Failed to create flange or face

[GraemeFV87HK]

Hi,

I'm having issues with creating the final flange on a sheet metal tray. The tray is derived from a solid base component because the base of the tray has creases in it. I initially tired with the face tool but this didn't work. I've also tried with the flange tool but this doesn't work either.

I did manage to get a flange attached with a work around but this then caused flat patterns issues.  

Does anyone have any ideas or workarounds to generate the return flange and for the flat pattern to generate correctly?

Attached is the part file (J04931-0002) and the base component (J04931-0001)

[pcrawley · Accepted solution]

You've got a couple of problems in the model, but the one preventing the flange working is this seam:

If you look at the seam, there's zero gap.  I edited Sketch 10 and moved the vertical line defining the face by GapSize/2:

Now the Flange tool works all the way round, and the flat pattern works too.

 

The bottom corners at the "shallow end" of the tray could do with a bit of love 😉

[johnsonshiue · Accepted solution]

Hi! I think I know where the problem is. This sheet metal part cannot be unfolded because of colliding bends. If you look closely at the sharp tip of the Mirror1, you will see two bend zones merge. Inventor cannot unfold such bends. I suggest you delete the Flat Pattern. Create each Face as a separate solid body. Then use Bend feature to connect the faces. Once you have one solid body, create the Flat Pattern.

Many thanks!