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UNIGRAPHICS

SHEET METAL DESIGN


STUDENT GUIDE
March 2003
MT16020 - Unigraphics NX

EDS Inc.
Proprietary & Restricted Rights Notices

Copyright

Proprietary right of Unigraphics Solutions Inc., its subcontractors, or its suppliers are included in this
software, in the data, documentation, or firmware related thereto, and in information disclosed
therein. Neither this software, regardless of the form in which it exists, nor such data, information, or
firmware may be used or disclosed to others for any purpose except as specifically authorized in writing
by Unigraphics Solutions Inc. Recipient by accepting this document or utilizing this software agrees
that neither this document nor the information disclosed herein nor any part thereof shall be
reproduced or transferred to other documents or used or disclosed to others for manufacturing or any
other purpose except as specifically authorized in writing by Unigraphics Solutions Inc.

2003 Electronic Data Systems Corporation. All rights reserved.

Restricted Rights Legend

The commercial computer software and related documentation are provided with restricted rights.
Use, duplication or disclosure by the U.S. Government is subject to the protections and restrictions as
set forth in the Unigraphics Solutions Inc. commercial license for the software and/or documentation
as prescribed in DOD FAR 227-7202-3(a), or for Civilian Agencies, in FAR 27.404(b)(2)(i), and any
successor or similar regulation, as applicable. Unigraphics Solutions Inc., 10824 Hope Street, Cypress,
CA 90630.

Warranties and Liabilities

All warranties and limitations thereof given by Unigraphics Solutions Inc. are set forth in the license
agreement under which the software and/or documentation were provided. Nothing contained within
or implied by the language of this document shall be considered to be a modification of such warranties.

The information and the software that are the subject of this document are subject to change without
notice and should not be considered commitments by Unigraphics Solutions Inc.. Unigraphics
Solutions Inc. assumes no responsibility for any errors that may be contained within this document.

The software discussed within this document is furnished under separate license agreement and is
subject to use only in accordance with the licensing terms and conditions contained therein.

Trademarks

EDS, the EDS logo, UNIGRAPHICS SOLUTIONS, UNIGRAPHICS, GRIP, PARASOLID,


UG, UG/..., UG SOLUTIONS, iMAN are trademarks or registered trademarks of Electronic
Data Systems Corporation or its subsidiaries. All other logos or trademarks used herein are the
property of their respective owners.

Sheet Metal Design Student Guide Publication History:


Unigraphics NX . . . . . . . . . . . . . . . . . . . . March 2003
Table of Contents

Table of Contents

Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
Key Features of Sheet Metal Design . . . . . . . . . . . . . . . . . . . . . -2
Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3
Why do I need to know this? . . . . . . . . . . . . . . . . . . . . . . . . . -3
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4
Classroom System Information . . . . . . . . . . . . . . . . . . . . . . . -6
Class Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7
About Part File Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7
Class Part File Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7
Seed Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -8
Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9
Expressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -10
Layers and Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11
Unigraphics Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -13
Activity -1: Toolbars in Gateway Application . . . . . . . . . . . -15
Activity -2: Toolbars in Modeling Application . . . . . . . . . . -22
The Sheet Metal Feature Toolbar . . . . . . . . . . . . . . . . . . . . . . . . -29
Activity -3: Sheet Metal Toolbar in Modeling Application -31
Preferences and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Sheet Metal Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Global Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Reference Line Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Part Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Default Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Load Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Use Feature Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Check Standards on Create . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Enforce Creation State Editing . . . . . . . . . . . . . . . . . . . . . . . 1-6
Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Sequential Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Bracket Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Defining Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Checking Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Activity 1-1: Reviewing Preferences and Standards . . . . . . 1-11

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Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
The Flange Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Flange Profile Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Positioning Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Bend Allowance Formula (BAF) . . . . . . . . . . . . . . . . . . . . . . 2-8
Flip Bend Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Adjacent Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Parameter Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Reference Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Side Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Left and Right Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Butt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Global Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Confirm Upon Apply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Flange Instancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Activity 2-1: Creating Flanges . . . . . . . . . . . . . . . . . . . . . . . 2-20
Activity 2-2: Creating a Butt Joint . . . . . . . . . . . . . . . . . . . . 2-42
Miters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Miter Side Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Left and Right Miters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Simple Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Full Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Miter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Miter Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Miter Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Miter Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Flange Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Activity 2-3: Working with Miters . . . . . . . . . . . . . . . . . . . . 2-62

Sheet Metal Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


The Sheet Metal Corner Dialog . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Construction Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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Butt Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4


Parent Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Associate Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Simple Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Gap and Relief Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Full Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Multiple Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sheet Metal Corner Construction Tips . . . . . . . . . . . . . . . . . . . 3-10
Activity 3-1: Creating Sheet Metal Corners . . . . . . . . . . . . 3-11

Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
The Inset Flange Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Inset Flange Profile Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Inset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Use Expression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Outer Tangent Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inner Tangent Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Outer Mold Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
DIN Mold Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Inner Mold Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Relief Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Flange Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Left and Right Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Activity 4-1: Exploring Inset Flange Creation Techniques 4-11
Activity 4-2: Creating an Inset Flange . . . . . . . . . . . . . . . . 4-22

Sheet Metal Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1


The Sheet Metal Bend Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Construction Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Base Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Application Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cylindrical Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Existing Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Application Curve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Flip Bend Direction Vector . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

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Flip Stationary Direction Vector . . . . . . . . . . . . . . . . . . . . . . 5-7


Bend Allowance Formula (BAF) . . . . . . . . . . . . . . . . . . . . . . 5-8
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Sheet Metal Bend Construction Tips . . . . . . . . . . . . . . . . . . . . . 5-9
Activity 5-1: Creating Sheet Metal Bends . . . . . . . . . . . . . 5-10

General Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1


The General Flange Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Bend Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Spine String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Section Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Shaping Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Punch Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Add Tangent Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Parameters Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Reverse Bend Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Step Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Build to Sections Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Extend Start and Extend End . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Build to Faces Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Punch Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Adjacent Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Infer Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Infer Spine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
r Value and Area Preserve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Contour Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Mold Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Form Block Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Activity 6-1: General Flange Creation Methods . . . . . . . . . 6-26
Activity 6-2: Other General Flange Creation Methods . . 6-35

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Activity 6-3: Create a Gen. Flg. by the Punch Vector Method 6-43

Sheet Metal Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1


The Sheet Metal Punch Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Placement Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Tool Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Lancing Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Direction Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Punch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Top Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Size Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Face Normal Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Flip Side Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Activity 7-1: Creating Sheet Metal Punches . . . . . . . . . . . 7-14

Sheet Metal Solid Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1


The Sheet Metal Solid Punch Dialog . . . . . . . . . . . . . . . . . . . . . 8-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Target Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Tool Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Transformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Pierce Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Create Auto Centroid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Edge Blend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Activity 8-1: Creating Sheet Metal Solid Punches . . . . . . 8-9

Sheet Metal Hole and Sheet Metal Slot . . . . . . . . . . . . . . . . . . . . . . 9-1


The Sheet Metal Hole Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Hole Positioning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Through Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Positioning Edge 1 & Positioning Edge 2 . . . . . . . . . . . . 9-5
Direction Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

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Hole Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7


Size Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Face Normal Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Editing Sheet Metal Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Editing Hole Positional Parameters . . . . . . . . . . . . . . . . . . . . . . 9-9
Hole Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Activity 9-1: Creating Sheet Metal Holes . . . . . . . . . . . . . . 9-11
The Sheet Metal Slot Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Creation Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Orientation Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Size Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Slot Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Slot Positioning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Activity 9-2: Creating Sheet Metal Slots . . . . . . . . . . . . . . . 9-29
Sheet Metal Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Sheet Metal Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
The Sheet Metal Cutout Dialog . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Through Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Direction Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Flip Discard Region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Activity 10-1: Creating Sheet Metal Cutouts . . . . . . . . . . . 10-9

Unbend/Rebend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Unbend/Rebend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Region Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Boundary Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
The Unbend/Rebend Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Bend Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Unbend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Rebend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

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Unbend to Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6


Bend Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Adjacent Bend Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Global Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . 11-7
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Activity 11-1: Creating Unbend and Rebend Features . . . 11-8
Activity 11-2: Creating Unbends from an Extrusion . . . . . 11-19
Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
The Bead Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Centerline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Centerline Projection Vector . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Orientation Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Section Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Section Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Secondary Face Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
Target Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
Bead Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Bead Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Activity 12-1: Creating Beads . . . . . . . . . . . . . . . . . . . . . . . 12-18
Sheet Metal Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
The Sheet Metal Bridge Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Base Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Base Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Target Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Target Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Construction Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Flip Extension Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Construction Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Intersect Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Inside Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9

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Distortion Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10


Area Preserve and R Value . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
Construction Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Unite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Activity 13-1: Sheet Metal Bridge Creation . . . . . . . . . . . . 13-13
Multibend Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
The Multibend Bracket Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Tree List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Base Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Add Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Add Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Reverse Material Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Delete Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Inner Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
Intersection Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
Adjacent Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Sketch Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Editing Multibend Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
Activity 14-1: Creating a Multibend Bracket . . . . . . . . . . . 14-10
Sheet Metal Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
The Sheet Metal Bracket Utility . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
The Sheet Metal Bracket Dialog . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Base Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Base Clearance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Reference Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Reference Clearance Points . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Reverse Material Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Clearance Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Material Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Bend Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Pad Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

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Flange Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7


Offset Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Chordal Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Linear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Add Rounded Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Create or Unite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Edit Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Normal to Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Between Circles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Along Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Drag Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Point Constructor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Creation of a Sheet Metal Cutout . . . . . . . . . . . . . . . . . . . . . 15-16
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
MultiĆflanged Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Editing Sheet Metal Brackets . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Bracket Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Activity 15-1: Bracket Creation . . . . . . . . . . . . . . . . . . . . . . 15-18

Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1


The Flat Pattern Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Creating a Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Updating a Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Name and Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Traverse Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Unform and Form Sheet Metal Features . . . . . . . . . . . . . . . 16-6
Change Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Traverse Control Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Layout Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8
Area Preserving Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8
Distortion Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9
Projection Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9
Cutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-10
Additional Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-10
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11
Start Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11

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Orientation Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11


Activity 16-1: Creating a Simple Flat Pattern Drawing . . 16-12
Flat Pattern Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
Name and Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Chord and Angle Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Output Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Curve Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Bend Tangent Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Bend Center Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Auto Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Distortion Constraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Allow Multiple Flat Patterns . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Use Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . 16-21
Geodesics Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
Flat Pattern Annotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
Edit Display Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
Text Callout Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-23
Flat Pattern Annotation Preferences . . . . . . . . . . . . . . . . . . . . . 16-24
Flat Pattern Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-25
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-26
Activity 16-2: Creating a Flat Pattern Drawing Assembly 16-27
Additional Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Sheet Metal Part in Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Part In Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Unform Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Form Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Add Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Add Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Delete Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Unform Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Form Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Execute Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Add Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Add Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Delete Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Bridge and Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

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Flange and Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8


Process Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
General Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Surface Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Edge Constrains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Activity B-1: Creating a Process . . . . . . . . . . . . . . . . . . . . B-12
Working in Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22
Creating Process Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23
Sequential Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-24
Part Families . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-24
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-25
General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-25
Part Families Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Available Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Attribute Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Activity B-2: Generate Family Members for Model States B-28
Activity B-3: Adding Part in Process States to a Drawing B-32

Flat Pattern Additional Information . . . . . . . . . . . . . . . . . . . . . . . . C-1


Flat Pattern Woven Materials Options . . . . . . . . . . . . . . . . . . . . C-1
Warp Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Origin Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Grid Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Lock Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Activity C-1: Flat Patterns for NonĆSheet Metal Parts . . . C-6

Multibend Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1


Activity D-1: Creating a Multibend Bracket . . . . . . . . . . . D-2

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-1

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xii Sheet Metal Design


Student Guide
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Course Overview

Course Overview

The Sheet Metal Design course was developed to show the user how to employ
the sheet metal feature and design functions within Unigraphics to successfully
create and manipulate sheet metal parts.

The sheet metal design product supported within Unigraphics uses a


solidsĆbased, featureĆbased approach to defining sheet metal parts. From these
parts the user can create accurate manufacturing data such as flat pattern
definitions, forming tables, and bend sequence tables for downĆstream
applications.

This section contains the following activities:

Activity Page
-1 Toolbars in Gateway Application . . . . . . . . . . . . . . -15
-2 Toolbars in Modeling Application . . . . . . . . . . . . . -22
-3 Sheet Metal Toolbar in Modeling Application . . . -31

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Key Features of Sheet Metal Design

Some highlights of the sheet metal design product include:

 FeatureĆspecific attributes and standards checking to ensure design for


manufacturability principles are met.
 Associativity between sheet metal features and modeling features.
 Dynamic model states (formed, intermediate, and unformed model
stages).
 Multiple flat pattern generation, annotation, and update capabilities.
 Part tailoring through the creation of userĆdefined features, such as
cutouts.
 Preference settings for general and userĆdefined sheet metal
standards.
 Information options to display bend sequence and forming tables.

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Course Objectives

After successfully completing this course, the student should be able to:

 Create sheet metal parts using both modeling and sheet metal
features.
 Set up default standards and creation preferences.
 Effectively create and edit Flange, Inset Flange, Sheet Metal Bend,
General Flange, Sheet Metal Bridge, Bead, Sheet Metal Punch, Sheet
Metal Hole, Sheet Metal Slot, Sheet Metal Cutout and Sheet Metal
Bracket features. Sheet Metal Relief and Sheet Metal Strain features
will not be covered in this course. More information can be found on
these features using the Unigraphics onĆline documentation.
 Recognize the benefits and limitations of sheet metal features.
 Create and manipulate forming tables.
 Create and edit sheet metal flat patterns.
 Create and edit flat pattern display and callout annotations.
 Recognize the effect of using sheet metal parts in Assembly
applications.

Why do I need to know this?

You may be wondering why specific sheet metal features were created
independent from modeling features. Sheet metal features are unique from
modeling features in that they contain applicationĆspecific data such as bend
allowance formula and other material property information. Sheet metal
features also have the ability to change their geometric representation with
respect to the formed state of the model.

Because of these characteristics, it is essential to the creation of a valid, usable


sheet metal part that you know when and how to use sheet metal features
during the construction of your part. Incorrect implementation or nonĆusage of
sheet metal features may result in inaccurate or unproducible flat pattern
definitions.

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Prerequisites
The Sheet Metal Design course is intended for users who have experience with
the basic Unigraphics functionality found in the Practical Applications (PAU),
Design Applications (DAU) and Drafting fundamental courses. In order to
ensure that the above course objectives are met, it is anticipated that you are
able to perform the following prerequisites prior to this course:
 Log on, navigate through a directory structure, and create, open, close,
and save part files.
 Manipulate the display of a model using views and layouts.
 Organize the contents of a part file using layers.
 Utilize the WCS to define points, vectors, planes, and coordinate
systems in model space.
 Create and edit points, lines, arcs, fillets, and chamfers.
 Create and edit primitive features.
 Create and edit extruded and revolved bodies.
 Create, edit, and position form features.
 Create and edit datum planes and axes.
 Apply the operational features blend, hollow, taper, offset, and
instance.
 Create and edit simple/moderate sketches.
 Create and edit drawings.
 Work within an assembly file structure.

How to Use This Manual


It is important that you use the Student Manual in the sequence presented
because later lessons assume you have learned concepts and techniques taught
in an earlier lesson. If necessary, you can always refer to any previous activity
where a method or technique was originally taught.

The general format for lesson content is:


 lecture
 activity
 project
 summary

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Course Overview

The format of the activities is consistent throughout this manual. Steps are
labeled and specify what will be accomplished at any given point in the activity.
Below each step are action boxes which emphasize the individual actions that
must be taken to accomplish the step. As your knowledge of Unigraphics
increases, the action boxes will seem redundant as the step text becomes all that
is needed to accomplish a given task.

Step 1 Open part file xxx_topic_1.prt.

 From the menu bar, select File.

 Choose Open.

 DoubleĆclick on the parts subĆdirectory.

 Select the file xxx_topic_1.prt and choose OK.

While working through lesson activities, you will experience a higher degree of
comprehension if you read the CUE and Status lines .

It is recommended that students who prefer more detail from an Instructor Led
Course ask questions, confirm with restatement, and, more importantly, attend
and pay attention to the instruction as it is given.

Obviously, it is always necessary for students to consider the classroom situation


and be considerate of other students who may have greater or lesser needs for
instruction. Instructors cannot possibly meet the exact needs of every student.

At the start of each class day you will be expected to log onto your terminal and
start Unigraphics, being ready to follow the instructor's curriculum. At the end
of the day's class you should always quit Unigraphics and log off the terminal.

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Classroom System Information

Your instructor will provide you with the following items for working in the
classroom:

Student Login: Username:

Password:

Home Directory:

Parts Directory:

Instructor:

Date:

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Course Overview

Class Standards

The following standards will be used in this class. Standardization allows users
to work with others parts while predicting the organization of the part file. All
work should be performed in accordance with these standards.

About Part File Naming

In order to facilitate the identification of design models without requiring the


user to open a part file, the user community must establish standard names for
the various files associated with the part definition. The following is a sample
usage of a filenaming standard:

part name revision


(25 characters) (4 characters)

xxx_xxxxxxxxxxxx_xxxx_xxxx•prt

identifier configuration extension


(3 characters) (4 characters) (4 characters)

TIP Currently up to 128 characters are valid for file names. A four
character extension (.prt, for example) is automatically added to define
the file type. This means the maximum number of user defined
characters for the file name is actually 124.

Class Part File Naming

This course utilizes the following filenaming standard:

course identifier
(3 characters) part name

smd _ x x x x x x x x x x x x x x x x x x x x . p r t

extension
underscore delimiter (4 characters)

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Course Overview

Where the student is requested to save a part file for later use, the initials of
the student's given name, middle name, and surname replace the course
identifier smd" in the new filename with the remainder of the filename
matching the original.

Seed Part

Seed parts are an effective tool for establishing customer defaults or any
settings that are partĆdependent (saved with the part file). This may include
nonĆgeometric data such as:

 Preferences
 Commonly used expressions
 Layer categories
 UserĆdefined views and layouts
 Part attributes

TIP Once a seed part is established, it should be writeĆprotected to avoid


accidental modification of the seed part.

A seed part file is available for use in this course. This file incorporate the
standards described above, and include the TFRĆTRI view as the default view.

 smd_seedpart (Inches)

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Course Overview

Colors

The following colors are preset to indicate different object types:

Object Valid colors


Bodies
Solid Green
Sheet Yellow
Generating Curves (nonĆsketch)
Lines and Arcs Orange
Conics and Splines Blue
Sketches
Sketch Curves Cyan
Reference Curves Gray
Datum Features Aquamarine
Points and Coordinate Systems White
System Display Color White

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Expressions

The student will notice that there is a standard set of expressions resident in
each of the part files as follows:

Expression Name Intended Use


ANG DO NOT EDIT, this formula identifies the angle
for the JOGGLE
BR identifies outside bend relief
Delta DO NOT EDIT, this is a derived value
H identifies overall height
JOGGLE identifies a joggle offset value
L identifies overall length
R identifies inside bend radii
T identifies material thickness
W identifies overall width

These expressions could be entered by the user in each file or could be a


standard expression file that could be imported into the part file by the user.
Expression files that are valid for importing carry the file extension of .exp. The
total number of characters allowed in an expression is 132.

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Course Overview

Layers and Categories

The student will notice that there are standard layer assignments as well as
standard category names in each of the part files as follows:

Layers 1-100, Model Geometry (Category: MODEL)

Layers 1-14, Solid Geometry (Category: SOLIDS)

Layers 15-20, Linked Objects (Category: LINKED_OBJECTS)

Layers 21-40, Sketch Geometry (Category: SKETCHES)

Layers 41-60, Curve Geometry (Category: CURVES)

Layers 61-80, Reference Geometry (Category: DATUMS)

Layers 81-100, Sheet Bodies (Category: SHEET_BODIES)

Layers 101 - 120, Drafting Objects (Category: DRAFTING_OBJECTS)

Layers 101 - 110, Drawing Borders (Category: FORMATS)

Layers 121 - 130, Mechanism Tools (Category: MECHANISMS)

Layers 131 - 150, Finite Element Meshes and Engr. Tools (Category: CAE)

Layers 151 - 180, Manufacturing (Category: MANUFACTURING)

Layers 161-170, Flat Patterns (Category: FLAT_PATTERNS)

Layers 181 - 190, Quality Tools (Category: QUALITY_TOOLS)

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Course Overview

Platform Specific Dialog Variance (Windows vs Unix)

Most interaction with dialogs is the same on the Windows  platform and the
Unix platform. The appearance of some of the controls is slightly different as
shown in the example below. Notice the variance in the display of the slider
bars, check boxes, option menus, etc.

Unix Windows

Graphics shown in this text are from a Windows workstation, some of the
dialogs at your classroom workstation may differ slightly from those shown.

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Unigraphics Interface

Unigraphics utilizes a toolbar interface which is customizable for each user.


Many of the options located under the Menu bar and various cascades can be
accessed by selecting an icon from the appropriate toolbar. It is the intent of
this course to emphasis ease of use". Lessons will introduce functions and
identify their location with respect to toolbars and icons. The session of
Unigraphics that will be initiated has an out of the box" interface, therefore
the Gateway and Modeling applications will be customized through an activity.

Control of Toolbar display may be accessed from one of 3 places:

 Choose Tools"Customize from the main menu.


 Choose View"Toolbars from the main menu.
 Use the Third Mouse Button within the Unigraphics window, outside
the Graphics window.

The display of each toolbar, as well as each element of each toolbar, is user
customizable. To turn ON or OFF the display of a toolbar choose
Tools"Customize or click MB3 in the toolbar area and select Customize.
Placing a check in the box next to the toolbar name will instantly display the
toolbar in the graphics area.

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To turn ON or OFF the display of a toolbar element choose the Commands tab.
Placing a check in the box next to the toolbar command will instantly display
the command in the appropriate toolbar. Removing the check turns off the
display.

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Activity -1: Toolbars in Gateway Application

This activity will demonstrate working with toolbars to establish an efficient


working environment in the Gateway application.

Step 1 Open the part file smd_seedpart.

 Choose the Open icon.

Step 2 Display the Standard toolbar in the Gateway Application.

 Click Mouse Button 3 (MB3) in the toolbar area and choose


Customize.

Click MB3 within


toolbar area.

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The Customize dialog appears and shows the current toolbars


which are displayed.

 Verify that the Standard toolbar is checked ON.

The Standard toolbar should be displayed on the screen docked


in the upper left corner under the Menu bar.

 Choose Close to dismiss the Customize dialog.

Step 3 Display the View, Selection and Utility toolbars.

 Click MB3 in the toolbar area and verify the View, Selection
and Utility toolbars are checked ON.

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The toolbars are displayed on the screen in an Docked state.


Remember that toolbars may be docked horizontally on the top
or bottom and vertically on the left or right. Locate the toolbars.

View

Selection

Utility

NOTE: Icons may vary for each


toolbar

Locate the Utility toolbar in the Unigraphics window, it may be


docked or undocked.

NOTE: Icons may vary.

Step 4 Move a docked toolbar.


 Place the cursor on the handle portion of the Utility toolbar
and press and hold down MB1.

Select Here

 Drag the toolbar such that it is aligned under the Standard


toolbar completely to the left side of the window.

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 Release MB1.

The Utility toolbar remains docked to the Unigraphics window


in the proper position.

 Select the View toolbar on the handle and drag the toolbar
such that it is aligned to the right of the Standard toolbar.

Locate Here

 Select the Selection toolbar on the handle and drag the


toolbar such that it is aligned to the right of the Utility
toolbar.

Locate Here

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Step 5 Display the Application toolbar in the Gateway


Application.

 Click MB3 in the toolbar area and check ON the Application


toolbar.

Click MB3 within


toolbar area.

Checked ON

Locate the Application toolbar in the Unigraphics window, it


may be docked or undocked.

NOTE: Icons may vary.

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Step 6 Customize the Application toolbar.

 Click MB3 in the toolbar area and choose Customize.

 Select the Commands tab and highlight Application in the


Toolbars column.

Select these
options

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Course Overview

A listing with the commands for the Application toolbar is


displayed. The commands displayed on the toolbar are checked
in the Commands column.

 Scroll down to see all of the options in the Commands


column. Turn ON the Modeling, Drafting and Assemblies
commands and turn OFF all others options. Also, turn ON
the Separator above the Assemblies command.

Scroll
down
here

Note that the display of the toolbar changes immediately upon


selection of commands.

 Choose Close to dismiss the Customize dialog.

 Locate the Application toolbar as shown below.

Locate here

These toolbar settings will be retained for the Gateway


application for the rest of the course.

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Activity -2: Toolbars in Modeling Application

This activity will establish toolbars in the Modeling application for use in
conjunction with sheet metal features.

Step 1 Enter the Modeling Application.

 Select the Modeling icon in the Application toolbar.

Entering a different application will introduce a new set of


toolbars. The toolbars that were established in the Gateway
application may move and have different commands in them.

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Course Overview

Step 2 Display the common toolbars from the Gateway


application.

 Click MB3 in the toolbar area and verify that the Standard,
View, Selection, Utility and Application toolbars are checked
ON. Turn OFF all other toolbars. Other toolbars will be
turned ON throughout the course as they are needed.

 Dock the toolbars in similar locations as defined in the


Gateway application.

Step 3 Customize the toolbars.

 Click MB3 in the toolbar area and choose Customize.

 Select the Commands tab and adjust the toolbars to match


the commands in the table below.

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Toolbars Standard View Selection Utility Application


Select
Work
New Refresh General Drafting
Layer
Objects
Select Layer
Open Fit Assemblies
Features Settings
Select
Save Zoom Separator Gateway
Components
Zoom WCS
Separator Separator
In/Out Dynamics
Commands Delete Rotate Type Filter Orient
Undo Pan Reset WCS
Separator Separator Separator
Wireframe
Information Select All
Settings
Shaded
Deselect All
Settings
Wireframe Separator
View Up One
Orientation Level
 Choose Close to dismiss the Customize dialog.

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Step 4 Display additional toolbars in the Modeling application.

 Click MB3 in the toolbar area and turn ON the Form


Feature, Feature Operation, Edit Feature and Modeling
Toggles toolbars.

Form Feature

Feature Operation

Edit Feature

Modeling Toggles

NOTE: Icons may vary for each


toolbar

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 Dock the toolbars horizontally or vertically in the locations


defined below.

Modeling
Feature Edit Feature Toggles
Operation

Form
Feature

Step 5 Customize the toolbars.

 Click MB3 in the toolbar area and choose Customize.

 Select the Commands tab and adjust the toolbars to match


the commands in the following table.

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Form Feature Edit Modeling


Toolbars
Feature Operation Feature Toggles
Form
Edit Feature
Sketch Taper Feature
Parameters
Toolbar
Feature
Edit
Extruded Body Edge Blend Operation
Positioning
Toolbar
Edit
Revolved Body Edge Chamfer Move Feature Feature
Toolbar
Sheet Metal
Sweep along
Hollow Separator Feature
Guide
Toolbar
Instance Suppress
Separator
Feature Feature
Unsuppress
Hole Offset Face
Feature
Boss Separator Separator
Commands Delay Update
Pocket Trim Body
on Edit
Pad Separator Update
Slot Unite Separator
Feature
Groove Subtract
Playback
Separator Intersect
User Defined
Feature
Separator
Datum Plane
Datum Axis
Datum CSYS
Separator
Block
Cylinder

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 Choose Close to dismiss the Customize dialog.

Step 6 Leave the part open, it will be used again in the next
activity.

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The Sheet Metal Feature Toolbar

Within the Modeling application, sheet metal feature creation is accomplished


through the use of a dedicated toolbar. This arrangement permits the user to
remain within the modeling environment for the duration of the design process
and allows for the creation of sheet metal features which are associated to their
base model geometry.

One way to retrieve the Sheet Metal Feature toolbar it is to click MB3 in the
grey area next to any existing toolbar and selecting Sheet Metal Feature. In the
previous activity we turned on the Modeling Toggles toolbar and included the
icon for Sheet Metal Features. This icon can be conveniently selected to turn
ON and OFF the Sheet Metal Feature toolbar.

#1 Ć Click MB3 here

Sheet Metal
Feature toolbar
toggle

#2 Ć Click MB1 here

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Student Guide
-29
Course Overview

Nineteen sheet metal features are currently available for use. They are shown
in the figure below. In addition, a Form/Unform button allows any or all of the
formable features (e.g. flange, inset flange, profile flange, general flange, or
smbend ) to change their formed or unformed state while remaining within the
Modeling application. Information and activities have been included in this
manual for all the sheet metal features except Sheet Metal Routed Relief, Sheet
Metal Strain and Metaform.

