Can't create flat pattern after unfold/refold operation

[Anonymous]

Hi

I have tried to make a sheet metal part which flat pattern would be as close as possible to a working autocad version, so the model is a little messy. However, it seems to be flattening correctly, except the last corner (Face15). It should be exactly the same as the opposite corner (Face11), but for some reason it just don't flatten. I have also tried some simplier sketches with no help, so the problem seems to be related on creating the face.

And the other thing; why the 'Stationary Reference' doesn't stay stationary while refolding? That's happened on many occasions before, and is very annoying, but it hasn't prevented flattening though.

[Thomas_Savage]

Hello,

A lot of parts on your model are intersecting each other. That is why you will have trouble flat patterning your model.

Have you got the sizes of the model? If you have you would be better of modelling it in Inventor from scratch.

Thomas.

[Thomas_Savage]

Hello,

I had a go at modeling your part in Inventor.

I tried by best to copy the sizes off your model.

This is to show you, how you could model in in Inventor, or you could just change the sizes if you needed to. To the correct sizes you need.

Hope this helps,

Thomas.

[Anonymous]

I'm aware that parts are intersecting, but it didn't cause too much troubles in 'Face11' corner, and they don't intersect in flat pattern though. 

And yes, that's the way I did model it at the beginning, but because the flat pattern had to be very close to original DXF, that has been used in production, I had to do it the hard way.

So thank's for helping, but it didn't quite solve the problem yet. 🙂

[Thomas_Savage]

Hello,

But the metal will crash when you bend it. So surely you should remodel it so it doesn't crash? 

I just thought it would be better to remodel it in Inventor.

You need to put a bigger relief in the corner which won't unfold.

I will have a go at doing when i get a bit of time.

Thomas.

[Thomas_Savage · Accepted solution]

Hello,

Is the part attached what you wanted?

Thomas.

[S_May · Accepted solution]

Hi @Anonymous,

that was the hell for today

[JDMather]

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@Anonymous wrote:

original DXF, that has been used in production,...

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Can you attach the original DXF file here - I suspect that you are doing way too much work.

[Anonymous]

Thank you!

That wasn't exactly what I was after, but definitely better way to make that part. Maybe we'll focus on getting little less precise DXF and little more precise model in the future. 🙂

[JDMather]

I was going to build you a far far better model, but it looks like you are satisfied with what you have.

[Anonymous]

JDMAther, here is the original DXF, so if you can make good model based on those measures, that would be highly appreciated 🙂

[Anonymous]

Thomas, the part you send did flatten correctly, so it did the job, though I still don't understand exactly why. I also found out that Flanges 27 and 30 was one thing that was causing the problem. Suppressing them did the trick as well.

And why one corner works correctly, but another exactly similar corner won't. And of course, the problem with the 'Stationary' Reference still remains a mystery.

[S_May]

but the DXF was optimized for laser production?!