
I'm curious to see how you'd do it though, thanks.

[willemwilke1]

Alright, tried again today. 

Managed to simplify a lot of my actions, still might be doing things a bit too complicated but I'm learning this all by myself just messing around. A critical eye at the new attempt is appreciated!

[TheCADWhisperer]

Sketch1 is pretty much a disaster.

I would model with symmetry about the origin.

There would be no blue elements (all fully defined black).

All the dimensions needed to manufacture and inspect the geometry.

Tangents, Horizontals...

[willemwilke1]

origin being parallel to either X, or Z or Y axis?

that would mean starting over with the first sketch of the object?

[TheCADWhisperer]

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@willemwilke1wrote:

that would mean starting over with the first sketch of the object?

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Are you willing to start over?

If I take this on, that is exactly what I would do. 

Let me know, if you are not willing to start over - then

[willemwilke1]

Alright well, I made a working file now after 30 hours of manically trying to figure out this program so I'm relatively satisfied with what I made and learnt.

There are still a few questions though.

When doing it this way, I couldn't get the centre bend (i used the old sketch for this) in the centre of the oversized bent stock without moving it and potentially creating weird anomolies in geometry. The flange tool was unwilling to place the bend in the centre of the sketch I made.

and what are the most important lessons to take out of this? Start out with a sketch that has a better origin in X-Y-Z space?