Inset Flange
Flange

Sheet Metal Hole


Profile Flange Sheet Metal Slot
Sheet Metal Cutout
Multibend Bracket
Sheet Metal Corner
General Flange Sheet Metal
Sheet Metal Bridge Solid Punch

Bead
Sheet Metal Punch

Sheet Metal Bend

Unbend/Rebend
Metaform

Form/Unform Sheet Metal Strain


Routed Relief
Sheet Metal Bracket

EDS Unigraphics NX
-30 Sheet Metal Design
Student Guide All Rights Reserved
Course Overview

Activity -3: Sheet Metal Toolbar in Modeling Application

This activity will turn ON the Sheet Metal Feature toolbar in the Modeling
application.

Step 1 Continue using the part file smd_seedpart and ensure the
Modeling application is turned ON.

Step 2 Turn ON the Sheet Metal Features toolbar.

 Select the Sheet Metal Features icon in the Modeling Toggles


toolbar as shown below.

Click here

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Course Overview

 Locate the toolbar as shown below.

Sheet Metal Feature

Step 3 Choose File"Close"All Parts, do not save.

EDS Unigraphics NX
-32 Sheet Metal Design
Student Guide All Rights Reserved
Preferences and Standards

Preferences and Standards ÏÏÏ


Lesson 1
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

PURPOSE Create sheet metal standards and preference defaults


to ensure design for manufacturability goals are
concurrent throughout the company, division and/or
department.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Set up the Sheet Metal Preferences dialog


 Turn on the Sheet Metal Feature toolbar.
 Retrieve the default standards file for sheet metal
design
 Retrieve a part file's construction preferences and
determine its standards usage

This section contains the following activity:

Activity Page
1-1 Reviewing Preferences and Standards . . . . . . . . . . 1-11

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1-1
Preferences and Standards

ÏÏÏ Sheet Metal Preferences


ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Before beginning your part development, it's a good practice to always set up
and verify your sheet metal default preferences. Attempting to change these
preferences in the middle, or after completion of your design may result in
unĆmanufacturable parts or inaccurate flat pattern definitions.

With the implementation of sheet metal features, provisions are available to


allow for the establishment of standard values applied at the time of the feature
creation. These standards are called part standards and feature standards, and
are contained in a Standards default file (ugsmd_def.std). Part standard
parameters are attributes or expressions used throughout the sheet metal
design process. They include characteristics like material type and thickness.
Feature standards are used to define the size of the feature, and vary for each
sheet metal feature. Typical feature standards are flange width, bend angle,
bend allowance formula, and diameter (for sheet metal holes).

While in the Modeling application, sheet metal part and feature standards can
be controlled through the Sheet Metal Preferences dialog accessed by selecting
Preferences→Sheet Metal (shown in the figure below). While in the Sheet
Metal Design application, you can also access the dialog from
Preferences→SMD General.

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1-2 Sheet Metal Design
Student Guide All Rights Reserved
Preferences and Standards

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
All options are toggled ON for clarity

Global Parameters
The Sheet Metal Preferences dialog will allow you to set global parameters,
such as material thickness, bend radius, bend angle, and bend allowance
formula. This will reduce the number of parameters you need to enter while
creating sheet metal features. When you set any of these global parameters, all
of the sheet metal features that have these parameters will be created using the
global values. The widget for that parameter will not be available on the
feature's dialog. Default values and options for sheet metal feature dialogs are
contained within a Standards default file (ug_smd.def).

For example, if your company uses a standard bend allowance formula, enter
that formula on the Global Parameters dialog. When you open the Flange
dialog to create a flange, the Bend Allowance Formula button will no longer
appear on the dialog. The default Bend Allowance formula is also defined in
the ug_smd.def file.

If you want to turn off the Global Parameters for a single feature, you can
access Global Parameters from the individual feature's options dialog.

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Student Guide
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Preferences and Standards

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ Reference Line Color

During the creation of flange geometry, you can create mold lines, form block
lines and/or contour lines for each Flange, Inset Flange and General Flange.
This option allows you to select the display color for these reference lines. With
this preference setting, you will have the capability to blank these lines by their
color designation before importing the flat pattern into a drawing.

Part Materials

The list of Part Materials displayed is derived from the Standards default file.
The material characteristic is a part attribute that is used to define feature
standards with respect to material qualities. Selecting a material type from the
displayed list will load the type into the Default Material field. Again,
userĆdefined material types can be added to the list by editing the Standards
default file.

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1-4 Sheet Metal Design
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Preferences and Standards

ÏÏÏ
ÏÏÏ
Default Material
ÏÏÏ
1
ÏÏÏ
The material type specified in this field will determine available feature
standard options like thickness, inside bend radii, and bend angles. The initial
default material type is assigned within the ug_smd.def file.

NOTE Although material type is a part standard, it is not used


for any calculations (e.g. mass) nor does changing this
attribute have any effect on the part's geometry. This
attribute is only used to define what feature standards are
available for a given parameter.

Load Standards

This button allows you to load a properly formatted standards file from a
specified directory. When selected, the system will prompt you to enter the
appropriate file for loading. This is a useful way to update available standard
options and values during working sessions.

Use Feature Standards

Toggling this preference option ON allows the user to select from a list of
standard values for specific feature parameters during the feature creation.
Toggling this option OFF forces the user to manually enter the feature
parameter values.

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Preferences and Standards

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ Check Standards on Create

NOTE This option is only active if a standards file is installed


under the Load Standards button and the Use Feature
Standards option is toggled ON.

When toggled ON, this option causes the system to check entered feature
parameters against feature standards. When OK or Apply is selected on the
sheet metal feature creation dialog, the system will compare entered values
against feature standard values. If the values do not match, a warning will
display. This warning lists the nonĆstandard parameters and will allow you to
continue or go back to the feature creation dialog. If there are multiple values
that are not standard, they will all be listed.

If you choose OK, the system will create the feature using the nonĆstandard
values. Selecting Back will allow you to return to the feature creation dialog
and correct the values for the nonĆconforming parameters.

Enforce Creation State Editing

This option is used to enable or disable the ability to edit the parameters or
position of a sheet metal hole, slot or cutout when the model is in a state other
than the original feature creation state.

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1-6 Sheet Metal Design
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Preferences and Standards

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Forming Method
This option allows you to control how new Straight Brake and Solid Punch
features are formed and unformed. The option can be set to Use Self-Forming
Features or Use Forming Operators.

If the option Use Forming Operations is checked, Straight Brake and Solid
Punch features you create will not be listed in the Form/Unform dialog. The
way to get these features to Form or Unform is to create Unbend and Rebend
features on their cylindrical faces. If the option Use Self-Forming Features is
checked, Straight Brake and Solid Punch features you create will be listed in
the Form/Unform dialog.

Sequential Processing
Toggle this option ON or OFF to control the processing of groups or items in
Part in Process. If it is processed sequentially then the selected item and
everything above it in the tree list will be formed. Non-sequential will only
form the selected object. Information on Part in Process can be found in the
Appendix.

Bracket Margin
The bracket margin is used in the Sheet Metal Bracket utility. During
construction of a bracket, the system creates a base pad that is trimmed to the
proper size. The original base pad's size is determined by the intersection curve
and the clearance distance dimension. The Bracket Margin value is a
percentage used to increase these dimensions. It only affects the size of the
original base pad and not the final bracket. You should increase this margin if
the Bracket outline curves do not lie entirely on the base pad.

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Preferences and Standards

ÏÏÏ Defining Standards


ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Sheet Metal Design uses a Standards file named ugsmd_def.std to manage
material standards such as material types, BAFs, and thicknesses. This file also
manages feature standards for defining the size of each sheet metal feature. If a
sheet metal feature has standard values defined, it will have an active arrow
next to the input field. You can access the standard values by selecting the
arrow button. A list containing the standard values for that parameter will
appear. Selecting a value from this list will cause the system to insert it into the
parameter field.

Notice the arrow indicator is


highlighted. This means there is an
available list of standard values.

NOTE Remember, these selection arrows are only active if the


Use Feature Standards option is toggled ON in the Sheet
Metal Preferences dialog.

The ugsmd_def.std and ug_smd.def files are read when the Modeling or Sheet
Metal Design applications are first entered and every time you create sheet
metal features. The ugsmd_def.std file can be reloaded at any time by using the
Load Standards button on the Sheet Metal Preferences dialog.

Proper use of both standards files can ensure that only correct material
properties and feature standards are used per your design and manufacturing
specifications.

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1-8 Sheet Metal Design
Student Guide All Rights Reserved
Preferences and Standards

Checking Standards ÏÏÏ


ÏÏÏ
Within the Sheet Metal Design application, two methods are available to check
your part against the defined standards.
ÏÏÏ
1
ÏÏÏ

Two ways to
verify part
standards

You can use Information→Check Feature Standards to compare parameters of


a selected sheet metal feature against the feature standards. Or you can use
Information→Check Entire Part Standards to compare all sheet metal feature
parameters against the feature standards defined in the Standards file.

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Preferences and Standards

ÏÏÏ Choosing the Check Feature Standards option brings up the Feature Selection
ÏÏÏ dialog. You can select one or more features from this dialog. With either check

ÏÏÏ
1
ÏÏÏ
option, an information window displays the results of the standards check.

A PASS is reported if the feature parameter value conforms to the established


standards list. A FAIL is reported if the value does not conform. If a feature
standard option was not implemented during the feature construction, or no
standards list for that parameter was loaded in the Standards file, the system
will return a Warning message.

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1-10 Sheet Metal Design
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Preferences and Standards

Activity 1-1: Reviewing Preferences and Standards ÏÏÏ


ÏÏÏ
ÏÏÏ
1
ÏÏÏ
In this activity you will examine the Sheet Metal Preferences dialog and check a
part file's standards usage.

Step 1 Open and review a model's sheet metal preferences

 Open the part smd_prefs.

 Enter the Modeling application.

Step 2 Set your Preferences and load a standards file.

 Check the default preferences by selecting


Preferences→Sheet Metal.

NOTE The directory containing the sheet metal design


Standards file is specified by an environment variable
(UGII_UGSMD_STDS_LIBRARY). See your instructor
if you need further information.

 Set the default material to aluminum by selecting aluminum


in the Part Materials list.

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Preferences and Standards

ÏÏÏ  Ensure the Use Feature Standards option is turned OFF.


ÏÏÏ
ÏÏÏ
1
ÏÏÏ

NOTE The Check Standards on Create/Edit option is


automatically made unavailable if the Use Feature
Standards button is turned OFF.

 Choose OK in the Sheet Metal Preferences dialog.

Step 3 Check a flange's feature creation parameters.

 Choose the Edit Feature Parameters icon from the


Edit Feature toolbar.

 Select FLANGE(2) from the Edit Parameters dialog.

 Choose OK.

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1-12 Sheet Metal Design
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Preferences and Standards

Notice that the feature standard arrows are not activated


ÏÏÏ
(they're grayed out).
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

Standards are not selectable

Feature standards are not available for selection because the


Use Feature Standards option was toggled OFF in the Sheet
Metal Preferences dialog.

 Choose Cancel.

Step 4 Enable feature standards.

 Choose Preferences→Sheet Metal.

 Toggle the Use Feature Standards option ON.

 Choose OK.

 Choose the Edit Feature Parameters icon again.

 Select FLANGE(2) and OK.

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Preferences and Standards

ÏÏÏ Now you can select the arrow to display a list of standard values
ÏÏÏ for that feature parameter.

ÏÏÏ
1
ÏÏÏ

 Cancel out of the Flange dialog.

Step 5 Check feature standards.


To verify part features against specified standards you must first
enter the Sheet Metal Design application.

 Choose Application→Sheet Metal→Design...

 Choose Information→Check Feature Standards...

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1-14 Sheet Metal Design
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Preferences and Standards

 Select FLANGE(2) and OK.


ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

Warnings were issued for WIDTH and LENGTH because no


default standards were loaded into the ugsmd_def.std file for
these parameters.

Step 6 Choose File"Exit in the Information window and close


your part.

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Student Guide
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Preferences and Standards

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

SUMMARY Use standards and preference defaults to


maintain design for manufacturability goals
throughout your company, division or
department.

In this lesson you:


 Turned on the Sheet Metal Feature icons
 Set up the SMD Preferences dialog
 Retrieved the default standards file
 Determined a part file's standards usage
 Compared the Modeling environment to the
Sheet Metal environment

EDS Unigraphics NX
1-16 Sheet Metal Design
Student Guide All Rights Reserved
Flange

Flange
Lesson 2

PURPOSE Create and edit sheet metal flanges using the Flange
sheet metal feature
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
OBJECTIVES Upon completion of this lesson, you will be able to:

 Create and edit flanges


 Add taper angles and mitered corners to flanges
 Create expressions to customize flange creation
methods
 Add and properly locate modeling features on
flanges

This section contains the following activities:

Activity Page
2-1 Creating Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-2 Creating a Butt Joint . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-3 Working with Miters . . . . . . . . . . . . . . . . . . . . . . . . 2-62

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Flange

Flange

The sheet metal Flange feature allows for the parametric control and creation
of a straightĆbrake flange along a planar placement face. Because parameters
are used in the creation of all sheet metal features, they can be parametrically
edited like any other modeling feature using the Edit Feature Parameters icon.

ÏÏÏ
ÏÏÏ
2
Upon selecting Insert→Sheet Metal Feature→Flange, or the Flange icon
from the Sheet Metal Feature toolbar, the Flange dialog is displayed and the
ÏÏÏ
ÏÏÏ
system prompts you to choose a bend edge. To edit a Flange, use Edit→Feature
or the Edit Feature toolbar.

TIP The edge selected on a thickness face represents the


bend side of the flange.

Select this Bend


Edge

Select this Bend


Edge

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Flange

The Flange Dialog

Flange Profile
Inputs

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Flange Profile Inputs

These inputs can be manually loaded or a standard value can be chosen from an
active arrow button inside the parameter field. Remember, these arrow buttons
are only active if the Use Feature Standards option is toggled ON in the Sheet
Metal Preferences dialog.

Any grayed out input field will derive their values from internal system
information. The status of these input fields (active or inactive) can be
controlled through the Options icon.

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Flange

Width

Initially, the Width type is set to Infer Width and is inferred from the
highlighted face. The width is measured by the actual length of the bend edge.
In addition, when this option is set to Infer Width, the Width parameter is
grayed out and not available.

The flange parameter value can be switched to the Width Expression condition
which allows for a specific value or valid expression to be manually entered into
the parameter field.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Width
Expression

Inferred
Width

NOTE When the Width option is set to Width Expression, the


Positioning Method is set to Manual. The Positioning Method
can be set back to Automatic, if desired.

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Flange

Positioning Method

There are two methods for positioning a flange on a planar face: automatically
and manually. If flange positioning is set to Automatic, the system will line up
the flange with the planar placement face, and will create a parallel distance set
to zero and vertical positioning dimensions. If you select a Manual position
option you will be prompted to provide positioning dimensions. The Manual
position option is best used for flanges with userĆspecified widths.

NOTE The system will always initially locate the flange against the
edge of the face which was associated with the bend direction ÏÏÏ
ÏÏÏ
2
vector.
ÏÏÏ
ÏÏÏ
Perpendicular or Under Constrained
Horizontal
Horizontal combined with Vertical

Fully Constrained
Line onto Line or Parallel @ a Distance
combined with
Perpendicular or Horizontal

Over Constrained

Line onto Line or Line onto Line or Parallel @ a Distance


Parallel @ a Distance (Horizontal combined with
Reference) Line onto Line or Parallel @ a Distance

Examples of positioning dimensions used to


manually locate a feature

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Flange

Length

The length of the flange can be defined in one of three ways. The figure below
depicts the three methods for measuring length . The default length type is set
to Tangent Length.

Bend Area

Lengths are measured

ÏÏÏ
ÏÏÏ
2
parallel with the web of
the flange
Contour

ÏÏÏ
ÏÏÏ Web
Area
Tangent
Length
Length

Contour / DIN

Tangent

Tangent

Bend Angles < 90 DIN

Contour

Bend Angles > 90

NOTE To create a flange with no web area you must use Tangent
Length and set the length equal to zero. If a length of zero is
used for Contour Length the system will generate a warning
message.

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Flange

Angle

Angle represents the angle of the flange in the formed state. This angle can be
set to specify a bend angle or an included angle. The default angle type is Bend
Angle.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Bend Angle Included Angle

NOTE The maximum angular value is limited by the selfĆintersection


of the flange bend segment with the attachment body.

Maximum bend angle limited


by selfĆintersection.

Bend
Angle

NOTE The Angle field is removed from the dialog if the Global
Parameters option of Use Global Angle is toggled ON inside
Preferences"Sheet Metal.

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Flange

Radius

Radius is the radial value of the cylindrical surface representing the bent
portion of the flange. Either the inside or the outside radius value can be
specified. The default radius type is Inside Radius.

NOTE The Outside radius value must be greater than the thickness of
the part or the system will issue an error message.

ÏÏÏ
ÏÏÏ
2
NOTE The Radius field is removed from the dialog if the Global
Parameters option of Use Global Bend Radius is toggled ON
ÏÏÏ
ÏÏÏ
inside Preferences"Sheet Metal.

Bend Allowance Formula (BAF)

When you click on the Bend Allowance Formula button, the following dialog
will appear:

The BAF originally loaded in the Sheet Metal Preferences dialog will
automatically be loaded as the flange default Bend Allowance Formula. A new
BAF can be selected from the Bend Allowance Formulae list box, or a
userĆspecified formula can be directly entered into the BAF field.

NOTE The Bend Allowance Formula button is removed from the


dialog if the Global Parameters option of Use Global is toggled
ON inside Preferences"Sheet Metal.

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Flange

Flip Bend Direction

When you select a bend edge during the initial flange creation process, the
system automatically selects a bend direction for the flange. This direction is
displayed on the graphics screen as a vector located against the left edge of the
highlighted face. The Flip Bend Direction icon allows you to flip the vector
direction, thereby reversing the bend direction and left edge of the flange.

ÏÏÏ
ÏÏÏ
2
Adjacent Face
ÏÏÏ
ÏÏÏ
When you select a Bend Edge during the initial flange creation process, the
system automatically selects one of the two faces next to the Bend Edge. By
selecting the Adjacent Face icon, you can toggle between the two faces.

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Flange

Options

Selecting the Options icon within the Flange dialog activates the Options
dialog. Within this dialog, there are three tabs which access various options
used to derive feature parameters, side options and the use of global
parameters.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

NOTE The Options dialog may be accessed repeatedly, and


parameters changed, throughout the flange creation process.

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2-10 Sheet Metal Design
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Flange

Parameter Options

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Thickness

Initially, the value for the thickness is inferred from the highlighted face. The
thickness is measured perpendicular to the selected bend edge. In the Options
dialog, under the Parameters Options tab, this is the Infer Thickness from Edge
condition.

The thickness condition can be switched to the use an expression condition by


turning OFF the Infer Thickness from Edge option, which allows for a specific
value or valid expression to be manually entered into the parameter field.

NOTE The Standard arrow may also be selected to specify a thickness


if the Use Feature Standards option is turned ON in the Sheet
Metal Preferences dialog.

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Flange

Reference Lines

Contour lines, mold lines and form block lines can be generated for each flange
so that other features, such as holes or slots, can be positioned from these
reference lines.

The mold line of a flange is represented by the intersection of the base plane of
ÏÏÏ
ÏÏÏ
2
the part with a plane parallel to the placement face and tangent to the farthest
point of the flange bend face. Mold lines may only be created for flanges with
ÏÏÏ
ÏÏÏ
bend angles greater than 90 degrees.

Base Plane

Mold line

Plane parallel to the


placement face.

Contour lines are defined by the intersection of the base plane with the plane of
the web, and can be created for flanges with bend angles from 1 to 135 degrees.

Form block lines are similar to a contour lines except that they apply to the
inner surfaces of the Flange. Form block lines can only be applied to Flanges
whose angles have an absolute value less than 135 degrees.

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Flange

NOTE Because reference lines are statically positioned relative to the


base feature and the flange in the formed state only, reference
lines should be used to position features on the base faces
adjacent to the flange, and not the flange itself.

Contour line Mold line

ÏÏÏ
ÏÏÏ
2
Contour line
Flange (Typ)
ÏÏÏ
ÏÏÏ

Form block line

These reference lines may be generated separately, together, or not at all


during the flange creation stage and, because they are associated to the flange,
they will update if the flange parameters change.

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Flange

Side Options

Left and Right Settings

The Left and Right settings include None, Taper, Simple Miter, Full Miter and
Butt. None is the default and produces simple straight and square sides on the
flange.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Taper

Tapers can be added to each side of your flange, and can have parametric
values independent from each other. That is, the right side of the flange can
have a taper value which is different from the left.

The left and right side designation of a flange is governed by a front view, bent
down orientation. Positive angular taper values cause the flange to be trimmed
inward along the length of the flange. Negative angular values taper the flange
outward.

Right side
of flange

Left side
of flange
Negatively Positively
Straight Flange
Tapered Flange Tapered Flange

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Flange

Tapers can be implemented in three different ways: along the bend of the
flange, along the web of the flange, and along the total length of the flange. A
totally tapered flange has angular values in both the Bend and the Web input
fields. Independent tapers can be specified for the bend area and web of a
totally tapered flange.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
WebĆtapered BendĆtapered Totally Tapered
Flange Flange Flange

When Taper is selected, text fields will appear below the Left or Right Settings
columns in the Options dialog. These text fields allow input of a Bend Taper
Angle and/or a Web Taper Angle.

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Flange

Miter

When Simple Miter is selected, text fields will appear below the Left or Right
Settings columns in the Options dialog. These text fields allow input of a Miter
Angle, Phase or Relief. These options will be discussed later in this lesson.

When Full Miter is selected, text fields will appear below the Left or Right
Settings columns in the Options dialog. These text fields allow input of a Miter
Angle or Miter Phase. These options will be discussed later in this lesson.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Butt

Butt adds an extension to the side or sides of a flange so the web portions of the
flanges butt" up against each other. This option is ideal for flanges which meet
at a common corner and are bent at 90 degree angles. In earlier versions this
was accomplished using a Pad feature or an extrusion.

NOTE For flanges that meet at a common corner and are not bent at
90 degrees use the Sheet Metal Corner feature. The Sheet
Metal Corner feature will be discussed later in the course.

When Butt Joint is selected, a text field will appear in the Left or Right Side
Parameters window in the Flange dialog. These text fields allow input of a Butt
Length extension.

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Flange

ÏÏÏ
ÏÏÏ
2
Butt Joint
ÏÏÏ
ÏÏÏ

Butt Joint

Global Preferences

You can toggle the Global Parameters ON and OFF here. Global Parameters
are selectable only if the options are ON in the Sheet Metal Preferences.

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Flange

Confirm Upon Apply

Checking the Confirm Upon Apply button will add a chance for the user to
verify their selection before creating the flange.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

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2-18 Sheet Metal Design
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Flange

Flange Instancing
It is possible to create instances of a straight brake flange by using the
Insert→Feature Operation→Instance function. However, like all other
instances, the resultant flanges are directly linked to the master, or parent,
flange. Thus, trying to form or unform any one of the instances will cause all
instances, plus the master, to form or unform.

Flanges and Inset Flanges are currently the only Sheet Metal Features that can
be instanced. Sheet metal features such as SMHOLE and SMCUTOUT can be

ÏÏÏ
added to the master flange before or after instancing has occurred. However, in
neither case will the added feature be reflected in the resultant flange
instances. These features have distortion characteristics which are dependent ÏÏÏ
2
on the original placement face. Trying to instance these features would cause
inaccurate deformation profiles for each instance.
ÏÏÏ
ÏÏÏ
Sheet metal features can be individually added to each flange instance if
necessary. Any properly located Modeling Feature, such as Holes, Bosses, Slots,
Pockets, or Pads can be instanced with the underlying flange.

Flange parameters and instance array parameters can be edited in the normal
manner using the Edit Feature Parameters icon.

NOTE Modeling Holes and Slots can be instanced then converted to


Sheet Metal Features. This will be covered later in the course.

Master Flange

Flange
Flange Instancing instances

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Sheet Metal Design
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2-19
Flange

Activity 2-1: Creating Flanges

In this activity you will create and edit sheet metal flanges. You'll also attach
other model features to the created flanges.

Step 1 Open the part smd_flange. Save this part as xxx_flange


ÏÏÏ
ÏÏÏ
2
where xxx are your initials.

ÏÏÏ
ÏÏÏ Step 2 Set up your default preferences.

 Ensure you're in the Modeling application.

 Open the Sheet Metal Preferences dialog.

 Choose Global Parameters.

 Toggle ON Use Global Thickness.

 Set the Thickness option to Use Expression.

 Enter .080 for the Thickness.

 Confirm your settings and choose OK.

 Select aluminum in the Part Materials window.

EDS Unigraphics NX
2-20 Sheet Metal Design
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Flange

 Toggle ON Use Feature Standards.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose OK again to accept the preference settings.

TIP A seed partfile can be created which already


contains your company's sheet metal preferences
such as bend angle formulas and inside radius
standards. Use of this seed file would ensure
accurate initial design parameters are employed
from the beginning of the design effort.

EDS
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2-21
Flange

Step 3 Create the body of the part.

 Choose the Extruded Body icon from the Form Feature

toolbar.

 Select the sketch in the graphics window.

 Choose MB2.

ÏÏÏ
ÏÏÏ
2
 Accept the default extrusion method of Direction _Distance
by choosing MB2.
ÏÏÏ
ÏÏÏ  Choose MB2 to accept and create the extrusion vector.

Ensure vector is
pointing up.

 Enter a Start Distance of 0 and an End Distance of .080

EDS Unigraphics NX
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Flange

 Choose MB2.

 Select Cancel in the Extruded Body dialog.

 For clarity, make the SKETCHES and DATUMS layers


invisible.

Step 4 Create the first flange.

 Choose the Flange icon. ÏÏÏ


ÏÏÏ
2
Notice that the message in the Cue Line is prompting you to
select the Bend Edge of the Flange. ÏÏÏ
ÏÏÏ
 Select the top back edge of the part.

Select this edge

TIP The edge you select determines the initial bend


direction of the flange.

A vector arrow will appear in the corner of the part to indicate


the bend direction of the flange.

LEFT

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Flange

TIP You can change the vector direction at any time


while you're creating the flange by selecting the Flip
Bend Direction button in the Flange dialog.

Notice in the Flange dialog the Width field is grayed out.

ÏÏÏ
ÏÏÏ
2 The Width parameter

ÏÏÏ
ÏÏÏ
input field is grayed
out.

The Width input field was initially set to Infer Width. For now
we'll accept the default values.

 Ensure the Tangent Length is set to 2.00 .

 Change the Bend Angle to 90.

 Choose the standards arrow for the Inside Radius field.

Notice the available values, these values are stored in the


default file ugsmd_def.std.

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Flange

 From the Standard Values list choose 0.125 and then MB2.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
 Leave the remaining parameters at their default values, and
create the flange by selecting OK.
Your part should look like this:

Step 5 Create a tapered flange.

 Choose the Flange icon.

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2-25
Flange

 Select the bottom back edge of the part.

Select this edge

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
The flange bend direction vector should be pointing down.

 Change the flange bend direction by choosing the Flip Bend

Direction icon.

 Choose the Options icon.

 Choose the Side Options tab.

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Flange

 Change the Left Settings to Taper.

 Insert 45 into the Web Taper field.

Set Left Setting to Taper

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose OK.

Now you'll use the thickness and bend radius parameters to


define the length of the flange.

 Change the length option from Tangent Length to Contour


Length.

 Change the Contour Length value to the mathematical


expression: 2.00+.08+.125

Set to Contour Length

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Flange

TIP Expressions can be created for flange parameters


such as R for bend radius or T for flange thickness.
These expressions can then be inserted into any
parameter input field.

 Choose OK to create the flange.

Your part should look like this:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 6 Create a flange tab.

 Choose the Flange icon.

EDS Unigraphics NX
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Flange

 Select the top back edge of the new flange for the Bend
Edge. The flange direction vector should be pointing away
from the body of the part.

Select this edge

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Change the length option from Contour Length to Tangent


Length.

 Choose the Options icon.

 In the Side Options tab, verify the Left Settings is set to


None.

 Also verify the Right Settings is set to Taper.

 Insert 45 into the Bend Taper field.

 If necessary, change the Web Taper to 0.

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Flange

Your Options dialog should look like this:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose OK.

 Insert a Tangent Length value of .80

Your Flange dialog should look like this:

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Flange

 Choose OK to create the tab.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 7 Create a custom width flange.

 Choose the Flange icon.

 Select the top far edge of the straight flange for the Bend
Edge.

Select this edge

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Flange

 Choose the Options icon.

