Wildfire SHEETMETAL Design 2/18/2011

Presented by Henry Schille

Terms and Definitions

Bend: A feature that can be manufactured on a brake press. Brake press: a machine that uses radiused dies to bend sheetmetal. Deform area: material that is stretched or compressed in order to create a feature. Normally a deformation area will not create a reliable flat pattern. Flange: a bent sheetmetal wall. Miter: to join at a corner by various methods. Obround: rectangular cut ith Obro nd A rectang lar c t with one end f ll ro nded fully rounded. Relief: a cut in the metal which allows the adjacent material to be formed. Stretch Relief: A deformation of the material that would otherwise be cut away. Rip: A cut through the material. p g Sheetmetal: a sheet of metal. SHEETMETAL: The Wildfire (or Pro-E) module to design sheetmetal parts. Stress concentration: an area of high stress. The place a part will break or fail first. Stress relief: a feature such as a corner round which reduces a stress concentration concentration.

References:
Several references to a Sheetmetaldesign pdf are made throughout this Several Sheetmetaldesign.pdf document. This pdf can be found at G:\Public\HenrySchille\sheetmetaldesign.pdf

Wildfire SHEETMETAL Best Practices

The purpose of this presentation is to provide a feature overview and training on the best way to create SHEETMETAL wall features in Wildfire and when to use the features It does not cover all SHEETMETAL features. functionality. If you know the part is going to be mostly symmetric, create only one half o of the pa and mirror it about a datum plane or surface. e part a d o abou da u p a e o su a e

Non symmetric features can be added after the Mirror feature. Modifying, redefining, or creating features on one side will all be automatically updated on the other side (if the feature exists prior to the Mirror feature).
Screen pick on the part name in the Model Tree to highlight the part. Choose Edit>Mirror>Screen pick the plane or surface to mirror about about.

Note: File>Mirror Part creates a new part. It is a referenced mirror image of the parent part. This also can be useful, but is very different. If the part is symmetric about two planes, two mirror features can be created and only of the part needs to be designed.

Wildfire Wildfi SHEETMETAL Overview O i

The following will be covered (in order of icon):
1. 1 2. 3. 4. 4 5. 6. 7. 8. 9. 10. 11. Protrusion feature Conversion feature Flat (Flat Wall) Flange feature Fl f t Flat feature>Revolve/Blend/Offset Extended wall Bend>Edge Bend d d d Unbend>Bend Back Corner Relief>Punch/Notch/Rip/Merge Walls Punch Form Tool>Quilt Form Tool/Die Form/Flatten Form/ Deform Area Flat Pattern

Initial SHEETMETAL Feature

There are three common types of initial SHEETMETAL feature options: 1) Extrude: U when you want to extrude a shape, E t d Use h tt t d h such as a hat rail, a Z bracket, or an L shape as your first feature.

Can be used with Sketch > Feature Tools > Thicken t Thi k to dimension to both sides of the material:

Initial SHEETMETAL Feature (cont.)

2) Unattached walls: ) Flat: Use when you want a basic flat feature as y your initial feature. Sketch may include holes. y

Revolve: Use when you want the initial feature to be a fully revolved feature. Think Tube. feature Tube Blend: Use when you want the initial feature to be y p a blended feature. Think Generally more complex than we can manufacture at CarlisleIT.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature:
Conversion: Use when you have a solid part or a surface feature created outside the SHEETMETAL application that you want converted to a SHEETMETAL part in order to make a flat pattern. This feature will help convert the part into a manufacturable part by converting sharp corners to either bends or folded flanges with rips, edge h ih b d f ld d fl ih i d conditions, and relief. It is designed to work with sharp corners.

Initial solid part in general shape of final sheetmetal part part.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature (cont.):
With the unconverted part in the active window, choose Applications > Sheetmetal. Convert a constant wall thickness part using Driving Srf Convert a b oc pa t us g Shell which will a o you to Co e t block part using S e c allow choose surfaces to be removed. If a part will not convert, it is usually because a constant wall thickness cannot be achieved.

