Remove bevel from holes/edges

[Anonymous]

I've got a sheet metal part I've created, which has had some cut operations performed while in it's folded state.  Those features leave beveled edges in the sheet metal when flattened and I'm trying to figure out how to 'flatten' those cuts.  The parts will be cut out on a plasma cutter, but I also want the 3D model to represent what the finished part will look like. 

I got it done by projecting geometries onto a sketches and using extrude cut operations.  This seems overly complicated and , but

It swear I've seen a tutorial that had a very simple way to do this, but I cannot find it now. I'm hoping someone can point me in the right direction.

Thanks.

[Anonymous]

Hey there!

Could you export your project and post it here? There are a number of possible solutions depending on how your part was set up. 

[Anonymous]

Here's a copy of the project.  I've been playing with it.  You can roll the history back to before the unfold.  That's where the previous screen capture was taken.

[daniel_lyall]

why do you have this sketch on such an angle?

How close is the attached model to what you want?

[Anonymous]

I'm using it to extrude/cut holes for items that will pass through this part.  It's orthogonal to the longitudinal axis of a truck frame.

[Anonymous]

I'll have to take a look at what you've done later this evening.

[Anonymous]

Thank you, Daniel.

Okay, so yes, that flattened the holes, but I'm really looking to understand how to do this really quickly and easily. 
 
I want to be able to create features from odd-angle cuts/extrusions, flatten the piece, then square up all the edges (for a 2D cutting process) then re-fold the sheetmetal.
 
I thought I had seen something in a tutorial that was really simple, but I can't find it. 
 
I have managed to get it done, but what I did seems tedious and overly complicated. 

[jhackney1972]

Check out message 6 in this thread.  You may have to follow the whole thread but the process proposed in message 6 I think does what you desire is a quick each step.

[Anonymous]

Thanks, John.  I will check that out when I get some time. 

I was just watching this video that talks about the same issue when cutting though a cylindrical body.  Not sure it will work the same intersecting a plane at an angle.  Will have to play with it and see. 

https://www.youtube.com/watch?v=_3zj9IgDAA0

I'll check out your suggestion above, too.  I thought I saw a super easy solution in a video once (like click the hole feature and select an operation), but perhaps I'm misremembering. 

[jhackney1972]

I decided to do a Screencast using one of your sheet metal components and your angular sketch using the method that the guy described in the link I sent you.  It will make more sense to you if you see the process on one of your components.  I think it is one of the coolest process I have seen when you have to have angular cutouts through a sheet metal face and avoid the "chamfer" edges.  I am sending you your model I used to demo on to help you understand.

[daniel_lyall]

Another way to do it is to intersect the sketch onto the faces then extrude the resulting sketch.

You select the sketch element - select the faces - hit enter - then right-click push mouse up - rinise and repeat close the two ends by projecting the edge of the part then extrude cut it out it looks correct to what you have done squaring the holes up.

The posable problem is the squaring up off the outside edges manly on the left side looks wrong you just need to work out where the sketch needs to go to line up correctly or cut the angle parts off unfolded so then the edges are squire then add the angle sketch in then project it.

[Anonymous]

Interesting technique.  Very cool.  Thanks for taking the time to do the screencast.  There are still a few edges that are chamfered after this operation (some perimeter edges on the flattened sheet metal part).   I'll have to play with it some.

[Anonymous]

Thanks, Daniel.  I'll look at this.  I was thinking something like projecting that holes sketch then cutting.  I still have to deal with the perimeter edges of the sheet metal part and make them flat, too. 
 
I did arrive at a solution where after I flattened the sheet metal, I projected all of the edges (perimeter and holes) to a sketch  and essentially extruded those to the thickness of the sheet. 

I'll look into this again.  Thanks again for your input.