 In the Side Options tab, change the Right Settings option to


None.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose OK.

 Change the width option from Infer Width to Width


Expression.

 Change the Width value in the Flange dialog to .50

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Flange

 Verify the Positioning option is set to Manual.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose OK.

Because a manual positioning method was selected, you are


prompted to provide positioning dimensions.

CAUTION It is imperative that the flange location is sufficiently


specified by constraining at least two edges of the flange. Insufficiently
constrained flanges may fail to position properly when the part is
unformed.

 Choose the Line onto Line positioning icon.

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Flange

 Select the target edge, then the flange tool edge as shown.

Select this edge for


both the target edge
and tool edge.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ  Choose the Perpendicular icon from the Positioning dialog.

 Select the target edge, then the flange tool edge as shown.

TIP You may have to zoom up on the area to grab your target
and tool edges.

Select this edge for


both the target edge
and tool edge.

 Enter 1.0 into the Create Expression text field.

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Flange

 Choose OK.

An error message is displayed, warning you that the tool body


was positioned outside of the target body.

ÏÏÏ
ÏÏÏ
2
When overlapping edges are used as positioning edges, a
negative value must be supplied in order to move the feature in
the desired direction.
ÏÏÏ
ÏÏÏ
 Choose OK inside the message window.

 Repeat this step except this time use Ć1.0 instead of 1.0 for
the Perpendicular dimension.

TIP The flange parameters should already be set up with


the previous inputs.

Your part should look like this when you're finished:

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Flange

Step 8 Edit a Flange feature.

 Ensure the Selection toolbar is set to Select Features.

Select Features

ÏÏÏ
ÏÏÏ
2
 In the graphics window, double-click on the center flange.

ÏÏÏ
ÏÏÏ
Choose this flange

 Change the Width parameter to .80

 Choose OK.

 In the graphics window, select the center flange again.

 Place the cursor over the flange and select MB3.

 Choose Edit Positioning from the Pop-Up window.

 Choose Edit Dimension Value.

 Select the Perpendicular dimension and change the value


from -1.0 to 0.

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Flange

 Choose MB2 three times. The flange will update to the new
dimension and location specifications.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 9 Add a pad to the flange.

 Choose the Pad icon.

 Choose MB2 to accept the Rectangular default.

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Flange

 Select the far side of the straight flange as the placement


face.

Select the
thickness" face.

ÏÏÏ
ÏÏÏ
2 Select this front edge

ÏÏÏ
ÏÏÏ
as the horizontal
reference.

Hint: Select the


lower side of the
midpoint of the edge
to help position the
feature.

 Select the front edge of the face as the horizontal reference.

 Insert the following Rectangular Pad parameters:

 Length = 1.00
 Width = .08
 Height = .25

 Choose OK.

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Flange

 Position the pad .50 inches horizontally and 0 inches


vertically from the edges of the base flange. (Hint: Use Line
onto Line and Perpendicular)

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 10 Add a stiffening flange.

 Choose the Flange icon.

 Select the inside edge of the pad as the Bend Edge. The
flange direction vector should be pointing to the right.

 Set the Tangent Length to 0 .

Notice the Width input field is selectable. The system retains


the length of the placement face from the prior step. You can
correct the width to 1.00 or.....

 Change the width option back to Infer Width.

Notice the Width input field is now grayed out.

 Verify the Positioning option is set to Automatic.

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Flange

 Choose OK to create the flange.

Tab Stiffening
flange

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 11 Add blends.

 Using the blend feature, add .25 inch blends to the tab
corners.

 Add .125 inch blends to the inside edges of the stiffening


flange.

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Flange

When you're finished, your part should look like this:

2X R .125 4X R .25

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 12 Choose File"Close"Save and Close.

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Flange

Activity 2-2: Creating a Butt Joint

In this activity you'll start with a seed partfile and create a formable box with
butt jointed flanges.

Step 1 Open the partfile smd_seedpart. Save this part as


ÏÏÏ
ÏÏÏ
2
xxx_buttjoint where xxx are your initials.

ÏÏÏ
ÏÏÏ Step 2 Change the default variables of the seedpart.

 Ensure you are in the Modeling application.

 Select Tools→Expression...

 Choose the T variable and change the value to .060.

 Choose the R variable and change the value to 1/16.

 Choose the L variable and change the value to 6.00.

 Choose the W variable and change the value to 4.00.

 Choose the H variable and change the value to 2.00.

 Select OK.

Step 3 Change the default material for the part.

 Choose Preferences→Sheet Metal

 Choose Global Parameters.

 Toggle ON Use Global Thickness.

 Set the Thickness option to Use Expression.

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Flange

 Enter T for the Thickness.

 Toggle ON Use Global Bend Radius.

 Enter R for the Bend Radius.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Confirm your settings and choose OK.

 Select aluminum in the Part Materials window.

 Toggle ON Use Feature Standards.

 Choose OK again to accept the preference settings.

Step 4 Create the base feature.

 Choose the Block icon.

Notice the default block option is set to Origin, Edge


Lengths. The base feature will be created using this option.
 Enter the following parameters:

 Length (XC) = L-2*T-2*R


 Width (YC) = W
 Height (ZC) = T

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Flange

 Choose MB2 to create the block at the default 0,0,0 location


and Fit the part to the graphics display.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ Step 5 Create a flange with edge extensions using the Butt Joint
option.

 Choose the Flange icon.

Since the part you will build is made from aluminum, you will use a different
BAF than the default formula.

 Choose the Bend Allowance Formula button and choose the


formula from the list that uses the .40 factor.

NOTE The Bend Allowance formula could also be set in the Global
Parameters section of the Sheet Metal Preferences dialog.

EDS Unigraphics NX
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Flange

 Choose OK.

 Change the Length option from Tangent Length to Contour


Length.

 Change the Contour Length to 2.00

 Change the Bend Angle to 90.

Notice there is no Radius field. This is because we toggled


ON Use Global Bend Radius in the Sheet Metal
preferences.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
 Choose the Options icon.

 In the Side Options tab, choose the Butt option for the Left
and Right Settings.

 Insert R+T into the Butt Length field for both sides.

Your Options dialog should look like this:

 Choose OK.

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Flange

 Select the upper front edge of the Block as the Bend Edge.

ÏÏÏ
ÏÏÏ
2
Choose this edge
as the Bend Edge.

ÏÏÏ
ÏÏÏ
 Choose OK.

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Flange

Step 6 Create bend reliefs on the back corners of the part.

 Choose the Pocket icon.

 Choose Rectangular.

 Select the top face of the Block as the Placement Face and
the back edge as the Horizontal Reference.

ÏÏÏ
ÏÏÏ
2
Choose this edge
ÏÏÏ
ÏÏÏ
as the Horizontal
Reference.

Choose this face as the


Placement Face.

 Insert the following parameters:

 X Length = BR-T-R
 Y Length = BR-T-R
 Z Length = T

 Choose OK.

 Choose the Line onto Line positioning icon.

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Flange

 Select the upper back edge of the Block for the target
edge/datum.

 Select the upper back edge of the Tool Solid for the tool
edge.

Select this edge as


the target
edge/datum.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Select this edge
as the tool edge.

 Choose the Point onto Line icon from the Positioning dialog.

 Select the upper left edge of the Block for the target
edge/datum.

 Select the upper left edge of the Tool Solid for the tool edge.

Select this edge as


the target
edge/datum.

Select this edge


as the tool edge.

 Repeat the process for the other back corner.

EDS Unigraphics NX
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Flange

ÏÏÏ
ÏÏÏ
2
Step 7 Create side flanges to close the front corners using the
ÏÏÏ
ÏÏÏ
Butt Length option.

 Choose the Flange icon.

 Select the upper right edge of the Block as the Bend Edge.

 Check to see if the RH face of the block is highlighted. If the


top of the block is highlighted, choose the Adjacent Face
icon in the Flange dialog (the arrow should point up).

Select this edge as


the Bend Edge.

This face should


be highlighted.

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2-49
Flange

For better parameterization of our part we will link the contour


length to that of the front flange.
 Choose Information→Feature

 Select Flange(1)

 Choose OK.

In the Information Window locate and record the pX" value


for the Length of the Flange feature where X" is a integer.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Close the Information Window.


 Enter the following values in the Flange creation dialog:

 Contour Length = p5 (From the previous Information


window.)
 Bend Angle = 90

 Choose the Options icon.

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Flange

 In the Side Options tab, choose the Butt option for the Left
and Right Settings.
 Enter the following Butt Length values in the appropriate
fields:
 Left Butt Length = BR-T-R
 Right Butt Length = R-.001
 Choose OK.

 Turn ON Confirm Upon Apply.


Choose Apply.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ


 If the flange appears correct accept the results by selecting


OK.
ÏÏÏ
 Repeat the process for the upper left edge of the Block using
the same values. Ensure the Butt Length's are put on the
correct sides of the flange. The R-.001 butt length should be
towards the front.

Step 8 Create joggles on the back edges of the Block and the two
flanges.

 If necessary, choose the Flange icon.

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Flange

 Select the upper back edge of the Block as the Bend Edge.

 Check to see if the back face of the block is highlighted (the


arrow will point up). If the top of the block is highlighted,
choose the Adjacent Face button in the Flange dialog.

Select this edge as


the Bend Edge.

ÏÏÏ
ÏÏÏ
2
This back face should
be highlighted.

ÏÏÏ
ÏÏÏ

 Choose the Options icon.

 In the Side Options tab, set both the Left and Right Settings
back to None.

 Choose OK.

 Change the length option from Contour Length to Tangent


Length.

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Flange

 Enter the following values:

 Tangent Length = 0
 Bend Angle = ANG

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose Apply and check the flange to see if it appears


correct before accepting the results.

 Repeat the previous steps for the Right and Left flanges
using the same parameters and using the inside edges as the
Bend Edges.

Step 9 Continue creating the joggles using the Flange option.

 Choose the Flange icon if the dialog is not open.

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Flange

 Select the bottom edge of the back flange created in the last
step as the Bend Edge.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ Select this edge as
the Bend Edge.

 Enter the following values:

 Tangent Length = .500


 Bend Angle = ANG

 Repeat the previous steps for the Right and Left flanges
using the same parameters and using the outside edges of
the joggle flanges as the Bend Edges.

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Flange

Your part should resemble the one below.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 10 Unform the part to test its integrity.

 Choose the Form/Unform icon.

 Choose the Unform All button.

 Look over the part to see if anything obvious has changed. If


it looks okay, reform your part.

Step 11 Choose File"Close"Save and Close.

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2-55
Flange

Miters

NonĆlinear tapers can be added to the flange bend face to provide a mitered
corner in the formed state of the flange. Like regular tapers, right side mitered
values can be different than left side values.

Miter Side Options

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Left and Right Miters

Flange miter parameters are set within the Side Options tab in the Options
dialog, and can be specified as Simple Miter or Full Miter.

When Simple or Full Miter is selected, text fields will appear below the Left or
Right Settings columns in the Options dialog. These text fields allow input of a
Miter Angle, Miter Phase or Miter Relief.

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Flange

Simple Miter

A Simple Miter type allows you to create a mitered corner where only the
inside bend edges of the flange meet.

Perpendicular
sides

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Relief

Simple Mitered Flange with a Relief

Full Miter

A Full Miter type allows you to create a fully closed mitered corner between
two flanges in the formed state. Both the outside and inside edges of the
adjacent flanges meet. A miter relief radius is not available, nor is it required,
with the full miter condition.

Flange end
faces meet

Full Mitered Flange

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Flange

Miter Parameters

The Flange dialog contains three miter parameter input fields for each side of
the flange. Depending on the miter type specified under the Options button,
two or all three of these parameters will be activated to accept input values.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Full
Simple Miter
Miter

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Flange

Miter Angle

This parameter defines the angle of the mitered corner in the formed state of
the flange as viewed from an orientation normal to the adjacent highlighted
face. This angle is typically half of the desired corner angle.

Miter Angle = Angle/2

ÏÏÏ
ÏÏÏ
2
120 deg ref
Angle
ÏÏÏ
ÏÏÏ
60 deg

Thickness
30 deg

Miter Angle

NOTE Keep in mind the issue of positive miter vs. negative miter. In
the above figure, you would enter a negative 30 degrees for the
miter angle. A positive 30 degree miter would reverse the
miter such that the flanges would not meet at the corners.

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Flange

Miter Phase

The Miter Phase is usually employed when you are creating additional flanges
on existing flanges. The value of a miter phase is typically equivalent to the sum
of the bend angles of the base flanges. This parameter enables the creation of
tapered flanges which retain the orientation of a mitered cut from one flange to
the next.

Mitered edge retains


orientation from one flange to
the next.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Simple Miter Flanges with 455 and 905 Phase Angles

Mitered edge suitable


for a weld joint.

Simple Miter Flange with 905 Phase Angle

Miter Relief

This option allows you to apply a relief radius to the beginning of the simple
miter. The sides of the flange are perpendicular to the top and bottom faces of
the flange. In NX1 this value can now be zero between the first set of adjacent
flanges originating from a common corner.

Gap (e.g. .001) = Miter Relief

Miter Relief

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Flange

Flange Construction Tips

To ensure the viability of a part, there are a few design requirements which
should be followed when creating sheet metal flanges:

 Due to the positionally dynamic nature of flange features, it is


important to sufficiently position flanges by constraining at least two
edges of the flange. Insufficiently constrained flanges can fail to
position properly if their base attachment feature changes.
 Note that after being unformed, the bend area of a flange is no longer
ÏÏÏ
ÏÏÏ
cylindrical, but is planar. Therefore, datum axes should not be created
2
ÏÏÏ
through the axis of a flange's cylindrical bend area in the formed state.
 The only type of features which may be placed on the cylindrical bend ÏÏÏ
area of a flange are Sheet Metal Punch, Sheet Metal Hole, Sheet Metal
Slot, or Sheet Metal Cutout. Any other feature placed on the bend will
give unpredictable results during forming and unforming.
 When using instance sets on flange features, it is important to fully
constrain the feature placement using positioning dimensions. It is a
good practice to unform the flange after creating the instance to test
its integrity.
 A dependency is created between adjacent flanges if the Thickness
parameter is set to Infer From Edge for each flange. To break this
associativity, you must change the Thickness parameter to Use
Expression.

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2-61
Flange

Activity 2-3: Working with Miters

In this activity you'll start with a seed partfile and create a picture frame with
simple mitered corners.

Step 1 Open the partfile smd_seedpart.


ÏÏÏ
ÏÏÏ
2
Expressions have already been created for the thickness (T) and

ÏÏÏ
ÏÏÏ
inside bend radius (R) values. For this activity, we need to
change the inside bend radius value.

 Select Tools→Expression in the Modeling application.

 Choose the R variable and change the value to .125 and


choose OK.

Step 2 Create the base of the frame.

 Rotate the WCS about the +XC axis 90 degrees.

 Choose the Block icon.

 If necessary, select the Origin, Edge Lengths icon.

 Insert the following parameters:

 Length (XC) = 6
 Width (YC) = 8
 Height (ZC) = T

 Choose OK to create the block at the default 0,0,0 location


and Fit the part to the graphics display.

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Flange

Step 3 Add a cutout to the center of the frame using the pocket
feature.
Before adding a pocket, it's good modeling practice to create
reference datums as positional aids for locating added features.

 Create center datum planes using opposing faces of the


edges of the frame.

 Choose the Pocket icon.

 Choose the Rectangular option.


ÏÏÏ
ÏÏÏ
2
 Select the front face as the placement face and the bottom
ÏÏÏ
ÏÏÏ
edge as the horizontal reference. Accept these selections if
necessary.

Select this face as


the placement face.

Select this edge as


the horizontal
reference.

 Insert the following parameters:

 X Length = 4.5
 Y Length = 6.5
 Z Length = T

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Flange

 Choose OK.

 Using the Line onto Line and Point onto Line positioning
methods, center the pocket in the middle of the frame using
the reference datum planes.

 Move the reference datum planes to layer 61.

Step 4 Create a beveled edge around the frame using mitered


ÏÏÏ
ÏÏÏ
2
flanges.

ÏÏÏ
ÏÏÏ  Choose the Flange icon.

 Select the back right edge as the Bend Edge so that the
flange will bend behind the part.

Select this edge as


the Bend Edge.

 In the Flange dialog, choose the Options icon.

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Flange

 Choose the Side Options tab.

 Change the Left Side and Right Side options from None to
Simple Miter.

In this design, the angular value of the corner to be mitered is


90 degrees. Therefore, the miter angle for each side of the
adjacent flange is one half the total angular value, or 45 degrees.
But, because the miter needs to expand outward, a negative
angular value (Ć45) must be specified.

ÏÏÏ
ÏÏÏ
2
(Flange) ÏÏÏ
ÏÏÏ
(Frame)

(Flange)

Also in this activity we will add a Miter Relief on both sides of a


common corner. This will represent a gap similar to what would
be created during the manufacturing process. A value of zero
could be used if so desired.

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Flange

 Set the miter parameters to the following values:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose OK.

 Set the flange parameters to the following values:

 Choose Apply to create the flange.

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Flange

 Rotate your part to see the mitered edges of the flange.

Mitered
edge

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Mitered
edge

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Flange

 Create three more flanges with the same flange parameter


values on the remaining edge faces of the frame.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 5 Create the sides of the frame.

 If necessary, choose the Flange icon.

 Select the inside edge of one of the mitered flanges as the


Bend Edge. Your flange bend direction vector should be
pointing behind the frame body.
Because you are adding a mitered flange to the end of another
mitered flange, you must now provide a Miter Phase value in
order to maintain a constant miter orientation through both
flanges. Since you're creating a flange on only one base flange,
the Miter Phase value is equal to the bend angle of the base
flange (45 degrees).

 In the Flange dialog, choose the Options icon.

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Flange

 Choose the Side Options tab.

 Set the miter parameters to the following values:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

NOTE A miter relief is not necessary again since it will be carried


over from the base flange. Insert a 0 value into this field to
avoid adding an additional relief.

 Choose OK in the Options dialog.

 Choose Apply to create the flange.

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Flange

 Repeat the flange creation on the other flange edge faces to


complete the sides of the frame.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 6 Add a flange to three sides on the back of the frame.


These flanges will guide the picture into the frame.

 If necessary, choose the Flange icon.

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Flange

 Again, select the inside edge of the long rightĆhand mitered


flange to derive the Bend Edge.

ÏÏÏ
ÏÏÏ
2
Select the inside
edge of this flange
ÏÏÏ
ÏÏÏ

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Flange

 Set the miter parameters to the following values:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

NOTE The Miter Phase value is now the sum of both bend angles of
the base flanges (45 degrees + 45 degrees).

TIP Use expression p" values for better parameterization.

 Choose OK in the Options dialog.

 Change the Bend Angle to 90 .

 Choose Apply to create the flange.

 Repeat this step on the top and far side flanges to create the
guide edge on three sides of the frame.

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Flange

Your part should resemble the one below.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

NOTE You can also create this part using full mitered flanges.

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Flange

 Unform the part to test its integrity.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Step 7 Choose File"Close"All Parts, do not save.

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Flange

SUMMARY Flanges are a basic feature to sheet metal parts;

ÏÏÏ
upon which you can build simple to

ÏÏÏ
complicated sheet metal parts.
2
In this lesson you: ÏÏÏ
ÏÏÏ
 Created simple sheet metal flanges
 Created tapered and custom width sheet
metal flanges
 Created buttjoints
 Created simple and full mitered corners
 Edited flange features
 Applied these functions to create a bracket,
a box, and a picture frame.

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Flange

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
(This Page Intentionally Left Blank)

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Sheet Metal Corner

Sheet Metal Corner


Lesson 3

PURPOSE This lesson will teach you how to create various


associative corner types on formed straight-break
sheet metal flange features.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create corner geometry using butt, full miter,


simpler miter and machinery types.
ÏÏÏ
ÏÏÏ
This section contains the following activity: ÏÏÏ
3
ÏÏÏ
Activity Page
3-1 Creating Sheet Metal Corners . . . . . . . . . . . . . . . . 3-11

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Sheet Metal Corner

The Sheet Metal Corner Dialog


The Sheet Metal Corner feature allows you to create various corner fill"
geometry. Unlike some of the functionality inside the Sheet Metal Flange
feature, a Corner feature is added as a separate feature after flanges are
created.

In order for the Corner feature to be applied between two adjacent flanges, the
two adjacent flanges must share a common starting edge.

Common
starting edge

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ The Butt Joint option has more flexibility in that the two adjacent sides do not
have to be created using Sheet Metal flange features (e.g. Hollow operation
used to create a sheet metal type part). Currently the Miter and Machinery
corner features can only be applied to corners which are made from Sheet
Metal Flange type features. If the corner is not comprised of two Sheet Metal
Flange type features in this scenario, the system will display the following
message.

You can access the Sheet Metal Bend dialog by choosing Insert→Sheet Metal

Feature→Corner or the Sheet Metal Corner icon in the Sheet Metal


Feature toolbar. To edit a Sheet Metal Bend, use Edit→Feature or the Edit
Feature toolbar.

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Sheet Metal Corner

Construction Methods

The sheet metal Corner feature has a series of construction type icons available
to create corner geometry. There are four selections available in the Corner
feature, Butt Joint, Machinery, Simple Miter and Full Miter. The dialog is
dynamic and changes based upon the Corner type selected.

Machinery
ÏÏÏ
ÏÏÏ
Butt Joint ÏÏÏ
3
ÏÏÏ

Full Miter
Simple Miter

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Sheet Metal Corner

Butt Joint

The butt joint option works very similarly to the butt joint option within the
Flange feature. The advantage of using a Butt Joint within Sheet Metal Corner
dialog is the ease and added associativity you gain. The user has the option to
specify an Overlap or Gap value between the adjacent flanges which create the
corner.

Parent Flange

The flange whose edge or face you selected for creating the corner. A 1 is
displayed on the top bend face of this flange.

Associate Flange

ÏÏÏ The flange that shares a common edge with the parent flange. A 2 is displayed
ÏÏÏ on the top bend face of this flange.
ÏÏÏ
3
ÏÏÏ Switch Parent

The Switch Parent option allows the user the ability to change the Parent flange
which originates the Overlap.

1 2 2 1

Switch Parent changes where the


Overlap originates from

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Sheet Metal Corner

Overlap

The distance of the parent flange over the associate flange along the direction
of the parent flange side face normal. Overlap can be a negative value. Negative
overlap value cannot exceed the computed length of the parent butt joint. To
switch the Overlap to the other flange use the Switch Parent option.

Gap

The distance between two flanges along the direction of associate flange side
face normal. The system will only allow the corner to be created with a valid
Gap value, in which case the Apply button will be inactive until a valid value is
entered.

NOTE If no Overlap is specified (zero) there must be a Gap (e.g.


.001) specified to prevent a Non-Manifold solid error
(Similar to the Simple Miter function of the Flange
feature).

ÏÏÏ
ÏÏÏ
NOTE It is not possible to have a zero Gap because the surface
to surface contact would yield incorrect Flat Pattern ÏÏÏ
3
ÏÏÏ
results.

Gap
Overlap

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Sheet Metal Corner

Machinery

The machinery option yields a condition that is typical in thinner gauge


materials. The appearance of the Machinery corner in the formed state
represents a smashed" condition which is intended to depict the results of
forming two adjacent flanges simultaneously during the manufacturing process.
In the unformed state the intersecting corners of the two adjacent flanges are
filled in with material and a bisecting edge is shown.

NOTE It is called machinery corner because a corner like this is


typically filed by the machinist to remove a bur that is
created after the forming process.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

Unformed machinery
corner results

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Sheet Metal Corner

Simple Miter
The simple miter option works very similarly to the simple miter option within
the Flange feature. The advantage of using a simple miter within Sheet Metal
Corner dialog is the ease and added associativity you gain. The user does not
have to supply miter angle or miter phase because the feature calculates the
values based on the adjacent flanges on the corner it is being applied to.

The adjacent flanges must have the same bend angles or the following message
will appear.

Gap and Relief Radius

ÏÏÏ
Using the Gap option will define the distance between the two adjacent flange
ÏÏÏ
ÏÏÏ
inside edges. If Relief Radius is selected, the relief radius applied on parent and 3
ÏÏÏ
associate sides at the common edge will be equal to the value specified. In the
case of Relief Radius, the distance or gap between parent and associate Miter
bodies will be less than the value of Relief Radius. In NX1 this value can be
zero or greater for either option.

Relief Radius

Gap

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Sheet Metal Corner

Full Miter

The full miter option works very similarly to the full miter option within the
Flange feature. The advantage of using a full miter within Sheet Metal Corner
dialog is the ease and added associativity you gain. The user does not have to
supply miter angle or miter phase because the feature calculates the values
based on the adjacent flanges on the corner it is being applied to.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

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Sheet Metal Corner

Multiple Steps

The Multiple Steps option is available for both the Simple and Full Miter
options and allows the user to select a corner which has several flanges stacked
on one another. Again, the bend angle of the flanges must be equal to the
corresponding adjacent flange section.

ÏÏÏ
ÏÏÏ
NOTE The adjacent flanges cannot intersect one another at any
point before applying the simple miter. If they intersect
the following messages will appear. ÏÏÏ
3
ÏÏÏ

NOTE If there is a different number of flange segments on the


adjacent side, the corner feature will only be created
where there is an adjacent side to match up to.

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Sheet Metal Corner

Sheet Metal Corner Construction Tips

To ensure the viability of a part, there are a few design requirements which
should be followed when creating sheet metal corners:

 Editing Sheet Metal Corners uses the same dialog as for creation.
Sheet Metal Corner can be edited no matter what state its flanges are
in. You cannot change type of Sheet Metal Corner in Edit mode.
 You cannot form or unform the sheet metal corner feature by itself.
You can however, form and unform the two flanges individually that
flank the corner and the corner will follow those flanges.
 Butt Joint and Machinery Corners cannot be created between flanges
with a zero web length. If selected the following message will appear:

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
 Machinery Corners cannot be created between adjacent flanges if
taper options already exist on the flanges.

 No Corners can be created between adjacent flanges if miter or butt


options already exist on the flanges.

 Corners cannot be created if the bend angles of the adjacent flanges


are less than .5 degrees or greater than or equal to 180 degrees.
 Corners cannot be created for flanges in an intermediate state.

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Sheet Metal Corner

Activity 3-1: Creating Sheet Metal Corners

In this activity you will use different corner options to create different fill
conditions of the part shown below.

Step 1 Open part smd_corner and start the Modeling ÏÏÏ


application. ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Step 2 Check the expressions.

 Choose Tools"Expression.

Notice there are expressions in the list for thickness (T) and
bend radius (R).

 Choose Cancel in the Expressions dialog.

Step 3 Create a butt joint corner.

 Choose the Sheet Metal Corner icon.

 If necessary, choose the Butt Joint icon.

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Sheet Metal Corner

 Select the left flange edge in the corner area shown below.

Select this flange

NOTE The side that is picked is defined as the Parent Flange


and is identified by a number 1.

ÏÏÏ  Enter a value of T in the Overlap field.

ÏÏÏ
ÏÏÏ
3
ÏÏÏ
 Enter a value of .010 in the Gap field.

 Turn ON Confirm Upon Apply.

Before choosing Apply look at the graphics screen and


identify the Parent Flange (1) and the Associate Flange (2).

 Choose Apply.

Notice the Overlap comes from the Parent Flange (1).

 Choose Back.

 Choose the Switch Parent button and choose Apply.

Notice the Overlap now comes from the opposite flange,


which has been switched to the Parent Flange (1).

 Choose OK to accept your results.

 If necessary, choose the Sheet Metal Corner icon again.

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Sheet Metal Corner

 Select the right flange edge in the corner area shown below.

Part has been rotated 905 for clarity

Select this flange

 Change the Overlap value to 0 .

 Continue to use the same value for the Gap field.

Choose Apply.
ÏÏÏ


ÏÏÏ
ÏÏÏ
3
ÏÏÏ

 Choose OK to accept your results.

Step 4 Edit a flange to see the associativity.

 Choose Edit"Feature"Parameters or choose the Edit

Parameters icon.

 Select FLANGE(13) from the list and choose OK.

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Sheet Metal Corner

 Change the Bend Angle to 60 .

 Choose OK twice to update the model.

 Shade and Rotate your model to see the changes.

Notice both SM_CORNER features have updated and have


maintained the overlap and gaps defined in the previous
steps.

Step 5 Create a simple and full mitered corner

 Choose the Sheet Metal Corner icon.

 Choose the Simple Miter icon.

