Sheet metal for bumpers

[djstassen84]

Good day. I Amy trying to build a bumper for my vehicle, but I am struggling a lot with the sheet metal flanges, Fusion does not seem to do what I want it to do. I am new to the Sheet metaal environment and are not sure if it is the correct way of doing it. I have attached images of the bumper that I have designed, but my corners and flanges doen not seem to line up perfectly and I am sure that I should not be using Extrude function to vut through the panels. I have also attached a Fusion file with the flange that I would like to accomplish but can not get Fusion to work with me. Please if someone can assist, or if someone knows of an online trining course for Advanced Sheet metal, if you could please share the link of the course with me. It would be much appreciated. I keep on designing bumpers, but when it comes to manufacturing, everything just keeps falling apart. Image 1 is of the bumper that I have designed but the corners and flanges does not line up. Image 2 is what I would like my Sheet metal parts to be so that I can Flat Pattern it and then cut it with our laser machine. Image 3 is a Fusion file that is also attached, Not sure if that is the way to design the bumper or should I work in the 3D environment and then change everything to sheet metal. Please if someone can assist. It would be greatly appreciated.

[TheCADWhisperer]

@djstassen84 

What are the dimensions of your first rectangle?

[djstassen84]

This file was just for reference. Please see attached image:

[djstassen84]

There is some more measurements, I hope this information will assist.

[TheCADWhisperer]

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@djstassen84 wrote:

This file was just for reference. Please see attached image:

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In Message 5 of >>this thread<<

I requested that you Attach your progress file.

No further progress was indicated?

For reference, I would use the same hybrid modeling process.

If there are to be more than one sheet, you would of course split up the sheets.

In the reference file that you Attached in this thread I noticed that there were no dimensions, yet when I added the missing dimensions to the geometry, I observed that the geometry was perfect.  Not sure how you got perfect length lines without dimensions?

In any case, I would proceed along the reference given in the prior thread and continue on with developing the complexity.

Ask questions if (when) you get stuck on the hybrid modeling approach.

(Initially, you might model entirely as a solid body with no concern for the sheet metal thickness just to get an understanding of the outer geometry.)

I often consider my initial attempt(s) to be merely an exercise in understanding the geometry before I make a "clean" model.

[TheCADWhisperer]

@djstassen84 

First thing I would do is bring in the Top and Front view images onto Canvases and Calibrate and move such that the Origin is in a symmetrical/logical location.

Click on image above to enlarge the view.

[djstassen84]

Good day. I would gladly share my Fusion file with you with the complete bumper, but I don't want to share it on the Forum as everyone can then download and use the file. If you like, I can do a short screen recording showing my issues.

[djstassen84]

think I am taking the wrong approach to the design process, but I am not sure that other process to follow. I have attached a screen recording.

[djstassen84]

Or what I should maybe do is create a separate sheet metal body, draw and extrude it, the way I want it to fold, but I am nut sure how to join the 2 sheet metal body's with a fold. I have attached a screen recording.

[djstassen84]

If you look at the function "Convert to sheet Metal" in Solidworks. this is what I would like to accomplish in Fusion. 

Here is the link to a Youtube Video: https://youtu.be/v0rkCH16npE?si=64H6p4s_m3kWzpcG&t=192

[TheCADWhisperer]

@djstassen84 

I have been a Certified SolidWorks Professional since 2007.

The hybrid approach that I briefly demonstrated in the prior thread is a manual duplication of what the convert to sheet metal in SolidWorks does semi-automatically.

[djstassen84]

Not why I am struggling with Fusion so much. I just feel that paying a monthly fee for Software that does not work the way I want it to is just ridicoulous. I have been working in Adobe Suite for 23 years now and never have I ever struggled so much with software. Please can you recommend an online training course for Solidworks? Every company in our industry is using Solidworks, and I am thinking that there is a reason for it. I wanted to use Fusion as it works on our Mac's but I would rather buy a PC and purchase Solidworks, just so that I can keep the company going. I believe that Fusion is not up to par when it comes to manufacturing 4x4 bumpers. Their Sheet metal environment needs a lot of updates to compete with the leaders in the industry.