Cannot Flat Pattern

[HogueOne]

I'm trying to turn this yellow surface into sheet metal. It's fairly straightforward with the cylindrical faces, but this cone shape is not cooperating. In real life we're going to roll it into a cone and then bend the "Flanged" edges at 90 degrees. Inventor doesn't allow you to put a flange on a rolled face even if the edge is clean and flat. I've already tried filleting the corners and thickening the face. when you go to unfold it the flanges aren't folding. Is there a sheet metal expert that can help me with this? I calculate that I will need 11 formed plates to make this design. The attached file has a point cloud I'm referencing which won't resolve for you, but you shouldn't need it.

[kacper.suchomski]

Hi

You need to sketch a longitudinal section (one set of 3 edges, no thickness) and use the Roll forming tool.

This way you can even model a cone. 

[HogueOne]

I'm sorry I'm not fully grasping the solution... I imagine you're referring to the contour rolling command, but I don't know how I would use it to create this shape. Could I trouble you to give me a quick demonstration?

[HogueOne]

Thank you for the demonstration. I understand how to use the contour roll. Unfortunately this doesn't solve my problem. your flanges are rolling with the contour, and are constructed using the same sketch profile as your base face. the flanges I'm trying to construct are on the ends of the roll. normal to the edge.

This is the end shape that I want. you cannot make this with the contour roll command by itself. Unfortunately the flanges don't unfold, even though realistically they should. Do you understand?

[kacper.suchomski · Accepted solution]

You can use Unwrap tool.

And submit this on Idea Station.

[HogueOne]

This is a great idea. One more question...

How do I get the faces I'm unwrapping to not detatch from the faces I don't want to unwrap? I tried playing with the linear and rigid result behavior and I don't think that's going to help me...

[kacper.suchomski]

Select Auto face chain.

[HogueOne]

I don't want to unwrap the whole surface, just those flange parts. I think I'll have to thicken the surface and use direct edit to rotate the solid back into place.

[kacper.suchomski]

Sorry *Merge result body

[HogueOne]

I checked merge result body but it didn't seem to make a difference.

[kacper.suchomski]

The surfaces should be stitched.

[HogueOne]

They are. I'll have to keep experimenting. But the Unwrap seems to have given me the workaround I needed. Thank you.