ÏÏÏ
ÏÏÏ  Ensure the Gap is set to .010 .

ÏÏÏ
3
ÏÏÏ  Toggle ON the Multiple Steps option.

 Select either side of the flange corner shown below.

Select either side

The Multiple Steps option selects all of the flange edges


after selecting the first edge.

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Sheet Metal Corner

 Choose Apply.

 Choose OK to accept your results.

 Choose the Full Miter icon.

 Select either side of the flange corner shown below.


ÏÏÏ
ÏÏÏ
Select either side
ÏÏÏ
3
ÏÏÏ

 Choose Apply and then OK to accept your results.

 Shade and Rotate your model to see the difference between


the Simple and Full Miters.

Step 6 Create a machinery corner.

 If necessary, choose the Sheet Metal Corner icon again.

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Sheet Metal Corner

 Choose the Machinery icon.

 Select either side of the flange corner shown below.

Select either side

 Choose OK to create the Machinery corner.


ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Step 7 Inspect your part.

 Shade and Rotate your model to see the difference between


all of the corners.

 Unform your part using the Form/Unform icon.

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Sheet Metal Corner

ÏÏÏ
Inspect the different results in each corner area. ÏÏÏ
ÏÏÏ

3

Step 8 Close your part. Do not save.


ÏÏÏ

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Sheet Metal Corner

SUMMARY The Sheet Metal Corner application provides


you with the ability to fill in the corners of
adjacent flange features using various options.

In this lesson you created:


 Various Sheet Metal Corners
 Edited flange geometry to see the effects on
ÏÏÏ a corner feature
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
 Unformed the part to see the results of a
corner in the flat condition

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Inset Flange

Inset Flange
Lesson 4

PURPOSE Create and edit sheet metal inset flanges using the
Inset Flange feature.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create and edit inset flanges.


 Recognize the six different methods to define the
inset distance of the flange into the body of the
part.
 Position an inset flange properly.

This section contains the following activities:

Activity Page
4-1 Exploring Inset Flange Creation Techniques . . . . 4-11
4-2 Creating an Inset Flange . . . . . . . . . . . . . . . . . . . . 4-22 ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Inset Flange

Inset Flange

Inset flanges fit and form like regular flanges, but have the added function of
being able to control a setback distance.

The Inset Flange feature allows you to create inset flanges on a planar
placement face while controlling its inset and relief characteristics . The Inset
Flange feature always removes material from the target body to create the
flange.

Upon selecting Insert→Sheet Metal Feature→Inset Flange or the Inset Flange

icon from the Sheet Metal Feature toolbar, the Inset Flange dialog is
displayed and the system prompts you to choose a bend edge. To edit an Inset
Flange, use Edit→Feature or the Edit Feature toolbar.

TIP The edge selected on a thickness face represents the


bend side of the flange.

ÏÏÏ
ÏÏÏ
4 Select this Bend Edge

ÏÏÏ

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Inset Flange

The Inset Flange Dialog

Inset Flange
Profile Inputs

ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Inset Flange Profile Inputs

Just like the Flange dialog, these inputs can be manually loaded or a standard
value can be chosen from an active arrow button inside the parameter field.
Remember, these arrow buttons are only active if the Use Feature Standards
option is toggled ON in the Sheet Metal Preferences dialog.

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Inset Flange

The Inset Flange dialog has additional feature options to specify the
characteristics of the inset condition. The Thickness, Length, Angle and Radius
inputs as well as the Flip Bend Direction, Adjacent Face and Options icons
function in the same manner as described in the Flange lesson.

Any grayed out input field will derive their values from internal system
information. The status of these input fields (active or inactive) can be
controlled through the Options icon.

The Options dialog also contains specific inset flange feature options under the
Relief Options tab such as Flange Width, and Left and Right Relief options.

Inset

The Inset field contains the value of the distance the flange is offset into the
body of the part. This distance may be either a userĆspecified or calculated
value. The calculated inset value depends on the specified thickness, angle and
radius values given in their respective fields when the inset is set to an option
other than Use Expression.

NOTE This field is only active if the Inset option is set to Use
Expression.

Inset using the


Outer Mold Line

ÏÏÏ
ÏÏÏ
Inset using the
4 Inner Mold Line

ÏÏÏ Inset
Inset of
UserĆDefined
value ( >zero )

NOTE Pressing Enter or Return while any text edit box is


highlighted will cause the system to create the flange.

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Inset Flange

Use Expression

With this inset method, the Inset field within the Inset Flange dialog becomes
active and you may insert any value or valid UG expression. The value will then
be used as the distance with which to offset the base of the flange from the
attachment face. Using a given value or expression for the flange inset yields
the same inset regardless of the thickness, angle or radius.

Outer Tangent Line

The Outer Tangent Line option adjusts the base of the flange so that the outer
bend tangent line of the fully formed flange is coplanar with the attachment
face plane.

Inset Inset

Attachment
Flange Face
base
Outer bend tangent
line is coplanar with
attachment face

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Inset Flange

Inner Tangent Line

This option adjusts the base of the flange so that the bend tangent line on the
inner surface of the fully formed flange is coplanar with the attachment face.

Inset Inset

Attachment
Face
Flange
base
Inner bend tangent
line is coplanar with
attachment face

Outer Mold Line

The mold line, also know in the Flange feature as the bend contour line, is the
line created by the intersection of the surface of the formed flange with the
surface of the target body.

The Outer Mold Line option adjusts the base of the flange so the outer flange
surfaces resides in the same plane as the upper edge of the attachment face.

Upper surface of
flange is coplanar Inset
Inset
with upper edge of
attachment face.

ÏÏÏ Flange

ÏÏÏ
base
4
ÏÏÏ

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Inset Flange

DIN Mold Line

This option is based on the calculation methods used in the Deutsches Institut
für Normung (DIN) Standard 6935. The calculated inset value is the same as
the Outer Mold Line value up to a bend angle of 90 degrees. The inset value
calculated at 90 degrees is retained for bend angles greater than 90 degrees.

Inset remains
unchanged for
bend angles
greater than
90°

Inset Inset

Attachment
Face
Flange
base

Inner Mold Line

The Inner Mold Line option adjusts the base of the flange so that the mold line
of the inner flange surface and inner body surface reside on the lower edge of
the attachment face.

Inset Inset

ÏÏÏ
Flange
base

ÏÏÏ
4
ÏÏÏ
Lower surface of
flange is coplanar
with lower edge of
attachment face.

NOTE Regardless of the method used, the calculated inset of the


flange base into the target body must be greater than zero
or an error will be generated.

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Inset Flange

Options

Selecting the Options icon within the Inset Flange dialog activates the Options
dialog. Within this dialog, there are four tabs which access various options used
to derive feature parameters, side options, the use of global parameters and
relief options. The parameter options, side options and global parameters act
the same as described in the Flange lesson.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

NOTE The Options dialog may be accessed repeatedly, and


parameters changed, throughout the creation process.

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Inset Flange

Relief Options

Flange Width

The width of an inset flange is either the width of the flange itself or the sum of
the base width of the flange plus the widths of the right and left reliefs. This
option is only selectable if the Width option in the Inset Flange dialog is set to
Width Expression. You have the option to choose either method to measure the
width of the inset flange. This applies to both normal and tapered flanges.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Excludes Excludes
Reliefs Reliefs
or or
Includes Reliefs Includes Reliefs

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Inset Flange

Left and Right Relief

Three different types of bend relief may be specified: None, Rectangular, or


Obround. When a relief type other than None is selected, text fields will appear
below the Left or Right Relief columns in the Options dialog. These text fields
allow input of a value which represent the width of the rectangular relief or the
diameter of an obround relief. A typical manufacturing recommendation is to
set this value greater than or equal to the material thickness, however any value
greater than zero is acceptable. The Bend Relief value can be individually set
for the left and right side of the flange.

No relief
(ripped edge)

Rectangular Obround
relief relief

The relief is aligned with the base of the flange, and the width of the relief is
ÏÏÏ measured perpendicular to the flange side face.

ÏÏÏ
4
ÏÏÏ Relief Width

Relief
Control points Control points Width
located at base located at base
of flange. of flange.

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Inset Flange

Activity 4-1: Exploring Inset Flange Creation Techniques

In this activity you'll create a two piece box using inset flanges and
parametrically controlled dimensions. Rather than mathematically accounting
for the use of regular flanges, two different inset flange creation techniques will
be used to control the interface between the box pieces.

Step 1 Open the part smd_insetflg2 and save it as xxx_insetflg2,


where xxx represents your initials.

 Ensure you're in the Modeling application.

 Check for part specific expressions by selecting


Tools→Expression. Notice that expressions have been
created for the bend radius (R), height (H), length (L),
thickness (T), and width (W). You'll use these expressions to
control the parametric definition of your box.

 Choose Cancel to close the dialog.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Inset Flange

Step 2 Create the base of the box.


In order to control the outside dimensions of your part, you
must account for the flange bend radius and part thickness for
each flange added to the body of the part.

T T

R R

R T

 Choose the Block icon.

 If necessary, choose the Origin, Edge Lengths icon.

 Insert the following parameters:

 Length (XC) = W-R-2*T


 Width (YC) = L-2*T
 Height (ZC) = T

ÏÏÏ
ÏÏÏ
4  Choose OK to create the block at the default 0,0,0 location

ÏÏÏ and Fit the part to the graphics display.

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Inset Flange

Step 3 Create relief cutouts.

 Choose the Pocket icon.

 Choose the Rectangular option.

 Select the upper surface of the block as the placement face


and accept.

 Select the near edge of the placement face as the horizontal


reference.

Select this face


as the placement
face

Select this edge


as the horizontal
reference edge

 Insert the following parameters:

 X Length = R
 Y Length = R
 Z Length = T

 Choose OK.
ÏÏÏ
ÏÏÏ
4
 Using the Line onto Line and Point onto Line positioning
methods, locate the pocket in the nearest front corner of the
ÏÏÏ
block.

 Choose OK to create the pocket.

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Inset Flange

 Repeat this step to create a pocket in the opposite front


corner of the block. When you're finished, your part should
look like this:

Step 4 Create the side of the box.

 Choose the Flange icon.

 Select the upper edge of the near face as the Bend Edge so
that the flange directional vector points up.

Select this edge


as the Bend Edge

ÏÏÏ
ÏÏÏ
4
ÏÏÏ  Ensure the Width option is set to Infer Width.

 Change the Length option to Tangent Length.

 Choose the Options icon.

 Choose the Side Options tab.

 Change the Left and Right Settings to None.

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Inset Flange

 Choose OK to accept the change.

 Change the following flange parameters:

 Tangent Length = H-R-T


 Inside Radius = R

 Ensure the Positioning method is set to Automatic.

 Choose OK to create the flange.

Step 5 Change the color of the part to facilitate the creation of


the other half of the box.

 Change the Selection toolbar setting to Select General


Objects and change the Filter option to Solid Body.

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Select General Objects Filter to Solid Body

 In the graphics window, select the solid body.

 Place the cursor over the part and select MB3.

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Inset Flange

 Select Edit Display... from the Pop-Up window.

 Choose the Color option and change it to Blue.

 Choose OK to apply the change and close the dialog.

Step 6 Create the opposite side of the box.

 Choose the Block icon.

 Insert the following parameters:

 Length (XC) = T
 Width (YC) = L-2*R-2*T
 Height (ZC) = H

 Change the Point Method to Point Constructor.


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4 Enter the following:
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 XC = -T (NOTE: remember the minus sign!)


 YC = R
 ZC = 0

 Choose OK twice to create the solid.

 Fit the view.

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Inset Flange

Step 7 Create the edges of the box.

 Choose the Flange icon.

 Select the inside edge of the left face of the new block as the
Bend Edge.

Select this edge


as the Bend Edge

 Change the Tangent Length to Contour Length.

 Set the Contour Length equal to W and the Inside Radius


equal to R .

 Choose Apply to create the flange.

 Create another flange with the same parameters on the other

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side of the block.

When finished, your box should look like this: ÏÏÏ


4
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Inset Flange

Step 8 Now you can create tabs without adjusting the part size
by using the Inset Flange feature.

 Choose the Inset Flange icon.

 Select the inside edge of the left flange as the Bend Edge.

Select this edge

 Ensure the Width option is set to Infer Width.

 Change the Contour Length to Tangent Length.

 Change the Inset option to Inner Mold Line.

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ÏÏÏ  Choose the Options icon.

 Choose the Relief Options tab.

 Ensure the Left and Right Reliefs are set to None.

 Choose OK to accept the changes.

 In the Inset Flange dialog, set the Tangent Length equal to


.500 and the Inside Radius equal to R .

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Inset Flange

 Select Apply to create the flange.

 Create another inset flange on the opposite edge of the box.


Your part should look like this when you're finished:

Step 9 Create a recessed flange on the face of the part.

TIP Blanking the green portion of the part will help with
the selection process in this step. (Ctrl+B)

 If necessary, choose the Inset Flange icon.

 Select the upper edge of the back face as the Bend Edge so
that the flange directional vector points up.

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Select the upper edge to
place the inset flange. ÏÏÏ

 Change the Inset option to Outer Mold Line.

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Inset Flange

 Choose the Options icon.

 Choose the Relief Options tab.

 Change the Left and Right Reliefs to Rectangular.

 In the text fields below the Left and Right Relief enter a
value of R .

 Choose OK to accept the changes.

 Ensure the Tangent Length is still .500 and the Inside Radius
is R .

 Choose OK to create the flange.

 Unblank and shade the part to review the geometry.

BEFORE AFTER

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Inset Flange

 Check the outside length, width and height of the part to


verify the dimensions. Why is the overall width off by .100
inches?

The Why" Some times when creating sheet metal parts which fit together you will
find that the parts may be off in size. You will also find in most cases the
parts are off by either a material thickness or bend radius value. It is a
good practice to occasionally measure the overall size after creating
flanges to see if you are capturing your design intent".

How Does it Work?

Depending on which type of flange you use you will get different
results.
The flange feature always adds length to the part so it is
necessary to accommodate the base feature's size.
The inset flange feature has options that can be set to
accommodate inset distances. It is common to use a
combination of the two type of flanges to get a part that
correctly represents your needs.

 Using Tools→Expression or Edit"Feature, edit the length,


width or height to correct the size of the parts.

Step 10 Choose File"Close"Save and Close.

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Inset Flange

Activity 4-2: Creating an Inset Flange

In this activity you'll create an inset flange and apply proper positioning
constraints.

Step 1 Open or change your displayed part to xxx_buttjoint,


where xxx are your initials.

NOTE If a finished part was not saved in the last lesson, you may
use smd_insetflg1 to complete this activity.

Step 2 Unform only the front flange. This step is done for clarity.

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Step 3 Add an inset flange.

 Ensure you're in the Modeling application.

 Choose the Inset Flange icon.

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4-22 Sheet Metal Design
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Inset Flange

 Select the inside edge of the right flange as the Bend Edge.
Select the edge such that the flange will form toward the
inside of the part. Accept your choice, if necessary.

Select this edge as the


Bend Edge

Before modifying any inset flange parameters, it's a good idea to


first establish the inset condition.
Change the Width option to Width Expression. ÏÏÏ
ÏÏÏ

4
 Change the Inset option to DIN Mold Line. ÏÏÏ
 Choose the Options icon.

 Choose the Relief Options tab.

 Change the Flange Width option to Excludes Reliefs.

 Change the Left and Right Reliefs to Obround.

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Inset Flange

 In the text fields below the Left and Right Relief enter a
value of T .

 Choose the Global Preferences tab.

 Turn OFF the Radius option.

 Choose OK to accept the changes.

 In the Inset Flange dialog insert the following values:

 Width Expression = 1.375


 Tangent Length = .50

ÏÏÏ Bend Angle = 90


ÏÏÏ

4
ÏÏÏ 
 Inside Radius = R

Ensure the Positioning option is set to Manual.

 Choose Apply to create the flange.

Notice that the inset flange cutout is currently located against


the end of the flange.

 Choose the Line onto Line positioning icon.

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Inset Flange

 Select the edge used as the Bend Edge for the target edge.

 Select the outside vertical line of the sketch for the Sketch
line.

Select this line


as the Sketch line

Select this edge


as the target edge

 Choose the Perpendicular icon from the Positioning dialog.

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Inset Flange

 Select the bottom tangent edge of the attachment face as the


target edge.

 Select the bottom horizontal line of the sketch as the Sketch


line.

Select this line


as the Sketch line
Select this edge
as the target edge

 Enter a value of (2-1.375)/2-R-T in the Create Expression


dialog.

ÏÏÏ Choose OK to create the flange.


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4
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Inset Flange

 Repeat Step 3 to create an inset flange on the opposite


flange. This time, while using the Perpendicular placement
function, enclose the entire expression in parentheses and
add a minus sign as follows: -((2-1.375)/2-R-T).

Step 4 Verify your part.

 Again, choose the Form/Unform icon.

 Choose the Unform All button. Your part should unform to


its flat pattern state.

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Step 5 Reform, save and close your part.

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Inset Flange

SUMMARY The Inset Flange feature has built in


functionality to allow for adjustable inset of the
placement face and also the ability to apply left
and/or right reliefs to the sides of the inset
flange.

In this lesson you:


 Created and edited an inset flange
 Positioned an inset flange properly

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4-28 Sheet Metal Design
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Sheet Metal Bend

Sheet Metal Bend


Lesson 5

PURPOSE This lesson will teach you how to create and edit
formable bend geometry from existing flat patterns.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create bend geometry using a bend centerline,


bend tangent line, contour line or mold line.

This section contains the following activity:

Activity Page
5-1 Creating Sheet Metal Bends . . . . . . . . . . . . . . . . . 5-10

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Sheet Metal Bend

The Sheet Metal Bend Dialog

The Sheet Metal Bend feature allows you to create formable sheet metal solid
models from non-sheet metal feature geometry. One example would be where
2D geometry has been extruded into a part which resembles a sheet metal
model. The various Sheet Metal Bend methods replace material in the solid
body with a formable region that has the ability to be unformed and reformed.

You can access the Sheet Metal Bend dialog by choosing Insert→Sheet Metal

Feature→Bend or choosing the Sheet Metal Bend icon in the Sheet Metal
Feature toolbar. To edit a Sheet Metal Bend, use Edit→Feature or the Edit
Feature toolbar.

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Sheet Metal Bend

Construction Methods

The sheet metal Bend feature uses a selection steps type of dialog to create and
edit the bend geometry and positioning parameters. There are four selections
available in the Bend feature, Base Face, Application Curve, Cylindrical Face
and Existing Edge.

Base Face

Select one face of the part on which to place the bend feature. This option is
followed by the selection of an Application Curve.

Application Curve

The application curves must be a line located on or at a distance to the


placement face. If they do not extend to the end of the face, the curve will be
extended to the end of the face. This step goes along with the selection of a
Base Face.

Application curve

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Sheet Metal Bend

Cylindrical Face

Cylindrical Face allows you convert a blended" edge that represents the
outside radius of a bend into a formable feature . Use this feature in cases
where it may be easier to create a 2D profile (sketch) with filleted corners and
an extrusion to make the model. Only modeled bends that need to be unformed
should be converted into a SM_Bend feature. Each modeled bend must be
converted individually before they can be recognized as formable features and
unformed.

The radius and angle is taken directly from the face selected. A Bend
Allowance Formula may also be chosen for application to each bend.

Sketch

Extruded

Cylindrical
Face Bend and
Unformed

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EDS Unigraphics NX
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Sheet Metal Bend

Existing Edge

Existing Edge allows you convert a sharp" edge that represents the outside
edge of a bend into a formable feature . Use this feature in cases where it may
be easier to create a 2D profile with sharp corners and extrude it . Each sharp
corner must be converted individually before they can be recognized as
formable features and unformed.

Sketch

Extruded

Existing Edge
method applied
to each sharp
corner

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Sheet Metal Bend

Angle

Angle represents the angle of the bend. This angle can be set to specify a bend
angle or an included angle. The default angle type is Bend. This option is only
available when using the Base Face and Application Curve method.

Bend Angle Included Angle

NOTE The maximum angular value is limited by the


selfĆintersection of the flange bend segment with the
attachment body.

Maximum bend angle limited


by selfĆintersection.

Bend
Angle

NOTE The Angle field is removed from the dialog if the Global
Parameters option of Use Global Angle is toggled ON
inside Preferences"Sheet Metal.

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Sheet Metal Bend

Radius
Radius is the radial value of the cylindrical surface representing the bend.
Either the inside or the outside value can be specified. The default radius type
is Inside. This option is available when using either the Base Face and
Application Curve method or the Existing Edge method.

NOTE The Outside radius value must be greater than the


thickness of the part or the system will issue an error
message.

NOTE The Radius field is removed from the dialog if the


Global Parameters option of Use Global Bend Radius is
toggled ON inside Preferences"Sheet Metal.

Application Curve Type

The application curve type options allow you to specify how the Application
Curve you select will be applied to the bend.

Flip Bend Direction Vector


When you select an application curve while creating a bend, the system
automatically determines the bend direction. This direction is displayed on the
graphics screen as a vector located at the midpoint of the application curve. The
Flip Bend Direction Vector button allows you to flip the vector direction,
thereby reversing the bend direction.

Flip Stationary Direction Vector


When selecting an application curve, an outside cylindrical face (using the
Cylindrical Face method) or an outer existing edge (using the Existing Edge
method) , the system also determines the stationary side of the bend. This
direction is displayed on the graphics screen as a vector located at the midpoint
of the curve or edge. The Flip Stationary Direction Vector button allows you to
flip the vector direction, thereby reversing the stationary side of the bend.

NOTE Care should be taken to ensure the correct Stationary


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Side and Bend Direction Vectors are displayed.
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Sheet Metal Bend

Bend Allowance Formula (BAF)

When you click on the Bend Allowance Formula button, The following dialog
will appear:

The BAF originally loaded in the SMD General Preferences dialog will
automatically be loaded as the default Bend Allowance Formula. A new BAF
can be selected from the Bend Allowance Formulae list, or a userĆspecified
formula can be directly entered into the BAF field.

NOTE The Bend Allowance Formula button is removed from the


dialog if the Global Parameters option of Use Global is
toggled ON inside Preferences"Sheet Metal.

Options

You can toggle the Global Parameters ON and OFF here. Global Parameters
are selectable only if the options are ON in the Sheet Metal Preferences.

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5-8 Sheet Metal Design
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Sheet Metal Bend

Sheet Metal Bend Construction Tips

To ensure the viability of a part, there are a few design requirements which
should be followed when creating sheet metal bends:

 The SMBend forms and unforms in the same manner as the flange
feature and allows other SMD features to be applied to it.
 Currently it is not possible to create a bend if there is a hole in the
bend area. This restriction will be removed in the future. In the below
example, apply the cutout after the bend feature has been applied.

Hole in bend area

Apply bend without hole

Create hole using


SM Cutout feature

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Sheet Metal Bend

Activity 5-1: Creating Sheet Metal Bends

In this activity you will use different bend construction techniques to form
different flanges from an existing flat pattern.

Step 1 Retrieve the part and start the Modeling application.

 Open the part smd_seedpart. Save the part as xxx_bend.

 Make layer 110 selectable.

 Choose File"Import"Part from the menu bar.

 Turn OFF the Create named group option.

 Change the Layer mode to Original layers.

 Choose OK.

 Select smd_bend from the parts folder and choose OK.

 Ensure the destination point for the import is set to 0, 0, 0.


This will import a flat pattern.

 Choose OK.

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5
ÏÏÏ
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 Cancel the Point Constructor dialog.

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Sheet Metal Bend

 Fit the display and make sure you're in the Modeling


application.

Step 2 Extrude the flat pattern.

 Choose the Extruded Body icon.

 Choose the Chain Curves option.

 Select one of the outside profile curves as the Start of the


section string.

Select one of the outside profile


curves as the Start of the section
string.

 Click MB2 to complete the chain.

 Choose OK.

 Select each circle in the flat pattern.

 Choose OK.

 Choose the Direction _Distance option.

 If the extrusion vector is pointing upward choose OK in the


Vector Constructor dialog, otherwise choose Cycle Vector
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5
Direction to flip the vector direction. ÏÏÏ
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Sheet Metal Bend

 Enter the following parameters:

 Start Distance = 0
 End Distance = T
 First Offset = 0
 Second Offset = 0
 Taper Angle = 0

 Choose OK.

Step 3 Check the expressions and standards

 Choose Tools"Expression. Notice there are duplicate


expressions in the list.

The Why" When the flat pattern part was imported the expressions in that file
where carried over. If there are duplicate expression names the system
assigns a prime (`) and a number to the duplicate expressions. We don't
need many of the expressions in the list so we will delete the unused
expressions.

 Choose Cancel in the Expressions dialog.

 Choose File"Utilities"Part Cleanup...

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 Toggle ON the Delete Unused Expressions option.
5
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 Choose OK.

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Sheet Metal Bend

 Choose Tools→Expression. Notice the duplicate expressions


are gone.

 In the Expression dialog create the expression:

 R=.06 (press Enter to store the expression)

 Choose OK.

 Choose Preferences"Sheet Metal...

 Toggle ON Use Feature Standards.

 Choose Global Parameters.

 Toggle ON Use Global Bend Radius.

 Enter R for the Bend Radius.

 Toggle ON Use Global for the Bend Allowance Formula and


select the BAF that uses the 0.40 factor.

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 Confirm your settings and choose OK. ÏÏÏ
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Sheet Metal Bend

 Choose OK again to accept the preference settings.

Step 4 Create the bend areas.

 Choose the Sheet Metal Bend icon.


 Select the top surface as the base face.
 Click MB2.
 Select the bend centerline shown below as the application
curve:

Choose this line as Choose the top surface as the base face.
the application curve.

 Ensure the Bend Angle is set to 90 .


 Ensure the Stationary vector points towards the middle of
the part. If necessary, choose the Flip Stationary SideVector
button to flip the stationary side.
 Choose Apply.

NOTE If your part contains flanges on multiple sides we


recommend that you start on the outside of the part and
work inward. If your part has a stacked set of flanges (one
side to the other) start at the ends and work towards to
the stationary section (middle). This ensures that your
stationary arrow points towards the same region for each

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bend section.
Repeat this process for all centerlines. Be sure to pick the
5
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base face surrounding each bend centerline.
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Sheet Metal Bend

When complete, your model should look as shown below:

The previous actions have replaced sections of the solid part


with formable geometry that represents the bends. Next, we will
form and then unform the flanges to check their integrity.

Step 5 Form and Unform your part to test its integrity.

 Choose the Form/Unform icon.

 Choose the Form All option.

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Sheet Metal Bend

 Unform the part using the Unform All button.

Step 6 Change the size of the part.


To change the size of the part we must edit the curves. The
curves drive the extrusion and dictate where the bend centerline
exists, therefore the curves are the parent geometry for the part.

 Replace the view to the Top view.

 Choose Edit"Curve"Stretch...

or choose the Stretch icon.

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Sheet Metal Bend

 Drag a rectangle around the top portion of the flat pattern as


shown below.

 Enter 1.00 in the Delta YC field.

 Choose OK.

Notice the solid went through an update process. The


extrusion and the bend features where updated according to
the stretch operation.

 Repeat the same stretch steps for the three other sides
making them all 1.00 inch longer. Make sure you use the
correct XC or YC direction and positive or negative value.

Step 7 Reform and inspect the changes. ÏÏÏ


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5
 Replace the view to the TFR-TRI view (MB3). ÏÏÏ
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Sheet Metal Bend

 Choose the Form/Unform icon.

 Choose the Form All option.

Step 8 Close your part. Do not save.

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EDS Unigraphics NX
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Sheet Metal Bend

SUMMARY The Sheet Metal Bend application provides


you with the opportunity to develop flanged 3D
parts from flat patterns.

In this lesson you created:


 Sheet Metal Bends
 Edited curve geometry to see the effects on a
bend feature

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Sheet Metal Bend

(This Page Intentionally Left Blank)

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General Flange

General Flange ÏÏÏ


Lesson 6
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6
ÏÏÏ

PURPOSE Create contoured sheet metal flanges using the


General Flange sheet metal feature.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create and edit a General Flange using the


Parameter Method
 Create and edit a General Flange using the Build
to Sections Method
 Create and edit a General Flange using the Build
to Faces Method
 Create and edit a General Flange using the Punch
Vector Method

This section contains the following activities:

Activity Page
6-1 General Flange Creation Methods . . . . . . . . . . . . 6-26
6-2 Other General Flange Creation Methods . . . . . . 6-35
6-3 Create a Gen. Flg. by the Punch Vector Method . 6-43

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General Flange

ÏÏÏ The General Flange Dialog


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6
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Parameters Build to Sections
Build to Faces

Punch Vector

This portion of
the window will
change per the
method selected

The General Flange feature was developed to enable the creation of formed
flanges along contoured (nonĆlinear) edges of a part. These flanges may be
created either as sheet bodies or as solid bodies, depending on the application.