Converted part using Shell. Notice top surface is removed.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature (cont.):
Point Reliefs: Creates a relief at a datum point placed along a curve. This is a useful feature to split surfaces for application of boundary conditions. Edge Rip: Add edge rips to all edges you do not want to be bent. Each edge chosen is called a Rip Piece. Either inside edge or outside edge can be g g chosen. No difference in result. Default edge miter condition is Open. Edge miter condition can be changed by selecting Redefine>Piece # X. Bug alert: trying to redefine edge miter condition after Conversion creation causes failure. failure Bends are auto chosen between Rip Pieces.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature (cont.):
Rip Connect: Must be defined to connect Rip Pieces across a flat surface. Bends: May be chosen instead of Edge Rip to model an extruded part (Think extruded box). p ( ) Edges chosen are called Bend Pieces. Default bend value is 1X thickness. May be changed by Double Clicking y g y g Bends>Piece #X. Many also be changed by editing the Smt Conversion feature. Corner Reliefs: May be added to remove sharp corners at bend corners. Best practice is to use Obround, 2X Thickness. S Seems lik it can only b chosen with S l t All. like l be h ith Select All Bug alert: Corner relief does not work on anything but open type corners.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature (cont.):
Edge Rips (all blue edges) Bends (all magenta edges) Rip Connect (yellow) Point Relief (Choose Datum point added as a feature)

Shelled part in process using Conversion feature.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature (cont.):
Edge Rips (default open shown)

Bends

Rip Connect Point Relief

Shelled part after using Conversion feature.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature (cont.):

Flat Pattern of shelled part after using Conversion feature feature.

Corner Relief shows up in flat pattern. May show up in less h l complex folded model.

Initial SHEETMETAL Feature (cont.) (cont )

3) Conversion feature (cont.):

1. P 1 Part with constant wall thickness ih ll hi k

2. 2 Converted using Driving Srf

Another example of the use of Conversion.

3. Sharp Bends rounded with Conversion>Bends.

Extrude (wall mode):

Use when you want an extruded unattached wall(s).

Each line will be a wall 1X material thick. ill all mate ial thick Feature is unattached. Normally used as 1st feature.

Extrude (wall mode) functionality: ( ) y

Choice between extrusion and surface feature. Extrude to a specified depth (dimension controlled). Extrude in both directions an equal amount (dimension controlled). q ( ) Extrude to a surface. (dimensionless) (Next to depth dimension) Changes direction of extrusion from sketch plane. Toggles between cut mode (default-remove matl) and wall mode (add matl) gg ( ) ( ) Tells you that you are making a thin sketch. Not functional in wall mode. (Last icon) Changes material side of sketch (inside to outside or top to bottom). Options: Adds 2 sided blind depth functionality; adds bends to sharp corners functionality; allows Capped ends on initial feature; controls which side is green (driving surface).

Extrude t ude (cut mode):

Use when you want an extruded shape cut through one or more surfaces.
Alternate for Insert>Hole.

Extrude (cut mode) functionality:

Largely same functionality as wall mode with the following additions: Extrude through to next surface (dimensionless). (dimensionless) Extrude through all (dimensionless). Extrude up to and including a surface. (dimensionless) Thicken Sketch: Toggles between a thin cut (each line has width) and a cut similar to a non-SHEETMETAL cut. Use the following for a cut with sketching plane at an angle to a surface: e o es ate a o a both surfaces. (A sketched circle becomes slot) Removes material normal to bot su aces ( s etc ed c c e beco es a s ot) Removes material normal to green surface. (A sketched circle becomes an oval) Removes material normal to other surface. (A sketched circle becomes an oval)

Flat Fl t

and Flange d Fl
a) Sketch looks at wall face. b) Can be used to make flat (no bend) wall. c) Can only be used on one ) l b d edge at a time. d) Can not be used on curved edges. edges e) Can make inconsistent wall sketch. f) Feature considered planar. g) Can be length controlled, offset, and relieved. h) Multiple edges cannot be chosen at the same time.

(walls): ( ll )
a) Sketch looks at wall profile. b) Can not be used to make flat wall. c) Can b used on multiple ) be d l l edges at once. d) Can be used on curved edges. edges e) Can only make constant wall sketch. f) Feature not considered planar even if it is. g) Can be length controlled, offset, and relieved. h) With multiple edges chosen, miter type can be specified.

