Sheet metal, relief shape gap

[bnv5YBJX]

Hi,

I have a weird situation and don't know the cause nor the good solution. When making a corner in sheet metal for a machine cover we used a large radius to make a smooth transition. While making the feature all looks like we want it (picture 1)

But after that it turns into a wide gap (picture 2). Also the flat pattern doesn't show the required curve to close the gap.
Tried al I know (chnging default radius, changing relief shape, miter gap etc.) Nothing worked. In the end unfolded, sketched surfaces, refolded. Looked "ok-ish" (opicture 3),  this we can fix in the workshop.

Does anyone know what is going wrong and how to decently get this done? 

[CCarreiras]

Hi!

Sharing the part would help to find a solution... we can do nothing with images...

[bnv5YBJX]

Made a simplified part to work it out, but system is the same.

[kacper.suchomski]

You can do it manually:

[johnsonshiue · Accepted solution]

Hi! This is a feature creation order issue. The problem is that the desirable 2-Bend Relief is overridden by a 3-Bend Relief. Unfortunately, there isn't an option called, "Preserve 2-Bend Relief." As a result, the 3-Bend Relief takes over and the relief shape changes.

Here is a simple workflow to avoid the behavior. Simply use the Rip command to remove the very first bend created by the Contour Flange. And create the Flange as usual. Then use the Bend command to connect the two flanges back together. Please take a look at the attached part.

Many thanks!

[bnv5YBJX]

Hi, This was a solution I thought about also, surface modelling. But dismissed it as too much of a hassle.
Gives very good result though. If I need a very estethic pleasing part I would consider it. But as this is for a construction machine it is overkill.

[bnv5YBJX]

Hi, Thanks for the solution. I see a proposal for improvement of the sheetmetal feature coming up. 😁