Sheet metal pyramid bending issues

[BrennanJWilkie]

I am making what is effectively a pyramid with an open top and bottom from sheet metal. I have gotten to the point when I am trying to Flat-pack my model, and am trying to put the bends in (I started it as an .ipt, then converted to sheet metal). When I select bending for the corners, an error message saying that "Matching faces could not be found". I have a feeling it has something to do with the bend over-running the edges, as is shown in the picture.

I am pretty new to sheet metal, so it might be a common, novice error, but anyone able to help with this?

[philip1009]

Could you provide an example part or drawing of what you're trying to achieve?  From the picture it looks like you're trying to convert a shell of a standard part, unfortunately it's not that easy.  Do you always plan on using a regular ipt to make your sheet metal shapes or are you comfortable making sheet metal parts from scratch?

[philip1009]

Here's a sample I came up with, it's not the most stable when dimensional changes are made, but it's a fast method for coming with a pyramid shape using a Lofted Flange.  Bring up your iLogic Browser and under the forms tab you'll find a form for adjusting dimensions and a readout of the angle used at the top flange.

[Sergio.D.Suárez · Accepted solution]

Hi, This error happens because you have a kind of "chamfer" on the edge of the sheet, perhaps the result of a previous cutting operation. In order to apply bends the faces must have straight edges, not angles

Watch the video and analyze the failure by that lateral angle, then you can see an example of a possible solution

I hope you have understood the use of the tool, greetings

[johnsonshiue]

Hi! Is it possible the thickness on the part is not uniform or the thickness setting is inconsistent with the body thickness? Please share the file here so forum experts can take a look.

Many thanks!

[BrennanJWilkie]

This certainly seems relevant to the issue that I am having. I am however going to be posting my part to see if I can get some more help since I use sheet metal so infrequently. If I remember, I will mark your response as an answer when we get there, but I don't want to do that yet, as it may keep people from clicking on the question.

Thanks for your help!

[BrennanJWilkie]

@johnsonshiue @Sergio.D.Suárez @philip1009 Here is the part in question. This is the full part, but as a shelled solid piece. I want to be able to unfold it into a sheet metal net, but the weird angles and the lack of a central piece on top are making it difficult. 

[JDMather · Accepted solution]

This could be solved within 2 minutes if you simply Attached your *.ipt attempt here.

Edit: I see that you posted while I was typing.

What version of Inventor did you state that you are using?

Shell will not result in a proper sheet metal part for this design.

Use Lofted Flange rather than Loft and Shell.

[BrennanJWilkie]

My Inventor version is 2016 Professional.

[BrennanJWilkie]

I got it to work. Thank you for your help.