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General Flange

The General Flange dialog is accessed from Insert→Sheet Metal


ÏÏÏ
ÏÏÏ
Feature→General Flange or from the General Flange icon in the Sheet
Metal Feature toolbar. To edit a General Flange, use Edit→Feature or the Edit
ÏÏÏ
6
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Feature toolbar.

General Flange is a selection steps type of dialog, the Selection Step icons will
highlight as you progress through the general flange creation process. You may
also select any icon at any time to specify, or reĆspecify, information for that
step of the process. Only the Selection Steps needed for each method will
appear for each method used. See the figure below.

NOTE Like the Flange dialog, the General Flange dialog can
resolve mathematical expressions. Also, it can create
expressions on the fly". You can enter a new expression
into the appropriate window. The system will resolve the
expression into its numeric value upon creation of the
flange.

Parameters Method Build to Sections Method

Bend
Edges Spine Section
String Strings

Build to Faces Method Punch Vector Method

Shaping Punch
Faces Vector

TIP Flange parametric inputs such as bend angle and web length can
be inserted at any time during the creation process. These values
can be defined before or after the bend edge(s) is/are selected.

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General Flange

ÏÏÏ
ÏÏÏ Bend Edges
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6
ÏÏÏ To create a General Flange, you must first select a bend edge or a set of bend
edges (a bend string) that will become the start edge of the General Flange.
The bend string must have the following criteria:

 All edges must be from the same solid body.


 They must be G1 continuous (tangentially joined edges).
 The faces that own the edges must be G1 continuous (tangentially
joined faces).

When you select the bend edge, the system will highlight the attachment face
upon which the General Flange will be built. The bend direction will be
displayed as a temporary vector. Also, the start of the bend edge is designated
using temporary text display. It is important to differentiate between the start
and end of the bend edged, especially when defining law functions and also
when extending section curves.

You must select edges (not curves). The system will filter your selections to
ensure these criteria are met. It is acceptable to select bend edges that form a
closed loop. You may set the selection Filter to choose All Edges, Solid Edges,
or Sheet Edges.

You may have the system automatically select all tangent edges by turning on
the Add Tangent Edges toggle. The system selects these edges after you select a
seed edge. As the model changes, the system will guarantee that all tangent
edges are selected. This toggle is only enabled while in the Bend String
selection step.

When you select a bend string, you implicitly select a set of tangent faces. Since
each edge is surrounded by, at most, two faces; there are no more than two sets
of tangent faces that could be used to construct the General Flange. The
General Flange will be built tangent to the unhighlighted face. The highlighted
face is the target attachment face. The system infers the tangent faces to be
those that yield the smaller thickness. You may change this inference by
pressing the Adjacent Faces button. If you have selected edges from a sheet
body, the Adjacent Faces option is not needed.

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General Flange

ÏÏÏ
Spine String ÏÏÏ
The Spine function is an optional step that allows you to select a curve which
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the system will use to govern the construction of the general flange. The spine
curve geometry is related back to the general flange through specific points
along the spine. At these points, perpendicular section planes are temporarily
constructed, then used to shape the general flange geometry.

Spine curves may be as simple as straight lines, or they may be as complex as a


twisted spline. Either way, when you select curves or edges for your spine curve,
they must be G1 continuous. To avoid potential construction failures, it is
recommended that spine curves be constructed as very fair curves. The
complexity of the general flange is reflected by the complexity of the spine.

Any G1 curve may be chosen as a spine curve, but the spine should be selected
carefully to achieve good results. Usually, the spine should follow the general
direction of the bend edge and have as little curvature as possible. A good
strategy is to start with the bend edge and smooth out places where the
curvature is excessive. It should be kept in mind that the spine controls not only
the shape of the creation state, but the distortion to other states when the
Along Sections distortion algorithm is used. If the spine has too much
curvature, nearby sections of the flange will be far from parallel and may cause
self-intersecting surfaces. In general, the larger the flange, the gentler the
spine needs to be.

If the spine string is shorter than the bend edge (or vice versa), the General
Flange will be truncated to the shorter curve/edge. If an independent spine
curve is not selected, the bend edge is used as the spine.

If you do not select a spine, you may set the Infer Spine toggle on the Options
dialog. This will enable the system to generate a spine that is suitable for the
input data you have selected.

The system evaluates all law functions (e.g., plus, angle, radius, and length)
using this spine string.

EDS
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Sheet Metal Design
Student Guide
6-5
General Flange

ÏÏÏ Refer to the figure below. Both General Flanges have curved bend edges. The
ÏÏÏ General Flange on the left was created using a curved spine (identical to the

ÏÏÏ
6
ÏÏÏ
bend edge). The General Flange on the right has a linear spine. Note how the
shape of the General Flange has changed.

Spine curve

Bend Edge

Bend Edge

Unformed general Unformed general


flange created without flange created with a
a spine curve spine curve

Section Strings

The Section Curves selection step is only available when using the Build to
Sections method. You may select curves or edges that define the shape of the
General Flange top face.

Shaping Faces

Use the Shaping Faces selection when you are using the Build to Faces method.
You may select faces from solid bodies or sheet bodies that define the shape of
the General Flange top face.

EDS Unigraphics NX
6-6 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

ÏÏÏ
Punch Vector ÏÏÏ
This selection step is used in Punch Vector method. It brings up the standard
ÏÏÏ
6
ÏÏÏ
vector selection method.

Depending on the vector selection method, a vector is inferred from the


selected geometry. The vector is displayed temporarily.

Among the vector selection methods are: Inferred Vector, Between Two Points,
At Angle, Edge/Curve Vector, Face Normal, Plane Normal, Datum Axis, XC
Axis, YC Axis, ZC Axis, and Vector Constructor.

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Sheet Metal Design
Student Guide
6-7
General Flange

ÏÏÏ Parameters
ÏÏÏ
ÏÏÏ
6
ÏÏÏ Add Tangent Edges

When in the Bend String selection step, the Add Tangent Edges toggle is
enabled. If you set this option, the system will automatically select all edges that
are tangent to your current selections. The system will maintain this setting so
the set of tangent edges can be re-evaluated whenever the model updates.

Thickness

If you have selected bend edges from a solid body, the system will produce a
General Flange with the given thickness.

If you turn ON Infer Thickness (from the Options dialog), the system will build
the General Flange using the thickness derived from the target geometry. The
thickness will be associative to the target geometry ć if the thickness of the
target body changes, the General Flange thickness will automatically change.
Note that the system assumes uniform thickness.

You can control the thickness of the General Flange by turning OFF the Infer
Thickness toggle (from the Options dialog) and entering a valid expression into
the Thickness field. This field is only available if Infer Thickness is OFF. The
default thickness is the inferred material thickness. You cannot enter a negative
thickness. If you specify a thickness for the General Flange, the system will
create an expression to maintain that value.

If the thickness is greater than any bend outer radius, the General Flange will
not be thickened. You will be warned and the feature will be created as a sheet
body.

The thickness direction is inferred from the target faces. The system will always
thicken the General Flange such that the attachment face of the General
Flange aligns with the faces adjacent to the target faces.

EDS Unigraphics NX
6-8 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

ÏÏÏ
Parameters Method ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Parameters

When using the Parameters method, you must enter the parameters that define
the plus, bends, and webs. These parameters may be defined using constant
values or by defining laws. You may define parameters for up to 12 bend/web
combinations, called Steps. All these values can be defined in two ways:

 Constant ć Enter any valid expression to define a constant value (i.e.,


it yields a constant value as it is evaluated along the spine). An
expression will be created for each constant value you supply.

EDS
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Sheet Metal Design
Student Guide
6-9
General Flange

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

 Law Controlled – This brings up the Law Curve dialog, which can be used to
define a value that changes along the length of the spine.

Reverse Bend Direction

Upon selecting the bend string, the system displays a vector that defines the
direction of a positive bend angle. Toggle Flip Bend Direction to cause the
General Flange to build in the opposite direction. By default, the bend
direction will be normal to the tangent face.

Flange

Plus Extension

Bend Edge

Top View

Plus

The Plus lets you extend the tangent faces before attaching the bend. This
extension will follow a direction normal to the tangent face. This field is only
available in the Bend Edges selection step. Specify the plus as either a constant
or law controlled value. The Plus must be greater than or equal to zero. A Plus
value can only be entered for Step 1 when creating multiple stepped flanges.

EDS Unigraphics NX
6-10 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

Step Data
ÏÏÏ
The Step Data field lets you define bend and web parameters for each step. The ÏÏÏ
ÏÏÏ
6
delete steps. Set the menu to a step number (Step 1, Step 2, etc.) and the bend ÏÏÏ
option menu contains settings for all defined steps as well as fields to add and

and web parameter fields are populated with the values for that step. Select the
Add option to add a new step following the current step. The bend and web
parameter fields are populated with default values. The maximum number of
steps is 12. Select the Delete option to delete the current step. There must be at
least one step.

Radius

The Radius field controls the bend radius of the current step. Specify the radius
as either a constant or law controlled value. You may define either the Inner or
Outer radius. The outer radius must be greater than the thickness, or the
thicken operation will fail and the General Flange will be created as a sheet
body. The minimum allowable radius is the modeling tolerance.

CAUTION If you are working with a solid part, it's important to make
sure you insert the correct bend radius value for the selected bend edge.
If you specify an internal radius value but select the outside bend edge of
the target face, the resultant flange will not reflect the correct bend
geometry.

Angle

The Angle field defines the bend angle in degrees. Specify the angle as either a
constant or law controlled value. A positive value bends the General Flange in
the direction of the displayed bend vector. The angle may have any value
between -360° and 360° , but not zero, plus or minus the model's angle
tolerance (as set in the Preferences→Modeling dialog under the Modeling
Application). The bend angle should not allow a self intersection between the
general flange bend segment and the target body.

Length

The length of the general flange is defined as the length of the extension from
the edge of the bend to the end of the flange. It is equivalent to the Tangent
Length of a regular flange feature. The length can be specified using a constant
or law controlled value. The length can be zero or any value greater than zero.

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Student Guide
6-11
General Flange

ÏÏÏ
ÏÏÏ Build to Sections Method
ÏÏÏ
6
ÏÏÏ
Build to Sections

Section Curves

The General Flange can be defined using section strings. The section strings
must be created with Modeling tools. The General Flange dialog does not
support section string creation.

The section curves must have the following criteria:

 Each section must consist of an arbitrary number of curves and edges


that comprise an open, tangentially joined (G1) string.
 One end of each section must touch the bend edge. The section must
be tangent to the target face at this point.
 Strings can have a different number of curves in the string.
 It is acceptable to end a string with an arc.

NOTE There is builtĆin functionality which allows you to drag a


window around the section strings without having to
select them manually. In most cases, the system will figure
out the order.

EDS Unigraphics NX
6-12 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

Extend Start and Extend End


ÏÏÏ
ÏÏÏ
When section curves are not defined at the spine ends, the Extend Start and
Extend End toggles determine how the General Flange will be interpreted at
ÏÏÏ
6
ÏÏÏ
the spine ends. If either toggle is ON, the General Flange will maintain a
constant section from the last defined section to the spine start/end. If it is OFF,
the General Flange will only be created between the extreme section curves. If
there is only one section string, the General Flange is always extended to
spine/bend ends.

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Student Guide
6-13
General Flange

ÏÏÏ
ÏÏÏ Build to Faces Method
ÏÏÏ
6
ÏÏÏ
Build to Faces

Shaping Faces

You can build a General Flange by specifying shaping faces that define its top
face. The faces can come from either solid bodies or sheet bodies.

The shaping faces must meet the following criteria:

 They must not be from the body of the target faces.


 They must be G1 (tangent) with the target faces at the bend edge.

To select all G1 faces in the Shaping Faces selection step, set the Filter to G1
Faces, then select a seed face and drag a selection rectangle around the
remaining faces.

The General Flange top face is approximated by taking sections normal to the
spine through the shaping faces. The Tolerance field defines the section
sampling along the spine. The Minimum Number of Sample Points provides a
means of generating more sections along linear spine curves. Set these values
on the Options dialog. If a shaping face contains a hole or some other void, the
cross section curve that is generated will end at that void.

You will get the best results if you only choose G1 continuous faces from a
single body.

EDS Unigraphics NX
6-14 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

ÏÏÏ
Punch Vector Method ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Punch Vector

Punch Vector

Defining a General Flange using a Punch Vector is similar to using Parameters


method, however, the first bend angle is determined from a user-specified
vector. Select Punch Vector to bring up the standard vector selection method.
The other fields are identical to the Parameters method. The system displays
the punch vector to indicate the bend direction (similar to the bend direction
vector in Parameters method). You must select a punch vector ć there is no
default. The punch vector will be associative to the selected reference geometry
(if any).

The spine will be projected to a plane that is normal to the punch vector prior
to construction. This is necessary to generate the proper section curves.

EDS
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Sheet Metal Design
Student Guide
6-15
General Flange

ÏÏÏ Since the first bend angle is a function of the punch vector, the Angle field (for
ÏÏÏ the first step only) is the angle with respect to the punch vector. The angle can

ÏÏÏ
6
ÏÏÏ
be between ć360° and +360° . The default angle of zero makes the web parallel
to the punch vector. Angles for other steps are relative to the previous step, as
in Parameters method.

Bend Allowance Formula

You can choose a Bend Allowance Formula by pressing this button. The Bend
Allowance Formula dialog is displayed below. You can select the Bend
Allowance Formula (BAF) from the list or you can enter the BAF in the text
field.

If Use Global is turned ON in global parameters for Bend Allowance Formula,


this option will be removed from the General Flange dialog.

EDS Unigraphics NX
6-16 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

Adjacent Faces ÏÏÏ


ÏÏÏ
When you select the bend edge(s), there are two adjacent faces available if ÏÏÏ
6
ÏÏÏ
you're working with a solid body and only one adjacent face if you're working
with a sheet body.

Solid bodies Sheet Body

Selected Bend Edge

For solid bodies, the system measures the distance from each face to its
opposite face. The shorter distance is assumed to be the thickness and the
related faces become the sheet metal surface. The remaining faces are assumed
to be the target attachment faces. The target attachment faces are highlighted
when you select the bend edges. If the wrong faces are highlighted, simply press
the Adjacent Faces button.

This option is not available if you have selected edges from sheet bodies.

EDS
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Sheet Metal Design
Student Guide
6-17
General Flange

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ Options

Infer Thickness

Set this option if you want the system to infer the thickness of the General
Flange from the selected geometry. The system will sample the thickness at one
point on the tangent faces. It will assume uniform thickness.

If this toggle is turned OFF, you can enter a valid expression in the Thickness
field shown on the main dialog.

If Use Global Thickness is turned ON in global parameters, this option will be


grayed out (as shown above).

EDS Unigraphics NX
6-18 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

ÏÏÏ
ÏÏÏ
Infer Spine ÏÏÏ
6
ÏÏÏ
The Infer Spine option enables the system to generate a spine that will be
usable for the given input data. The spine will be created internally only ć it will
not be saved. If the user has explicitly selected a spine, the system will attempt
to use it as is, regardless of this setting of this toggle. If the spine does not
match the input data, (e.g., section curves are not normal to the spine), the
feature will give an error and the General Flange will not build.

The system will create this curve using various approaches:


 Bend edges that have a high degree of concavity can be problematic,
since they can often yield self-intersecting surfaces. Infer Spine will
attempt to generate a spine by smoothing out the bend edge. Note that
this will change the shape of the General Flange by making it spread
out more. This technique is used by all construction methods, except
Build to Sections. (See the figure below)
 If the creation method is Build to Sections, the Infer Spine option will
cause the system to generate a spine that is normal to all selected
section curves.
 If the creation method is Punch Vector the system will project the bend
edge to a plane that is normal to the punch vector. It will further apply
the smoothing algorithms to reduce the amount of concavity.

The Infer Spine setting will be used in all states of the General Flange (formed,
unformed, or intermediate).

The figure below shows a General Flange with a concave bend edge. The spine
has been adjusted as shown.

Original Spine

Adjusted Spine
Spine Adjustment

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Student Guide
6-19
General Flange

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ r Value and Area Preserve

The r value is the average strain ration or normal anistropic property of the
material formed. Higher r values represent a higher resistance to thinning when
the material is stretched, or resistance to thickening when the material is
compressed. This will affect how the General Flange is mapped to other states.

Selecting the Area Preserve button is equivalent to specifying an infinite r value.


The default value of 1.0 corresponds to a homogeneous material.

Distortion

When the general flange is placed in any formed or unformed state, the
material will distort. The flange profile will always remain fixed along the bend
edge, but outer edge distortion can be controlled by selecting either the Along
Section or BiĆdirectional distortion options.
 Along Section Ć this option calculates a distortion which is constrained
to be along sections normal to the governing spine. (Note that this is
the bend edge when a specific spine string is not selected during flange
creation). The end edges of the flange remain normal to the governing
spine while the far edge distorts.
 BiĆdirectional Ć this option causes a spreading type of behavior by
allowing the flange to distort on all three outer edges as it is unformed.

NOTE Regardless of the selected distortion method, additional


deformation constraints may be placed on the flange
when creating unforming sequences. This topic will be
addressed in the Forming and Process Tables lesson.

EDS Unigraphics NX
6-20 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Formed

Unformed Along Unformed


Sections BiĆdirectional

Distortion Algorithms

Tolerance

The construction of the general flange feature involves an approximation


process, which is controlled by the Tolerance option. The default value is the
distance tolerance found under the modeling preferences.

Note that unrealistically small tolerance values may produce excessively


complex geometry or a failure to construct the General Flange. It may be
necessary to experiment with various tolerances to determine the best value for
any particular General Flange.

A General Flange is built by creating section curves that are normal to the bend
edge (or spine) at points that are determined by the Tolerance field. Since this
would give a small number of sampled points along linear segments, the
Minimum Number of Sampled Points field can be used to increase the density
of these points. An example of its use is when using Build to Faces along a
linear bend edge. The faces may have details that require a larger number of
sections than the bend edge curvature would yield.

EDS
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Student Guide
6-21
General Flange

ÏÏÏ Reference Lines

ÏÏÏ
ÏÏÏ
Mold Line
6
ÏÏÏ

Contour Line Form Block Line

Contour Lines

You can request the system to create Contour lines for certain General Flanges.
The contour line is defined as the intersection of surfaces extended from the
tangent face and the web of the first step. You can only generate contour lines
for the first step of General Flanges created using Parameters Method or Punch
Vector Method. Contour lines can only be applied to General Flanges whose
angles have an absolute value less than 135°.

Mold Lines

You can request the system to create Mold lines for certain General Flanges.
The mold line is defined as the intersection of surfaces extended from the
tangent face and a surface normal to the tangent face and tangent to the bend
face. You can only generate mold lines for the first step of General Flanges
created using Parameters method or Punch Vector method. Mold lines can only
be applied to General Flanges whose angles have an absolute value greater
than 90°.

EDS Unigraphics NX
6-22 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

Reference Lines (cont'd)


ÏÏÏ
Mold Line ÏÏÏ
ÏÏÏ
6
ÏÏÏ

Contour Line Form Block Line


Form Block Lines

You can request the system to create Form Block lines for certain General
Flanges. The form block line is similar to the contour line, however it applies to
the inner surfaces of the flange. You can only generate form block lines for the
first step of General Flanges created using Parameters method or Punch Vector
method. Form block lines can only be applied to General Flanges whose angles
have an absolute value less than 135°.

EDS
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Student Guide
6-23
General Flange

ÏÏÏ Construction Tips


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
The following tips will help you to successfully create a general flange:
 The system may fail to boolean the general flange to the target body. If
this happens, a warning will be generated and a standalone feature will
be created. If this happens, it is suggested that you work with a sheet
body first, then thicken it. In simpler cases, check all of your values to
make sure they are realistic.
 Make sure the section curves are tangent to the target face and in a
plane normal to the spine.
 The flange creation may fail if the governing spine curve is too severe.
 At any given concave point on the flange, the bend radius must be less
than the radius of curvature of the edge or a selfĆintersection will
occur and the flange will fail to create.

Bend Radius of General Flange


Note: Bend Radius of
Material General Flange (R1) is
Convex Thickness larger than radius (R2) of
portion
concave portion of Bend
of Bend SelfĆ
Edge
Edge Intersection

R1 = 1.15 R1 = 1.15

General Flange
Bend Radius = R1 R2 = 1.11

Concave portion of
Bend Edge

 The system will not allow the selection of a spine curve which contains
discontinuities (such as sharp corners). The system will generate a
warning message to deselect invalid curves.
 Although the system can reĆsort the sequence of selection picks, it is
suggested that you pick a contiguous string of curves or edges when
selecting the bend edge or spine.

EDS Unigraphics NX
6-24 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

 Remember to load and activate your user standards if you wish to


ÏÏÏ
standardize the feature's parametric options.
ÏÏÏ
 Some text fields within the General Flange dialog (e.g. law options),
do not support expressions or mathematical statements (e.g. 1/2 or
ÏÏÏ
6
ÏÏÏ
p10).

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Sheet Metal Design
Student Guide
6-25
General Flange

ÏÏÏ Activity 6-1: General Flange Creation Methods


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
In this activity you will create general flanges using a variety of creation
methods.

Step 1 Open the part smd_genflg. Save this part as xxx_genflg


where xxx are your initials.

Step 2 Create a stepped general flange.


 Ensure you're in the Modeling application.

 Choose the General Flange icon.


Notice that the Bend Edges selection step is highlighted and you
are prompted to select continuous edges.
 Select the top edge of the spline curve in the graphics
window.

Select this edge


of the part

NOTE You can reselect any selection step icon at any time in the
creation process to correct that steps associated input.
Use the <Shift> MB1 combination to deselect unwanted
geometry.

EDS Unigraphics NX
6-26 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

 Change the Angle to 45


ÏÏÏ
ÏÏÏ
TIP Double click inside the input field to highlight and
replace the existing value.
ÏÏÏ
6
ÏÏÏ
 Change the Length to .50
 Choose the Step Data button and select the Add option.

Notice that the Step Data now displays Step 2.


 Change the Angle to -60
 Change the Length to .20
 Toggle Confirm Upon Apply ON and then choose Apply.
 Rotate and inspect your model; if the results appear correct,
choose OK. Otherwise, choose the Back button and flip the
bend direction or edit the parameters as necessary.

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6-27
General Flange

ÏÏÏ Step 3 See how a spine can be used to affect the flange geometry.
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
 If you are not in the wireframe mode, choose the Wireframe

icon.

 Make layer 41 selectable. Resize the graphics image if


necessary.

 Choose the Edit Feature Parameters icon.

 Select the general flange either from the Feature Selection


list, or from the graphics window.

 Choose OK.

 Choose the Spine String icon in the General Flange


dialog.

 Change the Filter option to Curve.

 Select the orange curve in the graphics window .

 Choose OK twice to complete the edit.

EDS Unigraphics NX
6-28 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

The flange is now limited by the length of the spine curve at one
ÏÏÏ
end and by the edge of the part at the other end. The taper
ÏÏÏ
characteristic of the flange is derived from section plane cuts
normal to the spine curve. ÏÏÏ
6
ÏÏÏ

Step 4 Create a Law Controlled general flange.

 Make layer 1 your work layer. Make layer 82 selectable and


all the other layers invisible.

 Using the sheet body, make an extruded solid .08 inches


thick.

 Make layer 82 invisible.

 Choose the General Flange icon.

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6-29
General Flange

ÏÏÏ  Select the front edge of the top face as the bend edge.
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

Select this edge as


the Bend Edge

 Set the Plus to .20

 Change the Radius from Constant to Law Controlled.

EDS Unigraphics NX
6-30 Sheet Metal Design
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General Flange

 Choose Linear from the Law Curve dialog.


ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

 Change the Start Value to .50 and the End Value to .15

 Choose OK.

 Change the bend Angle back to 90

 Change the web Length from Constant to Law Controlled.

 Again, choose the Linear option.

 Leave the Start Value at 1.0 and set the End Value to .50

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General Flange

ÏÏÏ  Choose OK.


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
 Ensure the Confirm Upon Apply button is ON.

 Choose Apply to create the flange. Rotate the part to


examine the flange geometry. Accept the results if they
appear as the in figure below.

Plus

Law Controlled
Web

Law Controlled
Bend Radius

EDS Unigraphics NX
6-32 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

Step 5 Review the unformed shape.


ÏÏÏ
ÏÏÏ
 Choose the Form/Unform icon.
ÏÏÏ
6
ÏÏÏ
 Select the general flange from the graphics window.

 Choose the Unform Selected Features button from the


Form/Unform dialog.

 Orient the view to the Right view.

Review the flange profile. Notice the spike at the outer edge of
the part?

Spike in the
flange profile.

Because the Distortion option was set to Along Section, the far
edge of the unformed flange will buckle to accommodate the
material compression occurring in this area.

 For reference, extract edge curves from the outer edges of


the flange using the Insert→Curve Operation→Extract
function.

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6-33
General Flange

ÏÏÏ Step 6 Change the flange distortion control.


ÏÏÏ
ÏÏÏ
6
ÏÏÏ  Choose the Edit Feature Parameters icon and select
the general flange feature.

 Choose OK.

 Within the General Flange Options dialog, change the


Distortion option from Along Section to BiĆdirectional.

 Choose OK until the general flange updates. (Watch the


status line. This should be 3Ć4 clicks with your mouse
button.)

Your unformed flange should now reflect a smooth outer edge.


The ends of the flange have shifted outward to compensate for
the material distortion.

Step 7 Choose File"Close"Save and Close.

EDS Unigraphics NX
6-34 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

Activity 6-2: Other General Flange Creation Methods ÏÏÏ


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
In this activity you will learn how to use section strings and faces to create
general flanges.

Step 1 Create a general flange using a single section string.

 Open the part smd_genflg2.

 Ensure you are in the Modeling application.

 Choose the General Flange icon.

 Change the method to Build to Sections.

 Select the bottom left fillet edge, the bottom back edge and
the bottom right fillet edge as the bend edges.

Select the bottom edges.

 Click MB2 twice to skip the Spine String selection step.

 At the Section Strings step, select the orange section curves.


Accept your selections, if necessary.

 Choose the Options button.

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6-35
General Flange

ÏÏÏ  Ensure the Distortion option is set to BiĆDirectional.


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
NOTE The system automatically determines the part thickness,
because Infer Thickness is toggled ON, and inserts the
value into the Thickness field.

 Choose OK twice to create the general flange.

Step 2 Create a flange using two sets of section curves.


 Make layer 43 selectable.

 Choose the General Flange icon.

 Select the bottom left edge as the bend edge.

Select this bottom edge.

 At the Section Strings step, select all of the orange section


curves (Remember to select the first string under the edges
of the last flange created). Accept your selections, if
necessary.

TIP You can drag a window around the curves you wish
to select.

EDS Unigraphics NX
6-36 Sheet Metal Design
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General Flange

 Choose OK to create the general flange.


ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

Step 3 Close your part. Do not save.

Step 4 Create a general flange using the Build to Faces method.

 Open the part smd_genflg3.

 Ensure you are in the Modeling application.

This is a model of three sheet bodies. They represent legacy


data imported into your file. You will use the Build to Faces
option to create a formable General Flange based on these
existing faces.

 Choose Insert→Form Feature→Thicken Sheet...

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6-37
General Flange

ÏÏÏ  Enter .125 for the First Offset.


ÏÏÏ
ÏÏÏ
6
ÏÏÏ

 Select the planer sheet body .

Select this face

 Choose OK.

EDS Unigraphics NX
6-38 Sheet Metal Design
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General Flange

ÏÏÏ
 Choose the General Flange icon. ÏÏÏ

ÏÏÏ
6
Choose the Options button and change the Distortion option ÏÏÏ
back to Along Sections.

 Choose OK.

 Change the method to Build to Faces and the Filter to


Solid Edge.

 Select the bottom front edge of the solid body as the Bend
Edge.

Select this bottom edge.

 Choose MB2 to advance to the next selection step.

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6-39
General Flange

ÏÏÏ  Select the bottom back edge of the solid body as the Spine.
ÏÏÏ (Change the filter to Solid Edge.)
ÏÏÏ
6
ÏÏÏ

Select this bottom


back edge.

 Choose MB2 to advance to the next selection step.