Features are similar, but different. A comparison:

Flat ( ll) Fl t (wall):

Use when you want a single straight wall. S l t an edge opposite of th di ti of desired bend direction. Select d it f the direction f d i d b d di ti Flat>Placement>Screen Pick
Default wall is rectangle, flush with selected edge, with rip relief, 90bend, with bend radius 1X thickness. All may be modified. Trapezoid, L, or T or can be chosen and then manipulated using the drop down box. User Defined is not functional. Shape>Sketch allows a user defined sketch to be made. The sketch must be continuous (holes not allowed) ( ) Sketches may be saved/retrieved using Save As / Open Offset>Add to Part edge makes the bend tangent to the selected edge. Automatic cancels out any offset chosen. By value moves the wall out up to the value of the outside radius. Relief adds relief to bend ends ObrndRelief is the most desirable from a stress and gp p manufacturing perspective. Note: Relief has no effect if feature is tangent to part edge.

Flat ( ll) ( t) Fl t (wall) (cont):

Boxes on feature represent modifiable items:
Offset from edge

Offset from end

Bend Direction (Edge selected)

Bend Angle

Length

Flat ( ll) ( t) Fl t (wall) (cont):

Other functionality:

This is non-functional. This changes material side offset is dimensioned to. This allows radius dimension to be changed from inside to outside. Properties is an alternate way t change th name to h the of a feature. These are an alternate method of modifying angle y g g and radius.

Flat ( ll) ( t) Fl t (wall) (cont):

Helpful Hint:
Add a Flat wall (no bend) with offset ends before creating a wall with a bend.

This allows stress relieving corner radii to be added without needing to cut away undesirable geometry.

Flange ( ll) Fl (wall):

Use when you want a complex wall shape, multiple walls of the same shape, or walls on a curved edge. edge Select an edge opposite of the direction of desired bend direction. Flange>Placement>Screen Pick. Holding down the Shift key allows multiple edges to be chosen.
Several drop down shapes can be chosen, but all may be created using Shape>Sketch Length: options are duplicated in drop down boxes, but do not work properly for multiple walls at the same time. Note: Negative value removes material, positive value adds material. Edge Treatment: options are very useful and self explanatory. Only functional when adjacent edges are chosen. Essentially specifies type of miter cut for each corner. Helpful hint: Flush edges are usually not manufacturable. Add some gap. Miter Cuts: does not seem to be functional. Use Edge Treatment. Relief: Bend Relief works pretty well for a single edge. Corner Relief works, but only seems to show up in a flat pattern.

Other functionality is identical to Flat feature.

Flat ( tt h d ll) Fl t (unattached wall):

Use the first three icon options as first feature only, or for purely cosmetic purposes. purposes Any other use will create an unattached feature Unattached feature. features may possibly be attached later (see Merge Walls), but a better option is Flat with no bend. The last icon, Offset, simply duplicates a wall at an offset distance. If a radiused edge is chosen, the offset wall radius will be increased/decreased by the offset dimension (same center).
Multiple surfaces cannot be chosen. I have not seen an application for this feature. feature

Extend: E t d
Useful for tweaking edges of miter corners.
Pulls adjacent bend material with it it. Does not work on Flange walls (not considered planar). Both positive (add material) and negative (remove material) values are possible.

Unmodified part.

Positive Extend value.

Negative Extend value.

Bend:
Useful for adding a bend to existing material.
Feature not updated with Dashboard Interface. Planar Plana Bends are not generally manufacturable, but interesting. ae gene all man fact able b t inte esting More information, including w/Transition info, can be found in sheetmetaldesign.pdf pages 129-142. (numbered pages 121-134.)

Angle R A l Regular Result. l R l What sketch should look like.

Roll Regular Result.

Angle Planar Result. A -90flips direction.

Edge Bend:
Useful for converting a sharp corner to a bend.
An alternate, more direct method to convert sharp corners instead of using Conversion Conversion.

Unmodified part.

Edge Bend added to four sharp bends.

Unbend and Bend Back:

Useful for adding cuts across bends in the flat state.

