Bullnose top

[linos.martinez]

Hi,

I was wondering if it would be possible to create a flat pattern of a bullnose profile 2mm 304 SS tabletop. Currently, I have created one as a typical solid part by creating a rectangle, adding fillets and shelling it, but when I go into the sheet metal, I have difficulty producing one.

I tried doing a bend down 90deg 18 deg radius but when I do the second bend to complete the bullnose profile, it creates a void in the corners. Any advice will be much appreciated.

Linos.

[pendean]

@linos.martinez What program are you using? This forum's ADR topic is for a software you cannot create or model in.

[linos.martinez]

Inventor

[The_Angry_Elf · Accepted solution]

@linos.martinez ,

From what I believe you are attempting to do, one, you're approach and or expectations are incorrect.

 The gaps you mention are a needed modification in order to keep material from folding into itself, or buckling, ripping, etc. and is typical of sheet metal processes.

My question is, if this is a 2mm thick part and you're wanting a bullnose edge around the entire part with no seems/gaps, I'd suggest simply getting a 2mm thick sheet and grinding the edges as you desire. That or accept the gaps needed for the folding process, then fill with weld and grind smooth.

From what I'm seeing, it seems you are making what should be a very easy part into one that's extremely complicated. Please clarify if I'm off on this.

[blandb]

If you are waning sheet metal, does the images below get what you want? By the time you weld the corners and grind it would appear as a radius?

  

[linos.martinez]

@The_Angry_Elf you're absolutely correct.

My initial intention was to accept the gaps needed for the folding process, then create an infill part for the gaps then weld and grind smooth.

I was just curious if there was another way around this, to create the part all as one, but it seems that I'd only be overcomplicating things like you said.

Cheers

[The_Angry_Elf]

@linos.martinez sounds good. I've been casually playing around with things, mainly to try and get a full bullnose and a flat pattern that had minimal gaps, etc and each attempt resulted in gaps that you'd need to fill and grind, just no way around such in sheet metal.

It's been about a good 12 yrs since I had worked extensively in the sheet metal environment. I've missed it (that and surfacing). So I was happy to dive into it a little. To think I had to do all this stuff manually on the board back in the day when I was designing wood/coal burning stoves for Better N Bens. Oh the charts and cheat sheets I created for stretching, bending, etc.....aaaaahhh the good old days of working harder...lol