 Change the Filter to Any Face.

 Select the remaining faces as the Shaping Faces.

Select these faces.

EDS Unigraphics NX
6-40 Sheet Metal Design
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General Flange

 Choose OK.
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

Step 5 Examine your part.

 Choose the Form/Unform icon.

 Choose the Unform All button.

 Choose the Top view icon and then the Trimetric view

icon.

 Choose the Form All button to reform your part.

Step 6 Edit the Shaping Faces that created the General Flange
and see the associativity between the two.

 Make layer 50 selectable. This will show the spline used to


create the nonĆplanar face.

 Change the view to top by selecting the Top view icon.

 Choose Edit→Curve→Parameters...

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6-41
General Flange

ÏÏÏ  Select the spline.


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
 Choose the Edit Pole button.

 Place your cursor over any interior pole, click and hold MB1
to move the pole to a new location (within a reasonable
distance from its origin). Repeat for other interior poles as
desired.

 Choose OK three times and watch your part update.

 Shade your image and inspect the part.

 Unform your part.

Again, look at your part using the Top view Trimetric view
icons.)

 Form your part.

Step 7 Close your part. Do not save.

EDS Unigraphics NX
6-42 Sheet Metal Design
Student Guide All Rights Reserved
General Flange

Activity 6-3: Create a Gen. Flg. by the Punch Vector ÏÏÏ


ÏÏÏ
Method ÏÏÏ
6
ÏÏÏ
Step 1 Create a general flange using the Punch Vector method.

 Open the part smd_genflg4.

 Ensure you are in the Modeling application.

 Choose the General Flange icon.

 Change the Method to Punch Vector and if necessary,


set the Filter to Solid Edge.

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General Flange

ÏÏÏ  Select the top edge of the hole in the solid body as the Bend
ÏÏÏ Edge.
ÏÏÏ
6
ÏÏÏ Select this top edge

 Choose MB2 twice to advance to the Punch Vector selection

step.

 Select the Punch Vector in the diagram.

Select this vector

 Change the Plus factor to 0 .

 Change the Radius to .09 .

 Change the Length to .50 .

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General Flange

 Toggle ON the Confirm Upon Apply button (if it is not ON


ÏÏÏ
already).
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

 Choose Apply to create the flange. Rotate the part to


examine the flange geometry.

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General Flange

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

 Accept the results if they appear as the in figure above.

Step 2 Edit the expression used to orient the Punch Vector and
see its association to the General Flange.
 Choose Tools→Expression...

 Choose the angle variable and change the value to 15 .

EDS Unigraphics NX
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General Flange

 Choose OK.
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

Step 3 Examine your part.

 Change the view orientation using the Top view icon

and then the Trimetric view icon.

Step 4 Close your part. Do not save.

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General Flange

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

SUMMARY The General Flange application enables you to


create formed flanges along contoured
(nonĆlinear) edges of a part.

In this lesson you:


 Created and edited a general flange using
the Parameter method.
 Created a general flange using the Build to
Section Curves method.
 Created and edited a general flange using
the Build to Faces Method.
 Created and edited a general flange using
the Punch Vector method.

EDS Unigraphics NX
6-48 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Punch

Sheet Metal Punch


Lesson 7

PURPOSE Create and edit sheet metal punch objects using the
Sheet Metal Punch feature.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
OBJECTIVES Upon completion of this lesson, you will be able to:

 Create a Sheet Metal Punch.

This section contains the following activity:

Activity Page
7-1 Creating Sheet Metal Punches . . . . . . . . . . . . . . . 7-14

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7-1
Sheet Metal Punch

The Sheet Metal Punch Dialog

The Sheet Metal Punch feature allows you to create userĆdefined emboss, coin
and lance operations across multiple, adjacent placement faces, including the
formable bend surface of a flange. Open and closed profiles intersecting the
periphery of the part are also available.

You can access the Sheet Metal Punch dialog from Insert→Sheet Metal

ÏÏÏ
Feature→Punch or from the Sheet Metal Punch icon in the Sheet Metal

ÏÏÏ
7
Feature toolbar. To edit a Sheet Metal Punch, use Edit→Feature or the Edit

ÏÏÏ
ÏÏÏ
Feature toolbar.

The Sheet Metal Punch dialog steps you through the process of placing and
creating the punch feature. As with all selection step type of dialogs, you can
jump to any step of the process and make adjustments before completing the
creation of the feature. However, all steps must have their required inputs
specified before you will be allowed to create the feature.

Size
Parameters

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7-2 Sheet Metal Design
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Sheet Metal Punch

Selection Steps

Placement Face

Like other sheet metal features, a placement face must be selected for the
location of the Sheet Metal Punch feature. The Placement Face defines
whether the outline curves will be projected onto the top or bottom of the
target body. By default, the top of the punch follows the contours of the ÏÏÏ
ÏÏÏ
7
placement face and any adjacent faces onto which the punch outline projects.
ÏÏÏ
ÏÏÏ
The placement outline curves (see figure below) are projected onto any
adjacent faces, if necessary. This way, only a single placement face need be
selected. A punch feature may also cross formable faces (also shown below).

Adjacent faces

Placement face

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Sheet Metal Punch

Placement Outline

The placement outline is a set of curves which define the profile of the punch
on the placement face. The profile may be open or closed; however, if it is
open", it must intersect the periphery of the part. Also, the curves must be
contiguous, but sharp corners are allowed.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Open profiles crossing the periphery

If the curves are not created on the placement face, the system will project
them onto the face along the specified punch direction vector. To avoid possible
projection errors, it is suggested that the curves be created on the placement
face.

The outline curves are associated to the punch feature. Like other sheet metal
features, you should place the model in the original creation state (formed or
unformed) before editing the outline curves. The punch will not update its
profile until the part is placed in the original creation state.

EDS Unigraphics NX
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Sheet Metal Punch

Tool Center

Tool Center allows you to select a point to indicate the center of the punch (e.g.
the index point). This point can be on or off of the placement face. By default
the Auto Centroid option is ON within the Options dialog, in which case, this
step is grayed out.

NOTE If the Auto Centroid option is not used, the point used
for the Tool Center must be created prior to entering the
Sheet Metal Punch operation.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
The punch direction vector will be established from this point. In the case of a
nonĆplanar placement face, the reverse face normal" vector is calculated at
this point after being projected onto the placement face.

Lancing Curves

Lancing Curves allows you to select a curve or set of curves to indicate where
the punch will be ripped" away from the adjacent curves. These lanced curves
are part of the placement outline curves and should be included in the
Placement Outline selection step.

NOTE This option is only available if the Punch Type is set to


Lance.

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Sheet Metal Punch

When selecting the lancing curve(s), the system will automatically select any
curves that are tangent to the one(s) selected. When the string comes to a sharp
corner the selection process stops.

ÏÏÏ
ÏÏÏ
7
Lancing curves on both
sides.When selecting a

ÏÏÏ
ÏÏÏ
curve, all tangent curves
will also be selected.

Lancing curves on two sides

Lancing curve

Lancing curve on one side

EDS Unigraphics NX
7-6 Sheet Metal Design
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Sheet Metal Punch

Direction Vector

Direction Vector will bring up the Vector Method option. Use this option to
choose a punch direction other than the default or flipped default directions. It
allows you to specify the direction along which the outline curves and the actual
punch feature will be applied to the part.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Punch Type

V18 has added the option to choose between Embossed, Coin or Lance punch
types, with the default set to Emboss. Coin punches are used to create stamped
shapes. Coin acts similar to an extrude and subtract function. Lance allows the
definition of ripped edges (see Lancing Curves).

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Sheet Metal Punch

Top Type

By default, the top of a punched feature will follow the contour of the
placement face. This is the Offset setting for the Top Type.

If the Top Type is set to Flat, the top of the punch will be a surface which is
perpendicular to the punch direction vector.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Offset Top Type Flat Top Type

If the punch outline is compromised of a closed, circular profile, the additional


option of applying a Round or ConeĆshaped top will be available. Round and
Cone top types require a closed, circular profile and can only be placed on a
single, planar placement face.

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7-8 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Punch

Size Parameters

There are five geometric parameters which define the Sheet Metal Punch
feature. They are Depth, Die Radius, Taper Angle, Punch Radius and Cone
Depth.

ÏÏÏ
ÏÏÏ
7
The Depth parameter is the distance which the punch extends beyond the ÏÏÏ
ÏÏÏ
surface of the part, as measured along the punch vector. If the Depth is less
than or equal to the Punch Radius, you will create a Dimple. The depth can be
less than the material thickness, however the die and punch radius values must
be considered when do this.

The Die Radius, or Blend Radius, is the value of the blend between the face on
the opposite side of the placement face and the sides of the punch. This is a
fixed value resulting in a constantĆradius blend.

The Taper Angle is a constant angle measured from the punch direction vector
to the side faces of the punch.

The Punch Radius, or Top Radius, is the blend radius between the inner sides
of the punch and the punch top, or it is the value of the inside radius of any
closed, circular emboss (e.g. a dimple or cone type top).

Taper Angle
Punch Radius

Depth

Die Radius

Offset Punch with Taper Angle

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Sheet Metal Punch

The fifth parameter, Cone Depth, is the height of the cone portion of a punch
as measured from the base of the cone to the top of the punch feature. This
option is only available if the Top Type is set to Cone.

Punch Radius

Die Radius
Depth

ÏÏÏ
ÏÏÏ
7
Cone Depth

ÏÏÏ
ÏÏÏ Cone Top Punch with no Taper Angle

Taper Angle

Depth

Die Radius

Round Top Punch with Taper Angle

Circle defines
Spherical Radius

Die Radius Only Depth

Dimple

EDS Unigraphics NX
7-10 Sheet Metal Design
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Sheet Metal Punch

Face Normal Direction

When Face Normal Direction is toggled ON, the axis of the Sheet Metal Punch
will align normal to the placement face. If you prefer to define a specific vector
for this axis, turn this toggle OFF and use the Direction Vector selection step to
define a new vector.

Flip Side Vector


ÏÏÏ
ÏÏÏ
7
The side vector points to the region, on either side of the placement outline, to
be punched (area that will be displaced). Using this button, you can flip this
vector to change the region you want to punch.
ÏÏÏ
ÏÏÏ

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Sheet Metal Punch

Options

Options allows you to assign the Placement Outline as either the Inside or the
Outside of the punch perimeter. The punch outline either shows the Inside
surface of the punch or the Outside surface of the punch.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Inside Outside
Placement Outline Placement Placement

Auto Centroid Creation: When ON this option will create an automatic tool
center point (centroid) based on a 2D analysis of the placement outline curves.
The default setting is ON.

If the profile curves do not lie on the placement face(s), neither will the
centroid. It will be projected to the placement face internally along the punch
vector.

Flanged Cutout: When ON this option will create a flanged cutout (drawn
cutout or flanged hole) in lieu of the emboss or coin punch. The default setting
is OFF.

Flange Cutout

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7-12 Sheet Metal Design
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Sheet Metal Punch

Construction Tips
 Do not place Round top or Cone top punches on the bend surface of a
flange feature. The formable nature of the flange produces distortion
within the punch feature which will lead to Boolean errors during the
forming or unforming process.
 When using sketches to define the placement outline, it is
recommended that you create a separate sketch for each punch
feature. This will ensure that edits made to a sketch will not
accidentally affect a nonĆintended feature.
 If using splines for the placement outline, the resultant punch faces ÏÏÏ
ÏÏÏ
7
will be comprised in some areas of trimmed BĆsurfaces. This may
present minor difficulties while attempting to dimension the feature,
or a section cut of the feature.
ÏÏÏ
ÏÏÏ

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Sheet Metal Punch

Activity 7-1: Creating Sheet Metal Punches

In this activity you will create the base of a sheet metal housing while practicing
several different Sheet Metal Punch creation techniques.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Step 1 Create the body of the part.

 Open the smd_seedpart and save it as xxx_punch, where xxx


are your initials. Ensure you are in the Modeling application.

 Change the bend radius and thickness expressions to the


following values (Tools→Expression):

 R = 3/32
 T = .080

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Sheet Metal Punch

 Create a 14 x 4 x T inch block as your base feature and locate


it at (XYZ=0,0,0).

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Step 2 Create sheet metal flanges.
 Create a bent up flange with the following parameters on the
back edge of the block:
 Tangent Length = .35
 Bend Angle = 30
 Inside Radius = R
 Create a bent down flange on the end of the existing flange
using the following parameters:
 Tangent Length = 5.50
 Bend Angle = 30
 Inside Radius = R
Your part should look like this when you're through:

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Sheet Metal Punch

 Change the work layer to 2 .

 Create a bend up flange on the front face of the part. Use


the following parameters:

 Tangent Length = .25


 Bend Angle = 90
 Inside Radius = .35

ÏÏÏ
ÏÏÏ
7
 Reference Lines = Contour (Under the Options icon)

ÏÏÏ
ÏÏÏ NOTE You'll use the contour line to position future features.

Flange Contour
Line

EDS Unigraphics NX
7-16 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Punch

Step 3 Create sheet metal punches on the flange feature.

 Create and locate two separate 1.00" diameter circles on the


upper face of the flange web surface (Recommend creating a
sketch on layer 21).

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Choose the Sheet Metal Punch icon.

 Select the top face of the flange web as the Placement Face.

 Choose MB2 to advance to the next selection step.

 Select one of the circles as the Placement Outline curve.

 Choose the Options button.

 Adjust the follow:

 Placement Outline = Inside


 Auto Centroid Creation = ON
 Flanged Cutout = OFF

 Choose OK in the Options dialog.

 Change the Top Type to Flat.

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Sheet Metal Punch

 Enter the following size parameters:

 Depth = .125
 Die Radius = .02
 Taper Angle = 0
 Punch Radius =.02

 Choose Apply to create the punch feature.

ÏÏÏ
ÏÏÏ
7
 Create another punch with the same parameters using the

ÏÏÏ
ÏÏÏ
other 1.00" diameter circle. Your part should look like this
when you're through:

Punch placement curves and tool centers invisible for clarity

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7-18 Sheet Metal Design
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Sheet Metal Punch

Step 4 Edit a Sheet Metal Punch feature.


 Create and position the following outline curve on the top
face of the part.

TIP You can create a sketch to contain and position the


curves (use work layer 22).

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Using the curves, create a Sheet Metal Punch feature with


the following parameters:
 Top Type = Flat
 Depth = .21
 Die Radius = R
 Taper Angle = 30
 Punch Radius = R

NOTE Unlike other modeling operations, you must select each


sketch curve individually until the entire profile is
highlighted or drag a selection box around the entire
profile.

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Sheet Metal Punch

 Ensure the Side Vector is pointing inward from the outline, if


not choose Flip Side Vector.

 Choose OK to create the punch.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Punch placement curves and tool center invisible for clarity

 Stretch your curves or edit your sketch and change the length
of the rectangle from 4.00 to 5.00 .

 If you used a sketch, choose the Update Model icon or

simply exit the sketch using the Finish Sketch icon.

EDS Unigraphics NX
7-20 Sheet Metal Design
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Sheet Metal Punch

Step 5 Use the Flanged Cutout option to create a Flanged Hole.


 Make two circles to use as the outlines for a flanged cutout
(sketch on layer 23). Create and locate them as shown below.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Use Flange Contour Line Use Flange Contour Line

TIP If using a sketch, use the contour line, as shown, to


locate the circles.

 Choose the Sheet Metal Punch icon.

 Choose the Options button.

 Ensure the Placement Outline is set to Inside.

 Toggle ON the Flanged Cutout option.

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Sheet Metal Punch

 Choose OK.

 Select the bottom face of the original block as the Placement


Face.

 Choose MB2 to advance to the next selection step.

 Select one circle and create a Sheet Metal Punch feature


with the following parameters:

Depth = .125
ÏÏÏ


ÏÏÏ
7
 Die Radius = .02
ÏÏÏ
ÏÏÏ
 Taper Angle = 0

NOTE A punch radius is not necessary since the floor of the


punch will be pierced by the flanged cutout option.

 Choose Apply to create the punch.

 Repeat the steps for the other circle.

Punch placement curves and tool center invisible for clarity

 Unform your model to test its integrity.

Step 6 Create a punch that crosses the periphery of the part.

 Reform the part.

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Sheet Metal Punch

 Create and locate the curve profile shown below (use work
layer 24).

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Use Flange Contour Line

TIP If using a sketch, use the contour line, as shown, to


locate the curves.

 Choose the Sheet Metal Punch icon.

 Choose the Options button.

 Toggle OFF the Flanged Cutout option.

 Choose OK.

 Select the top face of the base block as the Placement Face.

 Choose MB2 to advance to the next selection step.

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Sheet Metal Punch

 Select the curves and create a Sheet Metal Punch feature


with the following parameters:

 Depth = .25
 Die Radius = R
 Taper Angle = 45
 Punch Radius = R

ÏÏÏ
ÏÏÏ
7
 Ensure the side vector is pointing towards the center of the
outline. If necessary, choose Flip Side Vector.

ÏÏÏ
ÏÏÏ  Choose OK to create the punch.

Punch placement curves and tool center invisible for clarity

EDS Unigraphics NX
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Student Guide All Rights Reserved
Sheet Metal Punch

Step 7 Create a lanced punch.

 Create and locate the curve profile shown below (use work
layer 25).

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Use Flange
Contour Line

TIP If using a sketch, use the contour line, as shown, to


locate the curves.

 Choose the Sheet Metal Punch icon.

 Change the Punch Type to Lance.

 Select the top face of the base block as the Placement Face.

 Choose MB2 to advance to the next selection step.

 Select the three curves as the Placement Outline.

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Sheet Metal Punch

 Choose MB2 to advance to the next selection step.

 Select the vertical line as the Lancing Curve.

 Enter the following parameters:

 Depth = .25
 Die Radius = R
Taper Angle = 45
ÏÏÏ


ÏÏÏ
7  Punch Radius = R
ÏÏÏ
ÏÏÏ  Ensure the side vector is pointing towards the center of the
outline. If necessary, choose Flip Side Vector.

 Choose OK to create the punch.

 Make layer 1 your work layer and all other layers invisible.

 Shade and rotate your model to examine the various


punches.

Step 8 Choose File"Close"Save and Close.

EDS Unigraphics NX
7-26 Sheet Metal Design
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Sheet Metal Punch

SUMMARY The Sheet Metal Punch application allows you


ÏÏÏ
ÏÏÏ
7
to create embossed and coined features on
sheet metal parts.
ÏÏÏ
ÏÏÏ
In this lesson you:
 Applied the Sheet Metal Punch function
using the emboss option.
 Applied Auto Centroid and Flanged cutout
functionality.

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7-27
Sheet Metal Punch

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
(This Page Intentionally Left Blank)

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Sheet Metal Solid Punch

Sheet Metal Solid Punch


Lesson 8

PURPOSE Create and edit sheet metal punch objects using the
Sheet Metal Solid Punch feature.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create a Sheet Metal Solid Punch.

ÏÏÏ
This section contains the following activity:
ÏÏÏ
Activity Page ÏÏÏ
8
ÏÏÏ
8-1 Creating Sheet Metal Solid Punches . . . . . . . . . . 8-9

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Sheet Metal Solid Punch

The Sheet Metal Solid Punch Dialog


Similar in results to the Sheet Metal Punch, the Sheet Metal Solid Punch
feature embosses the shape of a solid tool onto a target sheet metal body. The
solid tool body may cross multiple, adjacent placement faces, including the
formable bend surface of a flange. Solid punches that intersect the periphery of
the part are also valid.

The Sheet Metal Solid Punch's advantage over the Sheet Metal Punch feature
is that you have direct control of what you want the punch to look like based
upon how you model the tool body.

You can access the Sheet Metal Solid Punch dialog from Insert→Sheet Metal

Feature→Solid Punch or from the Sheet Metal Solid Punch icon in the
Sheet Metal Feature toolbar. To edit a Sheet Metal Solid Punch, use
Edit→Feature or the Edit Feature toolbar.

The Sheet Metal Solid Punch dialog steps you through the definition of a target

ÏÏÏ face, tool body (which depicts the punch), transformation (optional) and

ÏÏÏ
selection of pierce faces (optional). As with all selection step type of dialogs,
you can jump to any step of the process and make adjustments before
ÏÏÏ
8
ÏÏÏ
completing the creation of the feature. However, some steps must have their
required inputs specified before you will be allowed to create the feature.

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Sheet Metal Solid Punch

Selection Steps

Target Face

Like other sheet metal features, a target face must be selected for the location
of the Sheet Metal Solid Punch feature. The Target Face defines the direction
in which the punch will be applied to the target body. By default, the solid
punch is applied using the reverse face normals of the target face (see figure
below).

Tool Body

ÏÏÏ
ÏÏÏ
Placement face
ÏÏÏ
8
ÏÏÏ
Placement face

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Sheet Metal Solid Punch

Tool Body

The tool body is a solid body which defines the shape of the punch applied to
the target body. Create a solid tool body using any desired modeling technique.
The tool body may also intersect the periphery of the part (see figure below).

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

Tool Body crossing the periphery

NOTE Currently only punch" type tools can be selected. The


ability to select a die" tool will be available in upcoming
releases.

EDS Unigraphics NX
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Sheet Metal Solid Punch

Transformation

Place the tool body at the desired emboss depth so that it intersects with the
target sheet metal body. Alternately, you can reposition a copy of the tool body
so that it intersects with the target body by selecting the Transformation step.
When selected, you will be prompted to select a CSYS/point on the tool body
(From) and a CSYS/point on the target body (To). The Solid Punch will
transform a copy of the tool body to align the CSYS's. This step is only
necessary if you wish to move a copy of the tool body from its created location.

Pierce Faces

This optional step allows selection of face(s) on the tool body that will be
pierced. These pierced faces allow you to create features such as louvers.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

Pierce face

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Sheet Metal Solid Punch

NOTE Faces which would create openings, such as holes, cannot


be selected because it would cause the tool body to be
split into multiple pieces. If the pierce face(s) selected
cause this condition the following message appears.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

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Sheet Metal Solid Punch

Options

The Options dialog allows access to various creation aids.

Thickness

This option allows you to choose from Infer from Target (default) or Use
ÏÏÏ
Expression. If Use Expression is chosen the Thickness field in the main Solid
ÏÏÏ
Punch dialog will become active for input.
ÏÏÏ
8
ÏÏÏ
Create Auto Centroid

When ON this option will create an automatic tool center point (centroid)
based on a 3D analysis of the tool body. The default setting is ON.

Edge Blend

When ON this option will create edge blends for the inside and outside edges
created as a result of the boolean between the target and tool bodies. The blend
features are created immediately after the solid punch feature and can be
independently edited or deleted. The default setting is ON.

NOTE It is not necessary to enter a value for both Inner and


Outer Radius. If a value is entered in either field, the
system will calculate the opposing radius by taking the
thickness of the target body into consideration.

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Sheet Metal Solid Punch

Construction Tips
 You may find it easier to create the Solid Punch in place where it is to
be applied to the target body, otherwise you will need to create
additional objects (CSYS or points) which would be used in the
Transformation step.
 Solid Punch features may be instanced after creation. If the Edge
Blend option is turned ON and the blends are desired in the arrayed
copies, you must first group the Solid Punch and the two Edge Blends
together. Doing this will ensure all duplicate features have the edge
blends applied as well.
 Consider building a library of standard" punches to be used at your
company. Communicate with your manufacturing group to find the
off the shelf" punches and build a tool body to reflect those punches.
Doing so can significantly cut costs during manufacturing by not
requiring special tooling to be built.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

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8-8 Sheet Metal Design
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Sheet Metal Solid Punch

Activity 8-1: Creating Sheet Metal Solid Punches

In this activity you will apply several different Sheet Metal Solid Punch features
using various creation techniques.

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8
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Step 1 Open the part smd_solid_punch and save it as
xxx_solid_punch, where xxx are your initials. Ensure you
are in the Modeling application.

Step 2 Create a gusset using Solid Punch.

 Make layer 2 selectable.

 Shade a rotate the part to better understand how the tool


body will be applied to the part.

 Turn OFF the Shading and orient the view to Trimetric.

 Choose the Sheet Metal Solid Punch icon.

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Sheet Metal Solid Punch

 Select the outside bend face as the Target Face.

Bend outer
face

 Choose MB2 to advance to Tool Body.

 Select the green solid as the tool body and accept if


necessary.

 Choose the Options button.

ÏÏÏ  Turn OFF the Create Auto Centroid option.

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8
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 Ensure Edge Blend is toggled ON.

 In the Inner Radius field, enter a value of R and choose OK.

 Ensure Blank the tool body is toggled ON and choose Apply.

Step 3 Create an instance of the gusset.

 Open the Model Navigator.

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Sheet Metal Solid Punch

 Using the Ctrl key, select the SOLID_PUNCH and the two
BLEND features below the Solid Punch.

 With all three features highlighted, place your cursor over


one of the features and press MB3.

 Choose Group...

The Sets of Features dialog becomes available.

 At the top of the dialog, enter GUSSET for the Feature Set
Name.

 At the bottom of the dialog turn ON the Hide Feature Set


Members and choose OK.

 Open the Model Navigator.

Notice the three features have been replace by a single


feature named GUSSET.
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 Choose the Instance icon.
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8
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 Choose Rectangular Array.

 Select the GUSSET feature from the list and choose OK.

 Enter the Parameters for the Instance as shown below:

Method General
Number Along XC 1
XC Offset 0
Number Along YC 2
YC Offset 5

 Choose OK.

Step 4 Create a Louver using the pierce faces option.

 Make layer 3 selectable and 2 invisible.

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Sheet Metal Solid Punch

 Shade a rotate the part to better understand how the tool


body will be applied to the part.

 Turn OFF the Shading and orient the view to Trimetric.

 Choose the Sheet Metal Solid Punch icon.

 Select the top face as the Target face.

 Choose MB2 to advance to Tool body.

 Select the green solid as the tool body and accept if


necessary.

 Choose the Pierce faces icon.

ÏÏÏ  Select the flat front face as the Pierce face as choose OK.
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8
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Pierce face

 Shade and rotate to examine the solid punch.

Step 5 Create an instance of the louver.

 Open the Model Navigator.

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Sheet Metal Solid Punch

 Using the Ctrl key, select the SOLID_PUNCH and the two
BLEND features below the Solid Punch.

 Create a group named LOUVER and Hide the Feature Set


Members.

 Choose the Instance icon.

 Choose Rectangular Array.

 Select the LOUVER feature from the list and choose OK.

 Enter the Parameters for the Instance as shown below:

Method General
Number Along XC 1
XC Offset 0
Number Along YC 6
YC Offset 1 ÏÏÏ
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 Choose OK. ÏÏÏ
8
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Step 6 Create a rectangular solid punch.

 Make layer 4 selectable and 3 invisible.

 Shade a rotate the part to better understand how the tool


body will be applied to the part.

 Turn OFF the Shading and orient the view to Trimetric.

 Choose the Sheet Metal Solid Punch icon.

 Select the bottom face as the Target face.

 Choose MB2 to advance to Tool body.

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Sheet Metal Solid Punch

 Select the green solid as the tool body and accept if


necessary.

 Choose Apply to create the Solid Punch.

 Shade and rotate to examine the solid punch.

Step 7 Create a solid punch and use transformation to locate it.

 Make layers 5 and 10 selectable and 4 invisible.

 Turn OFF the Shading and orient the view to Trimetric.

Notice the CSYS associated to the conical punch tool body


and the CSYS located on the target body.

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8
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 Choose the Sheet Metal Solid Punch icon.

 Select the bottom face as the Target face.

 Choose MB2 to advance to Tool body.

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Sheet Metal Solid Punch

 Select the green solid as the tool body.

Since the tool body does not intersect the target body the
following message appears.

 Choose OK to the warning message.

 Choose MB2 to advance to Transformation.

The Cue line prompts you to select a from" csys/point and a


to" csys/point.

 Choose the CSYS on the Tool body (green solid) as the ÏÏÏ
FROM CSYS. ÏÏÏ
 Choose the CSYS on the Target body as the TO CSYS.
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8
ÏÏÏ
 Choose Apply to create the solid punch.

NOTE A copy of the tool body was transformed into place to


create the solid punch. This is done for every solid punch
feature, even if the location of the punch tool is already
defined. Unblanking the tool will reveal the original tool
body.

 Choose Edit→Blank→Unblank All of Part.

 Make layers 5 and 10 invisible.

Step 8 Choose File"Close"Save and Close.

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Sheet Metal Solid Punch

SUMMARY The Sheet Metal Solid Punch allows you to


create embossed and features on sheet metal
parts.

