Refold on Helical Part gives different position for part

[nathan_wostrel]

I have a part that is going to be made in the folded state (cast), but some of the features need to be created on a flat surface.  The part unfolds just fine, I am able to create the features, then it refolds.  The problem is:  The refolded part is in a different position and orientation to the origin planes/axis.  I need the part to be in the same orientation for constraining into a larger assembly.

Is there an issue with the way I have created the part?  Or is this just strange behavior for Inventor?  Our team has been able to successfully unfold/refold these helical parts in the past, so I'm not sure why it isn't working now.

Inventor 2018

Build: 284

Release: 2018.3.4

[JDMather]

If you add a tiny planar face you might be able to use Project Flat Pattern and Cut Across Bend rather than Unfold/Refold. 

Looking at your part though, I think all of this is incorrect technique for the holes.

I think there should a  workpoint and axis at pierce point for the holes, otherwise they will be warped.

[nathan_wostrel]

Tried a couple times with no success.  The Project Flat Pattern is not able to be used.  I did create a flat pattern before attempting.

[JDMather · Accepted solution]

Check Attached file.  Round holes with conic chamfer.  Fasteners will seat properly.

[nathan_wostrel]

Thank you very much.  I would have never thought to use the hole/counterbore on the formed part.  I will pass this along to the rest of my team, might make this process a lot simpler in the future.

[JDMather]

Make sure to set the hole to extend in both directions (I think that was new in 2018) because it is on a curved surface, otherwise you will end up with a sliver face.