Not optional after an unattached wall. More information available in sheetmetaldesign.pdf pages 142-149 (numbered pages 134-141.)

Unmodified part.

Unbend area(s) to be t b modified. difi d

Add cut(s) across bend(s). b d( )

Bend Back all.

Corner Relief:
Marginally Useful for adding corner relief to ripped corners.
This is an optional method to specify relief to ripped edge corners. Otherwise use Conversion. Not an option to use on Flange feat es Define corner relief fo Flange feat e in the feat e se features. co ne elief for feature feature. Will not override corner relief set by Conversion, but will add to it. Bug Alert: Does not show up until part is unfolded. Bug Alert: Once feature is created it seems it cannot be redefined. Helpful hint: Ignore Corner Relief altogether. Add it with a Protrusion cut before the walls are created. Or, add it by creating an Unbend>Unbend All, cut an obround into all the sharp corners, then create a Bend Back.
This will allow the corner relief to display in the folded condition. This will allow better control of what you will actually get and want. want This will allow the gaps and corners to be dimensioned as they should appear.

Ripped corner with Corner Relief.

Same corner, corner unfolded.

Corner relief added as a cut after an Unbend.

Same corner, corner folded.

Punch and Notch:

Useful for adding UDF defined cuts to SHEETMETAL parts.
More information available in sheetmetaldesign.pdf pages 123-129 (numbered pages 115-121.) 115-121 ) Punches are useful for placing predefined cut geometry into a part.
An excellent example would be to set up UDF defined punches for disconnect bracket cutouts. Nut plate cutouts could also be set up as a UDF punch.

Rip: Ri

More information available in sheetmetaldesign.pdf pages 99-102. sheetmetaldesign pdf 99-102

Disconnect Cutout Example.

Useful for adding infinitely thin saw like cuts to SHEETMETAL parts.

Unmodified part.

Rip added. (Sketch is Zigzag line)

Flat Pattern now possible.

Merge Walls:
Useful for joining unattached walls to your model.
Normally, having unattached walls is the result of poor modeling techniques. Can be used to fi model so a flat patte n can be made sed fix pattern made.

Punch Form Tool / Quilt Form Tool/ Die Form:

Useful for adding deformation features to SHEETMETAL parts. Punch Form Tool uses a model of the core. Die Form uses a model of the cavity.
Mate flat surface to SHEETMETAL part. This is also your Bound Plane and must completely surround the form. The colored surfaces (see below) are Exclude Surfaces and result in a cutout of that shape. Seed Surface is one surface on the form which is used to select all surfaces of the form. CAUTION: This feature can stretch material in ways that is not physically possible. For instance, if the 4MCU-DEF part below were used without the exclude surfaces, then the resulting feature would include a large extruded oval attached to the deformation with all material at 1X thickness. Note that in real life, this type of feature would be stretched very thin if not to the point of breaking. Helpful Hint: If your feature fails it is often because a constant wall thickness cannot be achieved, often because an outside radius is not large enough to result in the inside radius being greater than zero.

Quilt Form Tool: I assume this feature allows you to deform a quilt much like you would sheetmetal. I have not tested this however.

4MCU-DEF Used to make 4MCU tray deformation.

Flatten Form:
Useful for flattening a Punch Form, a Die Form, or a chamfer.
Not a very useful feature as a Punch Form or Die Form does not prevent a flat pattern from being created, created the form however is not flattened with Flat Pattern Pattern. Holes created with Punch Form or Die Form are not retained with Flatten Form functionality. This feature does not flatten Hole features with included chamfers. I am not sure how this feature is more effective than just suppressing the Form. More information can b f f be found in Sheetmetaldesign.pdf pages 121-123 ( d h ld df (numbered pages 113-115). b d )

Deform Area:
Useful for defining an area to be distorted when unbending certain complex geometry.
A very good example can be found in Sheetmetaldesign.pdf pages 152-153 (numbered pages 144145).

Flat Pattern:
Useful for flattening your SHEETMETAL part when the design is complete.
A very good example can be found in Sheetmetaldesign.pdf pages 159-163 (numbered pages 151155). 155)

Questions?