In this lesson you:


 Applied the Sheet Metal Solid Punch
function using the punch option.

ÏÏÏ  Applied pierce face functionality.


ÏÏÏ
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8
ÏÏÏ
 Created rectangular arrays of grouped
features.

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Sheet Metal Hole and Sheet Metal Slot

Sheet Metal Hole and Sheet Metal Slot


Lesson 9

PURPOSE To see the advantage to creating hole features in a


sheet metal part using the Sheet Metal Hole feature.
As well as to create slots on formable features using
the Sheet Metal Slot feature.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create and edit holes in both a formed and


unformed sheet metal part.
 Create a hole through multiple sheet thicknesses
 Locate a sheet metal hole using an expression
 Create and orient a Sheet Metal Slot

This section contains the following activity:

Activity Page
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9
9-1 Creating Sheet Metal Holes . . . . . . . . . . . . . . . . . . 9-11
9-2 Creating Sheet Metal Slots . . . . . . . . . . . . . . . . . . . 9-29 ÏÏÏ

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Sheet Metal Hole and Sheet Metal Slot

The Sheet Metal Hole Dialog


The Sheet Metal Hole feature enables you to place a hole on any type of face.
When placed on a flange, the Sheet Metal Hole features are capable of forming
and unforming with the flange. Sheet Metal Holes may completely or partially
cross one or more bend areas, and can be used to create simple bend reliefs.
Sheet Metal Holes will distort when the state of the sheet metal part changes
from the original creation state.
You can access the Sheet Metal Hole dialog from Insert→Sheet Metal

Feature→Hole or by selecting the Sheet Metal Hole icon from the Sheet
Metal Feature toolbar. To edit a Sheet Metal Hole, use Edit→Feature or the
Edit Feature toolbar.

Positioning
Creation Method
Selection
Steps

Hole Types

Size
Parameters

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9
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Hole Positioning Methods


The Sheet Metal Hole feature has the unique ability to be located on a
placement face using two different positioning methods. Like the Modeling
Hole feature, you can use positioning dimensions to locate the hole center point
from other features of the part.

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Sheet Metal Hole and Sheet Metal Slot

To use the positioning method, the Method option on the Sheet Metal Hole
dialog must be set to Positioning.

The system will use the selected placement face as the reference plane for the
positioning dimensions. If this face is nonĆplanar, you must select another
planar face as the reference plane. When the placement face and the reference
plane are different, the hole center point will be projected along a vector
normal to the reference plane and onto the placement face.

You may also elect to locate the hole on a nonĆplanar surface using the Edge
Offsets option. With this placement option, the location of the hole is
determined by positive or negative offset distances from two intersecting face
edges which are attached to the selected placement face.

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Sheet Metal Hole and Sheet Metal Slot

Selection Steps

The Sheet Metal Hole dialog is a Selection Steps type of dialog. The icons at the
top of the dialog are selectable, and will highlight as you step through the
process of placing and creating the Sheet Metal Hole.

Placement Face Direction Vector

Through Face Positioning Edge 2

Positioning Edge 1

Placement Face

Upon entering the Sheet Metal Hole feature creation function, the first
selection step to highlight is the Placement Face. This step prompts you to
select a single face on the body of the part on which you wish to place the hole.
The top of the hole follows the contours of this face. The pick point on the face
is used to calculate a default starting position for the hole center point.

ÏÏÏ Through Face


ÏÏÏ
9
ÏÏÏ Sheet Metal Hole can place a hole through more than one set of solid faces.
The Through Face step prompts you to select the last face on the opposite side
of the body from the placement face. The far edge of the last hole will follow
the contours of this face.

NOTE The Through Face selection step is only active when the
hole type is set to Through.

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Sheet Metal Hole and Sheet Metal Slot

Positioning Edge 1 & Positioning Edge 2

When the positioning method is set to Edge Offsets, these selection steps
become active. The positioning edges are used to position the hole center point.
These edges must be edges on the placement face and they must intersect with
each other. Upon selecting each edge, a conehead vector will display on the
edge, indicating the direction of a positive offset.

NOTE If a curved edge is chosen as a positioning edge, the offset


distance may be an arc extension. This can create
confusion in determining which arc and edge intersection
point is the desired location. ReĆorienting your view can
help alleviate mislocating the origin point.

Once positioning edges are selected, edge offset values can be entered into the
Edge 1 Offset and Edge 2 Offset fields. These values can be either positive or
negative and will be used to place the hole center point into, or outside of, the
placement face. There is no sequence order that must be followed, so any edge
may be chosen as the first or second positioning edge.

Direction Vector

The Direction Vector allows you to select a direction other than Face Normal to
define the axis of the Sheet Metal Hole. This option is only available when the
Face Normal Direction option is toggled OFF in the Sheet Metal Hole dialog. ÏÏÏ
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9
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Sheet Metal Hole and Sheet Metal Slot

Vector Method

The Vector Method allows you to select a way to define the vector you will use
for the axis of the Sheet Metal Hole when Face Normal Direction is toggled
OFF. This will appear in the Sheet Metal Hole dialog after you select the
Direction Vector selection step.

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9
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Sheet Metal Hole and Sheet Metal Slot

Hole Types

There are three different hole types; Punch, Through, and Depth.

The Punch option creates a hole on the placement face which extends along the
direction vector to the nearest face. That is, it extends through the thickness of
the part. This hole type only requires the identification of an attachment face, a
position location, a diameter size, and a direction vector.

The Through hole type requires the same parametric information as the Punch
hole, but also requires the identification of the through face.

NOTE The diameter, position and orientation of through Holes


are associative to the first (or master) Hole. If you edit
any one of them, they will all change per your inputs.

Concentric, positionally and orientationally


associated sheet metal Through holes

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9
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Sheet Metal Hole and Sheet Metal Slot

The Depth hole type is fundamentally the same as the Punch hole type but you
can specify a depth and tip angle parameter for the hole geometry.

NOTE Unlike the Punch and Through holes, the Depth hole
currently does not distort when its placement face
changes its formed state.

Hole Diameter

Depth

Tip Angle

Size Parameters

The diameter and depth dimension are specified in the units of the existing part
(English or Metric). The Depth and Tip Angle parameters are only active when
the Depth hole type has been selected. Since a Depth hole may be placed on a
nonĆplanar surface with a nonĆnormal orientation, the actual depth of the sheet
metal hole with respect to the surrounding faces may vary. The depth value
defines the distance along the direction vector from the placement face center
point to the bottom of the hole.
ÏÏÏ
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9 The Tip Angle is added to the depth value of a hole. The tip angle value must
ÏÏÏ be greater than or equal to zero, but less than 180 degrees. A zero tip angle
value results in a flat end (blind) hole.

Face Normal Direction

When Face Normal Direction is toggled ON, the axis of the Sheet Metal Hole
will align normal to the placement face. If you prefer to define a specific vector
for this axis, turn this toggle OFF and use the Direction Vector selection step to
define a new vector.

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Sheet Metal Hole and Sheet Metal Slot

Editing Sheet Metal Holes

When an Sheet Metal Hole is first created, the state of the part (formed or
unformed) is stored in the system and an undistorted hole is produced. Because
the sheet metal hole can be distorted by its underlying placement face, it is
important to place the model in this original creation state before editing its
geometric or positional parameters.

The system has a builtĆin warning mechanism that alerts the user whenever an
attempt is made to edit hole parameters while the model is in a different
formed state.

NOTE This mechanism is only available when you use the Edit
Feature operation. Editing a feature's parameters by
changing its expression value will bypass this warning
mechanism and may generate erroneous results. It is
imperative that all edits be accomplished through the
Edit Feature operation.

If you proceed with your edits despite the warnings, the system will reset the
holes creation state to the existing model state and an undistorted Sheet Metal
Hole will be created once the edits are accepted.

Editing Hole Positional Parameters

Depending on how the hole was originally positioned, different Edit Feature
operations must be used. ÏÏÏ
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9
If the Edge Offsets method was used to locate the hole, you must use the Edit
Parameters operation to modify the offset values for the hole. If Positioning
ÏÏÏ
dimensions were used to locate the hole, the Edit Positioning operation can be
used to add, modify, or delete positioning dimensions.

If you wish to convert from one location method to another, first use the Edit
Parameters operation to change the location Method, then proceed in the
normal manner required to define the new location.

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Sheet Metal Hole and Sheet Metal Slot

Hole Conversion

To help create multiple, associated sheet metal holes, you can now convert
simple Modeling holes and instances of simple Modeling holes into sheet metal
holes. Access this function through Edit→Feature→Parameters. Select the
SIMPLE_HOLE feature and choose OK. Then select Change Type in the
second Edit Parameters dialog.

Converted holes are named SMD_SIMPLE_HOLE and behave like Sheet


Metal Hole features with RPO dimensions. Sheet metal holes created in this
manner have all the properties of the original Hole feature, plus the
deformation capability of Sheet Metal Holes.

NOTE If you convert an instance of a Hole, the whole instance


set, including the master instance, is converted.

The state of every instance in an instance set matches the state of the master
instance. Therefore, all instances in an instance set form and unform together.
Their distorted forms may differ depending on their location on the part.

NOTE Because hole instances depend on the master instance to


dictate their formed state, instance sets must be limited to
like faces. That is, if the master instance is placed on a
bend surface, then all instances of the array should
remain on the bend surface, or their formed state will be
misrepresented (e.g. if an instanced hole falls entirely on
a planar face, it would be constructed using a BĆsurface).
ÏÏÏ Currently, we recommend creating separate arrays for
ÏÏÏ
9 bend areas and planar faces.
ÏÏÏ
Finally, any Modeling hole converted to a sheet metal hole can be reverted back
to a Modeling hole using the same Edit→Feature→Parameters ... Change Type
operation. However, Sheet Metal Holes cannot be converted to Modeling holes.

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Sheet Metal Hole and Sheet Metal Slot

Activity 9-1: Creating Sheet Metal Holes

Step 1 Create a simple sheet metal hole.

 Open the part smd_smhole.

 Make sure you're in the Modeling application.

 Open the Sheet Metal Preferences dialog.

 Toggle ON Use Feature Standards and Enforce Creation


State Editing.

 Choose OK to accept the preference settings.

 Select the Form/Unform icon.

 Choose the Unform All button to unform the part.

 Select the Sheet Metal Hole icon.

 First, make sure the hole locating Method is set to


ÏÏÏ
Positioning and the hole Type is set to Punch.
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9
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NOTE You can create a simple Sheet Metal Hole using any of the
sheet metal hole types. However, it's important to use the
appropriate hole type for the design. In this case, if you
specify a Through hole type when Punch will suffice, you
may encounter unnecessary modeling errors later on.

Notice that the first selection step icon is highlighted and the
Cue line is prompting you to select a placement face.

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Sheet Metal Hole and Sheet Metal Slot

 Select the right center bend segment.

Select this face

 Change the Diameter value to 2.00 .

 Choose MB2 (or Apply) to move to the next selection step.

 Select the Perpendicular icon.

 Select the front edge of the part as the first positioning edge.

Select this
edge first

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9
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 Enter 13.875 and choose MB2.

 Select the Perpendicular icon again.

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Sheet Metal Hole and Sheet Metal Slot

 Select the back outside edge of the face next to the


placement face as the tool edge.

Select this edge


second

 Enter 1.50 and choose MB2.

The simple sheet metal hole is created.

Step 2 Check the hole deformation.


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9
 Reform the part using the Form/Unform icon. ÏÏÏ

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Sheet Metal Hole and Sheet Metal Slot

Notice the deformation of the hole in the formed state.

Step 3 Edit the hole.


Try to edit the hole parameters without placing the part in the
original creation state of the hole.

 Select the Edit Feature Parameters icon.

 From the Edit Parameters dialog, select the


SIMPLE_SMHOLE feature.

 Choose OK.

A warning message is displayed because the model is not


currently in the hole creation state.

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9
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 Choose OK to exit the warning message.

Step 4 Disable the hole creation preference.


Although it's good practice to leave the Enforce Creation State
Editing option on, let's turn this option off and edit the hole.

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Sheet Metal Hole and Sheet Metal Slot

 Go to the Sheet Metal Preferences dialog and toggle the


Enforce Creation State Editing option OFF.

 Choose OK.

 In the Edit Parameters dialog, select the SIMPLE_SMHOLE


feature, again.

 Choose OK.

The warning message presented now gives you the option of


modifying the hole in the current model state, unforming the
model to the original creation state, or canceling the operation.

 Choose the Snap To Creation State button. Your model will


only unform the flanges affected by the Sheet Metal Hole
feature.

If you select the Yes option, the system will reĆcreate an


undeformed hole and apply it to the flange in its current formed
condition. This would become the new creation state of the hole
and deformation would only show in the unformed model state.

ÏÏÏ
This was not the original design intent of the hole.

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9
ÏÏÏ

 In the Diameter field, change the value to 1.00 .

 Choose MB2 twice to accept the change and close the dialog.

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Sheet Metal Hole and Sheet Metal Slot

 Now form the part again to review the change.

NOTE In some cases, if you encounter an error while editing a


sheet metal hole, it may be necessary to delete the
existing hole and then recreate it with the revised
parameters.

Step 5 Create a Through hole.


 Rotate your work coordinate system 105 in the +ZC Axis
direction.

 Activate the Sheet Metal Hole dialog.

 Change the hole Method to Edge Offsets and the hole Type
to Through.

 Select the nearest face of the part as the placement face.

ÏÏÏ Choose MB2 to move to the next selection step.


ÏÏÏ

9
ÏÏÏ Select this
face as the
placement
Select the back
face
face as the
Through face

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Sheet Metal Hole and Sheet Metal Slot

 Select the far side of the middle face as the Through face.

 Choose MB2 to advance to the next step.

 Select the top edge of the first face as the first positioning
edge.

TIP Use the Shift key and MB1 to deselect any edge
chosen by mistake.

 Set the Edge 1 Offset to 3.00 .

 Choose MB2 to advance to the next step.

 Select the near side edge as the second positioning edge.

First
positioning
edge

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9
Second
ÏÏÏ
positioning edge

 Set the Edge 2 Offset to 1.00 .

 DoubleĆclick MB1 in the Diameter field and change it to .50 .

 Turn OFF the Face Normal Direction option.

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Sheet Metal Hole and Sheet Metal Slot

 Select the Direction Vector icon in the Sheet Metal Hole


dialog. (See diagram below.)

 Choose the Inferred Vector button and select the YC Axis


option.

1 Select the Direction


Vector icon
2 Select the Inferred
Vector button

3 Select the
YC Axis option

 Choose OK to create the feature.

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9
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Sheet Metal Hole and Sheet Metal Slot

 Unform the part and review the geometry.

If you check the feature list of the part (Information→Feature),


you would notice that two separate SIMPLE_SMHOLE features
were created, one for each part intersection point. If you edit
either of the holes, both holes will change accordingly (size,
location and vector direction).

Step 6 Create and position a Modeling Hole.

 Reform your part.

 Reorient your WCS to the Absolute CSYS.

 Select the Hole icon in the Form Feature palette.

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9
 Select the Simple hole icon.
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Sheet Metal Hole and Sheet Metal Slot

 Select the front face of the nearest flange as the placement


face.

 Select the opposite face of the flange as the Thru Face.

Select the
Select this back face as
face as the the Thru Face
placement
face

 Make sure the Diameter is set to 1.00 and choose MB2.

 Position the hole center 1.50 inches from the side of the part.

TIP To avoid selecting a horizontal reference orientation,


use the Perpendicular positioning method to specify
both the horizontal and vertical dimensions.

 Using the bottom edge of the part, position the hole 3 inches
vertically.
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9
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Select this line

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Sheet Metal Hole and Sheet Metal Slot

 Check the distance between the top edge of the flange and
the hole center point. (Use Analysis→Distance from the
menu bar.)

 Now unform the part.

 Check the distance again between the hole center point and
the top edge of the face.

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9
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Sheet Metal Hole and Sheet Metal Slot

Because the hole is located from an edge other than a


placement face edge, the hole position on the flange will
relocate in order to maintain its vertical (or perpendicular)
positional parameter.
To avoid this flat pattern error, make sure you use static
placement face edges to position your modeling hole.

 Reform your part.

 Select the Edit Positioning icon.

 Select the SIMPLE_HOLE feature from the Edit Positioning


dialog.

 Choose MB2.

 Delete the existing vertical dimension.

 Select the SIMPLE_HOLE feature again and choose MB2.

 Choose Add Dimension.

 Select the Perpendicular icon.

 Select the bend tangent line of the flange placement face as


ÏÏÏ the target object.
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9
ÏÏÏ
Select this
edge

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Sheet Metal Hole and Sheet Metal Slot

 Choose Identify Solid Face.

 Select the cylindrical face of the hole as the tool face and
accept the choice.

 In the Create Expression dialog, insert the following


expression:
3-br-thk

 Choose MB2 four times to relocate the hole.

 Check the distance of the hole center point to the top edge
of the placement face.

 Unform the part and check the distance again. The hole is
now positioned properly.

Step 7 Try using the Modeling Hole feature to create a hole


through all three flanges. What happens when you try to
unform the part?

Step 8 Close your part. Do not save.

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9
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Sheet Metal Hole and Sheet Metal Slot

The Sheet Metal Slot Dialog

The Sheet Metal Slot feature, like the Sheet Metal Hole feature, will allow you
to place a slot feature on and through any type of planar and nonĆplanar
formable face. Sheet Metal Slots may completely or partially cross one or more
bend areas, and will distort when the underlying placement face changes shape.
Currently, the Sheet Metal Slot feature only allows for the creation of an
obround perimeter.

You can access the Sheet Metal Slot dialog from Insert→Sheet Metal

Feature→Slot or from the Sheet Metal Slot icon in the Sheet Metal
Feature toolbar. To edit a Sheet Metal Slot, use Edit→Feature or the Edit
Feature toolbar.

Creation
Selection
Steps Positioning
Method

Slot Types

Size
Parameters

ÏÏÏ
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9
ÏÏÏ

The Sheet Metal Slot dialog functions in the same manner as the Sheet Metal
Hole dialog. The icons across the top of the dialog represent the discrete steps
you must take to create and locate the sheet metal slot.

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Sheet Metal Hole and Sheet Metal Slot

Creation Selection Steps

The Sheet Metal Slot dialog is a Selection Steps type of dialog. The icons at the
top of the dialog are selectable, and will highlight as you step through the
process of placing and creating the Sheet Metal Slot.

Orientation
Vector
Placement Face

Through Face Direction Vector

Positioning
Positioning
Edge 2
Edge 1

Orientation Vector

The Orientation Vector allows you to select a vector to define the direction of
the length of the Sheet Metal Slot. The slot feature is associative to the
orientation vector. Therefore, if the vector used to define the orientation vector
changes, the slot will change its orientation to match the new vector.

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9
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Sheet Metal Hole and Sheet Metal Slot

Size Parameters
The Sheet Metal Slot feature has three size parameters; Length, Width, and
Depth. The Depth parameter is only available when the Depth slot type is
selected. All input values for the size parameters are specified in the units of
the existing part (English or Metric), and all must be positive values.

Note that the Length is measured


from arc tangent to arc tangent

Slot Conversion

You can convert a Modeling Slot to a Sheet Metal Slot using the same
procedure as to convert a Modeling Hole to a Sheet Metal Hole. This is useful
to show slot deformation in a bend segment of your part when you have an
array of slots.

Slot Positioning Methods


ÏÏÏ
ÏÏÏ
9 Sheet Metal Slots, like Sheet Metal Holes, can be positioned either from the

ÏÏÏ edges of the placement face, or through the use of positioning dimensions.

The origin of the slot when using Edge Offsets to position the feature is defined
at the exact center.

Slot Origin

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Sheet Metal Hole and Sheet Metal Slot

To position a slot using the Positioning method, the Method option on the Sheet
Metal Slot dialog must be set to Positioning.

When using the Positioning method, you should specify the feature parameters
then select the OK or Apply button. You are then given the chance to add
Positioning Dimensions to the feature. If the Placement Face is nonĆplanar, you
must select a face (or datum plane) to serve as a reference plane for the RPO
dimensions. For the Slot, the Positioning dimensions can be referenced to any
of the Slot's tool edges including the additionally generated centerlines on the
reference plane. If the Placement Face and the reference plane are different,
the Slot position will be projected along a vector normal to the reference plane
and onto the Placement Face.

In the Edge Offset mode, the location of the slot center is determined by
positive or negative offset distances from two intersecting face edges which are
attached to the selected placement face.

Like the Sheet Metal Hole feature, when editing the position of a slot, make
sure to use the appropriate editing operation for the given positioning method.

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EDS
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Sheet Metal Design
Student Guide
9-27
Sheet Metal Hole and Sheet Metal Slot

Construction Tips
 Because data is maintained about their creation state, it is important
to place the model in the original creation state (formed or unformed)
before editing the hole. Make sure you use the Edit Feature operations
to insure that hole edits are implemented correctly.
 Before converting Modeling holes or slots into Sheet Metal Holes or
Slots, make sure no object references such as dimensions or mating
conditions are tagged to the original hole. Once converted, the Sheet
Metal Hole or Slot can vary its shape and reference objects may loose
their constraints.
 If Modeling Holes or Slots are used on flange web surfaces they must
be properly constrained from static placement face edges.
 Currently, you cannot create sheet metal holes or slots on sheet
bodies.
 Both the Sheet Metal Hole and Sheet Metal Slot features have a
builtĆin warning mechanism that alerts the user whenever an attempt
is made to edit their parameters while the model is in a different
formed state. Remember that this mechanism can be affected by the
Enforce Creation State Editing option in the Sheet Metal Preference
dialog.
 To avoid corrupting the original design intent of your hole or slot
features, you may wish to prevent ANY hole or slot edits from
occurring until the model is placed in its original creation state. This
may be accomplished by toggling the Enforce Creation State Editing
option ON in the Sheet Metal Preferences dialog.

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EDS Unigraphics NX
9-28 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Hole and Sheet Metal Slot

Activity 9-2: Creating Sheet Metal Slots

Step 1 Create a slot on a bend surface.

 Open the part smd_smslot.

 Make sure you're in the Modeling application.

 Unform the part using the Form/Unform icon .

 Select the Sheet Metal Slot icon.

 Make sure the Method is set to Edge Offsets and the Type is
set to Punch .

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EDS
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Sheet Metal Design
Student Guide
9-29
Sheet Metal Hole and Sheet Metal Slot

 Select the first bend face of the back flange as the placement
face.

 Use MB2 to move to the next selection step.

 Select the near edge of the face as the first positioning edge.

 Enter 2.50 in the Edge 1 Offset field.

 Use MB2 to move to the next selection step.

 Select the bend tangent line as the second positioning edge.

 Enter .15 in the Edge 2 Offset field.

Select this face as


the placement
Second face
positioning edge

First positioning
edge

ÏÏÏ
 Insert the following values:

ÏÏÏ
9 Length = 2.50
ÏÏÏ


 Width = .50

TIP Use the Tab key to cycle through the input fields.

EDS Unigraphics NX
9-30 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Hole and Sheet Metal Slot

 Select the Orientation Vector Selection Step.

 Select an edge parallel to the YC Axis of the WCS.

 Choose MB2 to create the slot.

 Reform the part and inspect the slot distortion.

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EDS
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Sheet Metal Design
Student Guide
9-31
Sheet Metal Hole and Sheet Metal Slot

Step 2 Create a partial slot.

 Unform your part.

 Return to the Sheet Metal Slot creation dialog.

 Select the second bend face of the back flange as the


placement face.

 Use MB2 to move to the next selection step.

 Select the near edge of the face as the first positioning edge.

Select this face as


the placement face

First positioning
edge

 Enter 2.50 in the Edge 1 Offset field.

 Use MB2 to move to the next selection step.

 Select the top bend tangent line as the second positioning


ÏÏÏ edge.
ÏÏÏ
9
ÏÏÏ Second positioning
edge

EDS Unigraphics NX
9-32 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Hole and Sheet Metal Slot

 Enter .625 in the Edge 2 Offset field.

 Use MB2 to move to the next selection step.

 Select an edge parallel to the XC Axis of the WCS.

 Insert the following parameters:

 Length = 1.50
 Width = .25

 Be sure the Face Normal Direction option is ON.

 Choose MB2 to create the slot.

 Reform and examine your part.

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Step 3 Close your part. Do not save.

EDS
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Sheet Metal Design
Student Guide
9-33
Sheet Metal Hole and Sheet Metal Slot

SUMMARY The Sheet Metal Hole application creates holes


that will move respectively with formed and
unformed flanges and distort if located on bend
areas. The Sheet Metal Slot application creates
slots that will move respectively with formed
and unformed flanges and distort if located on
bend areas.

In this lesson you:


 Created and Edited Sheet Metal Holes
 Used the Through option to create multiple
holes quickly.
 Learned the proper way to locate regular
Modeling Features (i.e.: Hole, Slot, Pad,
Pocket and Boss).
 Created and oriented sheet metal slots
through bend areas of formable features.

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EDS Unigraphics NX
9-34 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

Sheet Metal Cutout


Lesson 10

PURPOSE To create cutout profiles on sheet metal parts which


will distort with the underlying surface.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create a Sheet Metal Cutout feature.

This section contains the following activity:

Activity Page
10-1 Creating Sheet Metal Cutouts . . . . . . . . . . . . . . . . 10-9

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EDS
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Sheet Metal Design
Student Guide
10-1
Sheet Metal Cutout

Sheet Metal Cutout

In many sheet metal parts there is a need for userĆdefined cutout patterns
which form, unform, and distort with the underlying surface. The Sheet Metal
Cutout feature was created for this application.

With this feature, a series of contiguous curves depicting the cutout profile are
used to punch completely through the part body in a Face Normal or
userĆspecified direction. These curves, which are associative to the resultant
cutout profile of the part, can be a closed or open loop shape. The ends of an
open loop profile must intersect or extend beyond the existing periphery of the
part. The curves can either be a standĆalone set of curves or they can be
contained within a sketch.

Open cutout profile


Open cutout
profile

Closed cutout
profile

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EDS Unigraphics NX
10-2 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

The Sheet Metal Cutout Dialog

When you choose the Sheet Metal Cutout icon from the Sheet Metal
Feature toolbar, the Sheet Metal Cutout dialog is displayed. You can also access
this dialog upon selecting Insert→Sheet Metal Feature→Cutout. To edit a Sheet
Metal Cutout, use Edit→Feature or the Edit Feature toolbar.

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EDS
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Sheet Metal Design
Student Guide
10-3
Sheet Metal Cutout

Selection Steps

The Sheet Metal Cutout dialog is a Selection Steps type of dialog. The icons at
the top of the dialog are selectable, and will highlight as you step through the
process of placing and creating the Sheet Metal Cutout.

Placement Face Direction Vector


Through Face Outline

Placement Face

The placement face is the main face onto which the outline curves will be
projected. Additional faces through which the cutout outline will pass are
automatically identified by the system during the cutout creation process.

Once this placement face is selected, a conehead vector displays which shows
the direction by which the outline curves will be projected onto and through the
body of the part. You can reverse this projection vector, or you may specify a
new one. If you choose to apply the curves along a userĆdefined vector, you will
automatically be prompted to specify that vector.

Through Face

Sheet Metal Cutout can place a cutout through multiple sections on one solid
body. The Through Face step prompts you to select the last face on the opposite
side of the body from the placement face.

ÏÏÏ
ÏÏÏ NOTE The Through Face selection step is only active when the
10
ÏÏÏ
ÏÏÏ
cutout type is set to Through.

EDS Unigraphics NX
10-4 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

Outline

This step allows you to select a contiguous (i.e. connected endĆtoĆend) set of
curves to use as the cutout outline. The outline curves are associated to the
cutout so when they are edited the cutout will update along with it.

NOTE When the curve profile is edited it will be reĆprojected


onto the placement face(s). Therefore, it is important to
change the curves only after the part has been placed in
the original creation state (formed or unformed). Failure
to do this may cause the curves to project onto different
faces or miss the solid body altogether during the update
sequence.

Direction Vector

The Direction Vector step becomes available if the Project option is set to Along
Vector. This lets you choose a direction other than Normal to Curves or Face
Normal for projecting the outline onto the placement face. This is also the
direction the curves will cut through the target body. When the Direction vector
selection step is active, the Vector Method option appears in the selection
window.

NOTE The cutout feature is associative to the Direction Vector.


If the vector used to define the Direction Vector changes,
the cutout will change its orientation to match the new
vector.

