Sheet Metal Design in Solidworks

Sheet Metal Design in Solidworks

CAE Assignment #5July 26, 2007

Sara-Jane Squires, Meghan Couves, Bethan Martin and Mary Fowler

Summary

Introduction

Solidworks Features

Toolbox

Additional Features

Practical Applications

Conclusion

Sheet Metal IntroductionCould draw part and extrude or revolve like in most of the projects to date.Sheet metal application more powerful.Parts have constant thickness.Do not need to mess with feature order to get part to work right.Old way very order dependentEasy to change sketch of previously created flange.Automatically takes care of bend allowances

K FactorsK FactorsA single value which can be used to represent how sheet metal bends fold/unfold over a wide range of geometric parametersIf your model is being used for manufacturing, set K<0.5If not it will not unfold correctly for most bending scenarios.Use 0.42 or 0.33

Bend Type Common “K” factor

Large Radius Bend (radius 4larger than stock) 0.5Rotary Bender (like “Ready bender”) 0.43Vee Bend 0.42

90 Deg. Wipe - No Set Radius 0.38

90 Deg. Wipe Plus Set Radius 0.33

Bend AllowancesBend Allowance

How much material is needed between two panels to accommodate a given bend.

Solidworks automatically takes this into account when creating flat drawings from 3D.

Solidworks Features

Base Flange – Creates sheet metal part

Edge – Adds a wall to an edge

Miter – Adds a series of flanges to an edge (or edges)

Hem – Curls the edge of a sheet metal piece

Sketched Bend – Adds a bend to a selected sketch

Closed corner – Extends the face of a sheet metal part

Solidworks Features (Cont’d)

Jog – Adds 2 bends from a sketched line

Break corner – cuts material from a face or edge

Unfold – unfolds bends in a sheet metal part

Fold – folds flattened bends in a sheet metal part

Flatten – shows the flattened pattern of a part

Rip – creates a gap between two edges

Sheet Metal Toolbox

Bottom

1) Add Sheet Metal Toolbar (Right click; add Sheet Metal)

2) Choose icon labeled Base Flange

3) In the base flange window select Front View

4) Create a rectangle with dimensions 9.89” and 18”

5) Exit sketch and the base flange6) Properties window will appear

on the left hand side of the screen.

7) Under Sheet metal parameters set T1 value to 0.1 inches

Bends:

1) Select the Edge Flange icon

2) Select edge to be bent (18”long edge)

3) Drag the bend direction up4) Set D value under flange

length to 1 inch.

Cover

1) Create a “Base Flange”

drawing in the front plane.

2) Exit Sketch

3) Make to desired thickness.

End PiecesCreate a “Base Flange”drawing in the front planeExit sketchBoth ends need to be edge flanged Select “Edge Flange” from the toolbarSelecting one edge at a time, drag each arrow out (all in the same direction.)Pull these edge flanges out 1”Repeat until the entire end piece is flanged.

Sides

Create a “Base Flange”drawing of the side of 18” X 6”.Exit sketch and on the left hand side ensure that T1 is again set to 0.1 inches

NOTE: All flange lengths from this point on will be assumed as 1 inch unless otherwise stated.

HingesCreate a “Base Flange” drawing in the front plane

Exit sketch and ensure that T1 is set to 0.1 inchesCreate plane on top of rounded part; draw 2 rectanglesCut Extrude rectangles through allExtrude 4 bolt holes

HandleHandle Hinge

Create a “Base Flange” drawing in the front plane

Exit sketch and ensure that T1 is set to 0.1 inchesExtrude 2 bolt holes

Handle Circle extruded over path

Final Toolbox Design

Hem Feature

Select Hem icon Select edge to hemChoose hem outside or insideChoose hem type (closed, open (shown), teardrop or rolled

Choose distance to hem

Jog Bend

When the feature bends in one direction and quickly again turns in the other

Create a line on the piece you want bent

Choose jog offset (distance between the two bends), position and angle

Can keep original length of piece being bent or can add material as it bends.

Miter Flange

Select Miter Flange icon Create sketch plane on inside horizontal edgeDraw shape of flange you want to create Click PropagateIn Miter Parameters, underFlange position, click BendOutside icon

Sketched Bend

Select Sketched Bend iconCreate a line drawing on the surface you want to bendExit sketchIn the Property Managerunder Bend Parameters:• Select the face with the

sketch below the bend line for Fixed face

• Click Bend Outside• Set Bend Angle to 90• Select Use default radius.

Closed Corner

Select Closed Cornericon Select the edge of the base flange as shown for Faces to ExtendChoose corner type: Butt (Shown), overlap and under lap

Unfold / Fold

UNFOLDSelect Unfold icon Select edge to unfoldSelect Plane to which the edge unfolds

FOLDSelect Fold icon Select edge to foldSelect Plane to which the edge folds perpendicular

Flat PatternsLargest advantage is the flat

patterns ability.

Create items as you need them in 3D

When design is done, collapse to a flat pattern.

Keeps relationships true, but creates a 2D drawing.

Perfect for getting the flat parts cut in large quantities.

Forming ToolsForming Tools

Drag and drop from design library.

Maintain constant thickness.

Only used for sheet metal

Other Sheet Metal ApplicationsSheet Metal Applications

Made from hydro formed sheet metal

Other sheet Metal Applications Cont

Custom made Valve Covers

Sheet Metal Applications

Other sheet Metal Applications Cont

Hospital Bench

Sheet Metal Applications

Thank you!

Questions?