How to Model this efficiently

[Shag_Bore]

I was asked to make a drawing for our router operator to use to create some cladding panels. We have a structure that is 77-7/8"x60" with two 5" flanges. 

The panels are ACM 4mm thick, I believe the aluminum skin is .15mm on each face.

The want to route(create V groove) 2 lines down to the opposite .15 skin so that the two 5" flanges can be manually folded. 

I made the this part which was able to produce a drawing accurate enough to work, but the model is "funny" to me. I couldn't use sheet metal because the fold option created a bend radius in the routed path. Just curious as to what other methods would work better for future designs. 

Thanks!

[Frederick_Law]

Did not open your file.

You can set bend radius to 0.001" or smaller for 0.15mm thick sheet.

[pcrawley]

How to model it "efficiently"?  If that means fewer features, I would have drawn half the model and mirror it, rather than mirroring each feature individually.  

I think it looks "funny" because you have both folded and unfolded designs in the same model.  You could create a Model State to show folded and unfolded - that would look less funny.

I believe you were on the right track with Sheet Metal:  The 0.15mm skin will bend - so there will be a bend radius.  As @Frederick_Law suggested, set Thickness to 0.15mm and BendRadius to 0.001mm (or 0mm - that feature was added a few releases ago). 

You can now model the 0.15mm skin, add a Flange and sketch the rest of the 4mm panel (complete with V cut) and extrude it through the part.  (Mirror the result for the final model if you are lazy like me). 

Note however that Unfold/Refold and Flat Pattern features require at least a small area of the component to be the correct thickness (i.e equal to the Thickness Parameter), not including the unfolded bend, so I started the "V" cut 0.001mm back from the edge of the bend.  (Easier to look at Sketch8 than write it!)  Your model is attached (2023 format - hope that's OK).  Switch between Model States to see your version vs. mine.

In the interests of "efficiency" - your process is 7 features, mine is 4, and you could probably get it to 3 by using a Contour Flange 

[IgorMir]

Hi Sean,

Here is one of the ways of getting it done. The attached file is in IV2020 format. I hope - you will be able to open it.

Cheers,

Igor.

[Shag_Bore]

I wasn't sure what adjective to write to describe what I was going after, I can't open any parts unfortunately as I am running 2016. Model states seems like a cool feature to look forward to when we eventually upgrade. 

I know that I have some redundancies in terms of mirror features but I was having difficulties try to get this to work with sheet metal features which is why the part is shown with flat and folded features. 

I will try playing with the bend radius, and see if I can get a good result.

Thanks!!

[pcrawley]

It wasn't meant as a criticism of your adjective - just an observation that the English language is always open to interpretation and ambiguity.  It's a shame you're on 2016 - that's 7-years out of date - you're going to notice some fantastic changes when you upgrade!

Here's what you're missing 😉 

Model States means I can take your original sketch and create a bunch of features on it while leaving your version intact for quick reference.  Switching between the Model states automatically toggles the feature suppression.  

Model states have many uses, but tt's great for model development when you don't quite know where you're heading because - providing you use origin planes (or their derivatives), you can selectively keep some features, so model iterations are much faster than redrawing from scratch.

Back to your model:  This is what I was trying to explain with the bit about flattening tools requiring "a small area of the component to be the correct thickness":  The green part is the folded model - the visible sketch shows 0.001mm of flat either side of the bend.  Without these flats, Unfold (don't think that was in 2016!) and Flat Pattern won't work.

Hope this helps!

 

[Frederick_Law]

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flattening tools requiring "a small area of the component to be the correct thickness"

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Old way of flattening cylinders.

[pcrawley]

Old way of flattening cylinders

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Is there a new way?  C'mon - it's Christmas - share the secret!

In this instance, when you add the thickness to the model with the Extrude feature, none of the model matches the Thickness parameter, so Unfold/Refold/Flat Pattern don't work.

[Frederick_Law]

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@pcrawley wrote:

Old way of flattening cylinders

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Is there a new way?  C'mon - it's Christmas - share the secret!

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New way don't need flat on the end.

[pcrawley]

You'll have to demonstrate @Frederick_Law. 

It wouldn't unfold until I added those flats.

[Shag_Bore]

Looking at your pictures, this looks like it should work, I got moved to a more pressing project for the rest of the week, I will try it out and report back after the holidays!

Thanks everyone!

Cheers, Merry Christmas!

Sean