Problem with radius bend on angled surface

[denhen89]

Hello,

its my first post, but i found already many solutions here in this Forum for many problems i had, so i hope someone can help me out with my "little problem".

I am not sure if i found the right words in the title, but i think there is not much to explain, because if you look at the pictures below, you will understand my problem. I would like that the sheet metal body looks like on the first picture, but when i do the radius bend on the angled surface, the corners looks like you can see on the second picture.

I hope there is some quick trick for that 🙂

Thanks in advance and best regards,

Denis

[davebYYPCU · Accepted solution]

Not used Sheet Metal much, but if the side panels were wider, you can later extrude cut the excess off, 

may not be allowed in the sheet metal section as edges are square, but in the model workspace that is allowed.

So making the side panel wider should work.

Might help...

[denhen89]

davebYYPCU thank you very much for your quick reply.

Actually that is an very good and also quick solution for that problem. I have to admit that i should get this idea by my self... 

If there is no other solution which automaticly does fix that problem, then i will click soon on "accept solution".

Thank you very much!

[TheCADWhisperer]

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@davebYYPCU wrote:

Not used Sheet Metal much, but if the side panels were wider, you can later extrude cut the excess off, 

Can you Attach an example that results in valid sheet metal Flat Pattern? (Sides perp to flat.)

[chrisplyler]

It will still make a flat pattern. But of course some of the edges will be beveled. I think the best way to achieve the desired result in a real world part is to model it slightly oversized in the appropriate direction, cut and bend it, and finally square it up to a belt sander or similar to take off the excess.

[TheCADWhisperer]

One of the values I see to modern 3D modeling tools is designer often discover geometry (like sheet metal bend thickness) that they ignored in AutoCAD. 

When I worked out on the shop floor I would often run into issues where the designer did not have a true understanding of the true geometry and I might have to "adjust by hand", perhaps with sandpaper, file or grinder to compensate.

[chrisplyler]

Yeah. I wish I had a fab/machine shop. I would offer the best prices around.

Except for design consultation fees. Those would be through the roof.

[davebYYPCU]

I don’t think so.  I am not sure I understand the question / challenge.

What I said is now in Chris’ video,

oversize and post process.

[denhen89]

Hello,

i am sorry that i did not answer earlier, but i thought i got no replies any more.

@chrisplyler: Thanks a lot that you took your time to make an video and explain it! I really havent thought that that will be such a problem. Of course as you said, it could be done with an belt sander, etc., but that wouldnt be an smart if it should done as cheap and quick as possible. Also the belt sanding process wouldnt been very precisly. 

I will cut the parts out of aluminum sheet with my large CNC Router, so i could use 3D milling to get that shape on the bend corner, but it would need to be done on both sides (Double-sided milling - first 3D milling on top, then turning arround and 3D milling on the bottom). 

I think that is not an alternative and i will just need to accept that it is as it is :).

Again, thanks a lot!

Best regards,

Denis

[TrippyLighting]

I believe the model, when bent in actual sheet metal will look like in the original post.