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EDS
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Sheet Metal Design
Student Guide
10-5
Sheet Metal Cutout

Flip Discard Region

Once the curves are selected, the system displays another vector indicating the
region to be discarded from the part. You may reverse this region by selecting
the Flip Discard Region button.

Type

There are two types of Sheet Metal Cutouts: Punch and Through.

Punch is the default and requires you to specify a placement face and an
outline. A Punch cutout pierces one thickness of a solid body.

A Through cutout requires you to specify a placement face, an outline and a


second face. The second face or Through face is the end of the cutout opposite
to the placement face. A Through cutout pierces all faces in its path between
the placement face and the through face. Each cutout section created during
the creation process is associative to the curves selection in the Outline
selection step.

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EDS Unigraphics NX
10-6 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

Project
Use this option menu to decide how you want to project the curves onto the
target body.

The default method, Normal to Curves, uses a vector normal to the plane of the
Outline curves as the projection vector.

Along Face Normals projects the curves normal to all of the faces of the target
body that have smooth connection to the Placement Face.

The Along Vector method works along with the Direction Vector selection step.
This method allows you to explicitly define the vector you want to use.

Vector Method
The Vector Method allows you to choose a way to define the vector you will use
for the axis of the Sheet Metal Cutout when you are not using Normal to
Curves or Face Normals. This option will appear in the Sheet Metal Cutout
dialog after you choose the Direction Vector selection step.

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EDS
All Rights Reserved
Sheet Metal Design
Student Guide
10-7
Sheet Metal Cutout

Construction Tips
 When using open cutout profiles which terminate at the edge of the
part, we recommend you extend the ends of the profile beyond the
edge of the part. When the cutout profiles end tangent to the part,
extend the profile with short lines oriented ninety degrees to the
tangency point.
 If a sketch is used to constrain the cutout profile, use a plane other
than the face of a formable flange to contain the sketch. When the
placement face forms and unforms, an attached sketch will
automatically update. This will cause the Sheet Metal Cutout feature
to update and projection problems may result.
 Sheet Metal Cutouts that contain linear or circular (arc) segments will
produce Trimmed Planar and Cylindrical surfaces upon creation. The
Trimmed Planar surfaces are generated only by lines in the cutout
profile, therefore those planar surfaces do support the addition of
other modeling features (e.g. flanges). The edges created by the linear
segments can also be used as position edges for other modeling
features. Edges created by arcs can also be referenced by positioning
dimensions and can be dimensioned in the drafting application. This is
an enhancement over previous versions of the software.
 Any nonĆlinear or non-circular curves (e.g. splines) create BĆsurfaces
upon creation of the cutout. Minor difficulties can occur when trying
to dimension the BĆsurfaces in the Drafting application.

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EDS Unigraphics NX
10-8 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

Activity 10-1: Creating Sheet Metal Cutouts

In this activity you'll add cutouts to the box you created in the Flange lesson.

Step 1 Create the cutout profile.

 Open the part smd_cutout.

 Unform the front flange of the part.

Unform
this flange

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EDS
All Rights Reserved
Sheet Metal Design
Student Guide
10-9
Sheet Metal Cutout

Step 2 Create a sketch on the right side flange to be used for a


through cutout.

 On layer 22, create a sketch on the right side flange.

Select here for your


horizontal reference

Select this face as


the placement face

 Create and locate the profile to the dimensions shown below.

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EDS Unigraphics NX
10-10 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

Step 3 Create the through cutout.

 Choose the Sheet Metal Cutout icon.

 Change the Type option to Through.

 Select the right side as the Placement Face.

Select this face as


the through face

Select this face as


the placement face

 Click MB2 to advance to the Through Face selection step.


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10
 Select the far left face as the Through Face. ÏÏÏ
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Sheet Metal Design
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10-11
Sheet Metal Cutout

 Click MB2 to advance to the Outline selection step.

 Select the rectangle as the Outline.

TIP You can drag a window around the desired curves to


make the selection process easier.

 Ensure the Discard Region is pointing towards the center of


the outline. If necessary, choose the Flip Discard Region
button.

 Choose OK to create the cutout. Form the flanges and


review your part. What type of surfaces were created for the
cutout?

Step 4 Add a cutout to the joggled end on the left side of your
part.

ÏÏÏ
ÏÏÏ  Unform the part.
10
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EDS Unigraphics NX
10-12 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

 Make layer 21 selectable to reveal a sketch created to split


the left joggled flange.

 Choose the Sheet Metal Cutout icon.

 Change the Type back to Punch.

 Select any face of the part that lies within the cutout outline.

 Click MB2 to advance to the Outline selection step.

 Select the curves and the Outline.

NOTE Only lines that cross the surfaces you cut through are
needed for the cutout profile.

This line may be selected, but is


not needed for the cutout profile.

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EDS
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Sheet Metal Design
Student Guide
10-13
Sheet Metal Cutout

 Ensure the Discard Region is pointing towards the center of


the outline. If necessary, choose the Flip Discard Region
button.

 Choose OK.

 Reform your part.

Step 5 Close your part. Do not save.

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EDS Unigraphics NX
10-14 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Cutout

SUMMARY The Sheet Metal Cutout function allows the


removal of material through formable features
and shows distortion when formed. The cutout
also maintains associativity to the defining
geometry.

In this lesson you:


 Created a Sheet Metal Cutout.

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EDS
All Rights Reserved
Sheet Metal Design
Student Guide
10-15
Sheet Metal Cutout

(This Page Intentionally Left Blank)

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EDS Unigraphics NX
10-16 Sheet Metal Design
Student Guide All Rights Reserved
Unbend/Rebend

Unbend/Rebend ÏÏÏ
Lesson 11
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ÏÏÏ
11
ÏÏÏ

PURPOSE Create and edit sheet metal parts using the


Unbend/Rebend feature.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create a Unbend and Rebend features.

This section contains the following activity:

Activity Page
11-1 Creating Unbend and Rebend Features . . . . . . . . 11-8
11-2 Creating Unbends from an Extrusion . . . . . . . . . . 11-19

EDS
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Sheet Metal Design
Student Guide
11-1
Unbend/Rebend

ÏÏÏ Unbend/Rebend
ÏÏÏ
ÏÏÏ
11
ÏÏÏ
The Unbend/Rebend function allows for non-self forming, sheet metal type
features, to be unbent and rebent to allow creation of features which may need
to pass through bend areas and depict distortion. The use of this function
produces a feature that has a specific timestamp in the feature tree and
therefor updates in order when the model is edited or updated.

Region Preparation

Self-forming features (also called formable features) are capable of changing


their state to represent formed and unformed conditions. The Unbend/Rebend
operators form and unform the geometry of upstream features. To accomplish
this, the upstream features must be non-self-forming.

Before the Unbend/Rebend operation is applied, the system will check for any
parent features that are self-forming. If any are found, the following dialog will
appear to confirm that these self-forming parents will be converted into
non-self-forming parents.

Boundary Faces

The system may also create one or more of the following features to
pre-process the faces which cross the boundaries of the bend region:

 BOUNDED_PLANE
 INTERSECTION_CURVES
 SUBDIVIDE_FACE
 FACE_SUBDIVISION feature set

EDS Unigraphics NX
11-2 Sheet Metal Design
Student Guide All Rights Reserved
Unbend/Rebend

Forming Method
ÏÏÏ
ÏÏÏ
If the desire is to use Unbend and Rebend to unform sheet metal features (e.g.
Flange, Inset Flange or Bend), the Forming Method in the Sheet Metal
ÏÏÏ
11
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Preferences dialog needs to be set to Use Forming Operations. Use
Self-Forming Features is the default.

NOTE When using the Use Forming Operations method of


creation, all flange type features will be created is such a
manner that the Form/Unform function will not recognize
sheet metal flange type features.

EDS
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Sheet Metal Design
Student Guide
11-3
Unbend/Rebend

ÏÏÏ Advantages
ÏÏÏ
ÏÏÏ
11
ÏÏÏ
 The ability to use regular Modeling features in the creation of your
sheet metal part (e.g. extrusions, through holes, pockets, etc.). The
ability to use these features shortens the learning curve (i.e. more
knowledge is required for sheet metal features).
 Only unbend and rebend a flange type feature if it is necessary to
create a feature that depends on a given formed" state.
 The bend regions can be constructed from straight brake Sheet Metal
features such as Flanges and Bends as well as non-Sheet Metal
features such as Sketches and Extrusions.

Disadvantages
 The unbend a rebend functions will create additional features to
prepare the boundary faces so they can be unbent or rebent. There
are two things that you should be aware of:
 These features are blanked from the graphics window after the
creation of the feature is complete. Management of these
additional features/objects should be done through the use of
layers.
 The feature list for the part will be increased based upon the
how much preparation needs to be done to the boundary faces.
(e.g. a sheet metal flange will not require preparation of the
boundary faces to Unbend it).

EDS Unigraphics NX
11-4 Sheet Metal Design
Student Guide All Rights Reserved
Unbend/Rebend

The Unbend/Rebend Dialog ÏÏÏ


ÏÏÏ
You can access the Sheet Metal Solid Punch dialog from Insert→Sheet Metal
ÏÏÏ
11
ÏÏÏ
Feature→Unbend/Rebend or from the Unbend/Rebend icon in the Sheet
Metal Feature toolbar. To edit a Sheet Metal Solid Punch, use Edit→Feature or
the Edit Feature toolbar.

Bend Operations

Unbend

The Unbend option will create a feature that unforms a cylindrical face that
depicts a bend segment on a sheet metal type part. The cylindrical face can be
created by several different modeling techniques (e.g. blends or extruded
shapes with fillets) and does not have to be a Sheet Metal Flange or Inset
Flange feature.

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Sheet Metal Design
Student Guide
11-5
Unbend/Rebend

ÏÏÏ If an Unbend operation is selected, the filter will allow both edges and
ÏÏÏ upstream Rebend features to be selected. The bend angle of the new Unbend

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feature will be 0 degrees.

A bend edge is defined as a linear edge which defines the stationary side of a
bend region. Likewise the bend face is a cylindrical face which is adjacent to the
bend edge. The bending parameters are derived from the bend face.

Rebend

Use Rebend to reform an unbent feature, thus returning the bend region to its
original bend angle.

Unbend to Angle

If the Unbend to Angle operation is selected, the filter will allow both edges and
upstream Unbend/Rebend features to be selected. The angle of the new
Unbend to Angle feature will be specified by the user in the Angle expression
field.

Bend Angle

For Unbend to Angle operations, the bend angle field will be available. Use this
field to specify the new bend angle.

Adjacent Bend Face

The Bend region is defined by a bend edge and a bend face. If a bend edge is
selected, the dialog populates the bend face with the first cylindrical face it
finds which is adjacent to the bend edge. If multiple cylindrical faces are found,
the Adjacent Bend Face button will become available so that you can select a
different bend face. If an existing Unbend/Rebend operation is selected, its
bend edge and bend face will be used.

EDS Unigraphics NX
11-6 Sheet Metal Design
Student Guide All Rights Reserved
Unbend/Rebend

Once the bend edge and bend face have been determined, the system will
ÏÏÏ
highlight the faces which make up the bend region. These faces will be modified
ÏÏÏ
by the Unbend/Rebend operation.
ÏÏÏ
11
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Bend Allowance Formula

If Bend Allowance Formula is chosen, you can select the Bend Allowance
Formula (BAF) from the list or you can enter the BAF in the text field. The
Bend Allowance Formula only applies to the current operation. This button
will not be available if you have enabled a global Bend Allowance Formula or
the bend face belongs to a SMD feature that already has a BAF associated with
it.

Global Bend Allowance Formula

This option will be available if you have enabled a global Bend Allowance
Formula. If a non SMD feature bend edge is selected, this option will be
selectable and can be turned ON to take advantage of the global setting.

Construction Tips
 Converting parent features into non-self-forming features may lock
other SMD features (such as SMHOLEs and SMSLOTs) in a
non-creation state. To edit these features, you can temporarily
convert their parents back into self-forming features via the Make
Self-Forming Feature and Make Non-Self-Forming Feature MB3
pop-up menus in the Model Navigator. A Better solution is to replace
these features with regular Modeling features (e.g. Holes & Slots).
 Unbend/Rebend operations can be used to unformed individual bend
regions of Profile Flange and Multibend Bracket features.
 Unbend/Rebend operations cannot unform multiple regions at once
without ripping the material.

EDS
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Sheet Metal Design
Student Guide
11-7
Unbend/Rebend

ÏÏÏ Activity 11-1: Creating Unbend and Rebend Features


ÏÏÏ
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11
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In this activity you will use the Unbend/Rebend features in a different approach
to building a sheet metal part.

Step 1 Open the part smd_unbend and save it as xxx_unbend,


where xxx are your initials. Ensure you are in the
Modeling application.

Step 2 Create a through cutout.

 Choose the Cutout icon.

 Change the Type option to Through.

 Select the right outside face as the Placement Face.

 Choose MB2 to advance to Through Face.

 Select the left outside face as the Through Face.

 Choose MB2 to advance to Outline.

EDS Unigraphics NX
11-8 Sheet Metal Design
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Unbend/Rebend

 Select the profile on the right flange face. Do not select the
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centerline.
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Placement
Through Face
Face

Outline

 Ensure the Discard Region is pointing towards the inside


and choose OK to create the cutout.

Step 3 Edit the cutout in the unformed state to see what


happens.

 Choose the Form/Unform icon.

 Choose Unform All.

Notice the Sketch unforms with the right flange, this is


because the flange's web face is the placement face for the
sketch.

 Cancel the Form/Unform dialog.

 Double-click on the sketch centerline to enter the Edit


mode.

EDS
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Sheet Metal Design
Student Guide
11-9
Unbend/Rebend

ÏÏÏ  Change the value of p17 to 1.500 .


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11
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Edit

 Choose the Finish Sketch icon.

Notice the sketch profile is up to date but the two cutouts


are not. In order for the cutouts to update they must be put
into their creation state which is the formed state.

 Choose the Form/Unform icon.

 Choose Form All to see the updates to the cutout features.

Step 4 Convert self forming flanges to non-self forming flanges.


 Choose File→Close→Reopen Selected Parts...

 Select xxx_unbend from the list and choose OK.

 Choose OK to the Confirm window.

 Close the Information window.

 Open the Model Navigator.

EDS Unigraphics NX
11-10 Sheet Metal Design
Student Guide All Rights Reserved
Unbend/Rebend

 Highlight the first Flange feature, place your cursor over the
ÏÏÏ
feature and press MB3.
ÏÏÏ
 Choose Make Non-Self-Forming Feature from the list. ÏÏÏ
11
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 In the Model Navigator, note the subtle difference between
the icons of the first and second flange.

Indicates
self-forming
feature

 Repeat the steps to the second flange to Make


Non-Self-Forming.

 Choose the Form/Unform icon.

Since the two flanges are no longer self forming the following
message appears.

 Choose OK to dismiss the Info window.

Step 5 Create cutouts using a typical modeling feature.

 Choose the Extruded Body icon.

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11-11
Unbend/Rebend

ÏÏÏ  Select the sketch as the section string and choose OK.
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11
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 Choose Trim To Face/Plane.

 Choose Cycle Vector Direction to point the vector towards


the left flange and choose OK.

 Select the left outside flange face as the trimming face and
choose OK.

Trimming
Face

 Ensure the Offset and Taper values are set to 0 and choose
OK.

 Choose Subtract.

Since the Flanges can no longer unform by themselves it is


acceptable to use an extrusion to create the cutout" type
features.

Step 6 Create an unbend feature to add a feature through the


bends.

 Choose the Unbend/Rebend icon.

 Select the left inside bend edge and choose Apply.

EDS Unigraphics NX
11-12 Sheet Metal Design
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Unbend/Rebend

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Inside
Edge

NOTE The bend edge you select determines the portion of the
part that remains stationary and which portion unforms.

 Repeat the steps to create an Unbend feature for the right


flange.

Notice the sketch did not move with the flange this time.
This happens because there is now a feature that controls
the unformed state of the flange.

 Open the Model Navigator and review the feature list.

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Unbend/Rebend

ÏÏÏ Step 7 Create another Modeling feature through one of the


ÏÏÏ bends.

ÏÏÏ
11
ÏÏÏ  Choose the Pocket icon.

 Choose the Rectangular option.

 Select the top face as the planar placement face.

 Select the front edge as the horizontal reference.

Placement
Face

Horizontal
Reference

 Enter the Parameters for the Instance as shown below:

X Length 2.00
Y Length .375
Z Length T
Corner Radius 0
Floor Radius 0
Taper Angle 0

 Choose OK.

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Unbend/Rebend

ÏÏÏ
 Choose Parallel at a Distance. ÏÏÏ
 Select the front edge of the part as the Target Edge.
ÏÏÏ
11
ÏÏÏ
 Select the front edge of the rectangular pocket as the Tool
Edge.

Tool Edge

Target Edge

 Enter a value of .375 and choose OK.

 Choose Perpendicular.

 Select the far left edge of the part as the Target Edge.

 Select the far left edge of the rectangular pocket as the Tool
Edge.

Target Edge

Tool Edge

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Unbend/Rebend

ÏÏÏ  Enter a value of .500 and choose OK.


ÏÏÏ
ÏÏÏ
11
ÏÏÏ Step 8 Edit the sketch in the unformed state to see what
happens.

 Double-click on the sketch centerline to enter the Edit


mode.

 Change the value of p17 to 1.500 .

Edit

 Choose the Finish Sketch icon.

Notice this time the sketch and both cutouts" updated. This
happened because as the update process rebuilt the model
the extrude feature was updated before the unbend features.

Step 9 Rebend the flanges.

 Choose the Unbend/Rebend icon.

 Choose the Rebend icon.

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Unbend/Rebend

 Select the left flange choose Apply.


ÏÏÏ
ÏÏÏ
 Select the right flange and choose OK.
ÏÏÏ
11
ÏÏÏ
 Open the Model Navigator and review the feature list.

Notice the additional features created after the Rectangular


Pocket and between the Rebend features. These features are
created to prepare the boundary faces of the rectangular
pocket so it could be reformed. Some of these features (e.g.
bounded plane) are blanked so you do not see them.

 Make layer 21 invisible.

 Choose Edit"Blank"Unblank All of Part


(TIP: Ctrl+Shift+U).

 Fit the view.

 Choose Format"Move to Layer...

 Select the solid body.

 In the Class Selection dialog, choose All But Selected and


choose OK.

 Enter 81 as the destination layer and press Enter.

 Fit the view.

Step 10 Edit the rectangular pocket in the formed state.

 Open the Model Navigator.

 Double-click on the RECTANGULAR_POCKET feature to


enter the Edit Parameters dialog.

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Unbend/Rebend

ÏÏÏ  Choose the Feature Dialog option.


ÏÏÏ
ÏÏÏ
11
ÏÏÏ
 Edit the X Length to 3.00 and choose OK twice.

Step 11 Choose File"Close"Save and Close.

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Unbend/Rebend

Activity 11-2: Creating Unbends from an Extrusion ÏÏÏ


ÏÏÏ
ÏÏÏ
11
ÏÏÏ
Step 1 Open the part smd_unbend_2 and save it as
xxx_unbend_2, where xxx are your initials. Ensure you
are in the Modeling application.

 Open the Model Navigator and review the feature list.

Notice the part was created from a sketch and an extrusion.

Step 2 Create Unbend features to unform the part.

 Choose the Unbend/Rebend icon.

 Select the left inside bend edge and choose Apply.

Inside
Edge

 Repeat the steps to create an Unbend feature for the right


flange.

 Open the Model Navigator and review the feature list.

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Unbend/Rebend

ÏÏÏ Again, notice there are two BOUNDED_PLANEs and


ÏÏÏ FACE_SUBDIVISIONs before each Unbend feature. These

ÏÏÏ
11
ÏÏÏ 
were necessary to prepare the Bend Region for unforming.
Choose Edit"Blank"Reverse Blank All
(TIP: Ctrl+Shift+B).

 Fit the view.


 Choose Format"Move to Layer...
 Choose Select All and choose OK.
 Enter 81 as the destination layer and press Enter.
 Choose Edit"Blank"Reverse Blank All to return to the
original display.

 Fit the view.

Step 3 Create a sketch to be extruded.


 Make layer 22 the work layer.

 Choose the Sketch icon.


 Enter s22_cutout as the sketch name and press Enter.
 Select the top face of the middle section as the sketch plane.
 Select the front edge, on the right-hand side, for the
horizontal direction.

Placement
Face

Horizontal
Reference

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Unbend/Rebend

 Choose MB2 to create the sketch.


ÏÏÏ
ÏÏÏ
 Free-hand sketch the shape below.
ÏÏÏ
11
ÏÏÏ

 Create two lines across the corners of the diamond".

 If necessary, apply vertical or horizontal constraints as


applicable to the two lines.

 Convert the two lines to Reference.

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Unbend/Rebend

ÏÏÏ
ÏÏÏ  Dimension the profile as indicated below.
ÏÏÏ
11
ÏÏÏ

 Choose the Finish Sketch icon.

 Extrude the sketch downward using the Trim to Face/Plane

option and use the bottom face as the trimming face.

 Choose Subtract.

 Make layer 1 the work layer and all other layers invisible.

Step 4 Rebend the flanges.

 Choose the Unbend/Rebend icon.

 Choose the Rebend icon.

 Select the left flange choose Apply.

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Unbend/Rebend

 Select the right flange and choose OK.


ÏÏÏ
ÏÏÏ
 Cancel the Unbend/Rebend dialog.
ÏÏÏ
11
ÏÏÏ
 Open the Model Navigator and review the feature list.

Step 5 Edit the parameters of the extrusion.

 Open the Model Navigator.

 Double-click on the EXTRUDED(4) feature to enter the


Edit Parameters dialog.

 Choose the Feature Parameters option.

 Edit the End Distance to 4.00 and choose OK twice.

 Shade and rotate your part to examine the cutout.

Step 6 Move the additional features to another layer.

 Choose Edit"Blank"Reverse Blank All.

 Fit the view.

 Choose Format"Move to Layer...

 Choose Select All and choose OK.

 Enter 82 as the destination layer and press Enter.

 Choose Edit"Blank"Reverse Blank All to return to the


original display and Fit the view.

Step 7 Choose File"Close"Save and Close.

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Unbend/Rebend

ÏÏÏ
ÏÏÏ
ÏÏÏ
11
ÏÏÏ

SUMMARY The Unbend/Rebend feature allows better


control the unforming process of a sheet metal
part for aid in constructing features.

In this lesson you:


 Unbent a non-self-forming flange and
created Modeling features through bends.
 Unbent an extruded sketch to create a
feature that passed through the bends.
 Applied rebend features to form the part
back to its original bend angles.

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Bead

Bead
Lesson 12

PURPOSE To create and edit bead geometry using the Bead


feature.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
OBJECTIVES Upon completion of this lesson, you will be able to:

 Create UĆshaped, VĆshaped, and Circular Beads.


 Create a bead from a sketch curve.

This section contains the following activity:

Activity Page
12-1 Creating Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

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Bead

Bead

Beads are useful in the design of sheet metal products to add strength to the
product or to control the formability of the material during metal stamping
operations (i.e. lock beads can stop a sheet metal blank from sliding into the die
cavity).

You can access the Bead dialog from Insert→Sheet Metal Feature→Bead or by

selecting the Bead icon from the Sheet Metal Feature toolbar. To edit a
ÏÏÏ
ÏÏÏ
12
Bead, use Edit→Feature→Parameters or the Edit Feature toolbar.

ÏÏÏ
ÏÏÏ The Bead feature allows you to create formable geometry from existing solid
bodies. Like the general pad and general pocket features, beads form
protrusions or depressions in a variety of shapes. However, while pads and
pockets are defined by their outline shapes, beads are created by following a
prescribed centerline path.

NOTE The centerline guide curves cannot be selfĆintersecting or


a closed loop.

Beads come in three profiles or types: Circular, UĆshaped and VĆshaped.

Bead Types

UĆshaped VĆshaped Circular

For Circular beads, the length of the bead body is equal to the length of the
centerline curves. If the bead has optional end caps, a blend can be created
between the bead and the placement face, where the bead body will extend
beyond the centerline length.

For UĆshaped and VĆshaped beads, the tapered ends extend beyond the curve
endpoints. This cross section can also vary between the different shapes as you
move along the centerline.

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Bead

The following figures show examples of the different types of beads:

UĆshaped bead with a Circular bead with reversed


projected centerline face normals

Guide curves ÏÏÏ


ÏÏÏ
12
ÏÏÏ
ÏÏÏ

Variable
shaped
bead

UĆshaped bead with


end caps fading
into placement face

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Bead

The Bead Dialog

Positioning
Selection
Steps and
Filters Bead Types

ÏÏÏ
ÏÏÏ
12
UĆshaped

ÏÏÏ
ÏÏÏ This window
will change VĆshaped
per selection
step.

Circular

This window
will change
per bead
type.

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Bead

Selection Steps
The Bead feature uses a selection steps type of dialog to create and edit the
bead geometry and positioning parameters. The first three selection step icons
require that input be provided before you can cycle to the next step. The
remaining icons provide optional operations which further define the
orientation and direction with which the bead is applied.

Placement Centerline Section


Face Projection Orientation Axis

ÏÏÏ
Centerline Vector Section
Plane
Points

ÏÏÏ
12
ÏÏÏ
ÏÏÏ

Secondary Target
Face Definition Body

Placement Face

You may select one or more faces of the part on which to place the bead
feature. If multiple faces are chosen, they must be adjacent to each other.

While this step is active, different selection options are available within the
Filter control. These options allow you to construct a bead on other part faces,
datum planes, or userĆgenerated planes, then boolean the bead geometry to
different part faces using the Target Body selection step.

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Bead

NOTE If other part faces or planes are used as the construction


plane, it's important to note that the temporary bead tool
generated on that plane must be able to intersect with the
desired target body upon its creation, or a failure
condition will result.

Centerline

ÏÏÏ
ÏÏÏ
12
Multiple curves may be selected as guide curves, but they must be contiguous
ÏÏÏ
ÏÏÏ
and must form an open profile. These curves may be located on, or at a distance
to, the placement face. The bead body starts at the beginning of the centerline
and stops at the end of the centerline, unless a taper extends the bead. Bead
end caps are an example of an extension beyond this length.

Centerline Projection Vector

If the centerline guide curves do not lie on the placement face, you may specify
the vector along which the curves will be projected onto the placement face. If
you elect to use the Normal to String condition, the curves composing the
centerline must be coplanar. Other projection vectors may be specified by
selecting the Selected Direction button displayed in the Listing Box on the Bead
dialog.

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Bead

Orientation Plane

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
The Orientation Plane is an optional step used to specify the orientation of the
cross section of the bead. The default setting (Normal to String ) creates the
bead cross section normal to all points along the guide curve. You can specify a
different orientation plane by selecting the option button displayed in the
Listing Box when this step is active.

Guide curve

Cross section planes along Cross section planes along


the bead are normal to all the bead have a constant,
points on the guide curve. userĆdefined orientation.

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Bead

Section Axis

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
The Section Axis step provides an optional means of adding a tilt characteristic
to the bead feature. This vector determines the rotational orientation of the
bead cross section with respect to the orientation plane. It's through the use of
this step that the bead geometry is added to, or subtracted from, the base solid.

Cross section of different bead structures


showing section axis orientation

Section Axis
Placement Face
Placement Width

Placement Width
Section Axis

NOTE The Placement Width is measured from the Placement


Face side regardless of the Section Axis orientation.

The default creation state is parallel to the placement face normal vector. You
can define a customized section axis by selecting the button shown in the
Listing Box when this step is active.

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Bead

Section Points

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

The Section Points step allows you to define a variable shaped bead created by
specifying the section shape as variable. Specifically, a mixture of different
crossĆsections can be used at various points along the centerline by alternatively
displaying each section type and then selecting points for that section using this
step.

Note that the points should be on or near the centerline, as they will be
"dropped" to the nearest location on the centerline. These points will be
remembered for future updates if the centerline is modified. When sections are
not defined at the centerline endpoints, the closest section will be repeated at
the end. The point options in the changeable display are available to help you
select the points. Points may be deselected by reselecting the specified points
for each section type.

NOTE When creating a bead with varying shape using section


points it may be necessary to create the bead unattached
(Options menu). After creation the bead can be united to
the target body and a hollow operation can be performed.

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Bead

Secondary Face Definition

If the selected bead type has a UĆshaped cross section, this step is activated and
can be used to control the shape of the bead's top face, which is also called the
secondary face.

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

You may:

 Specify a fixed Height for the bead.


 Use the Offset Placement Face option. Enter a positive or negative
offset in the Distance input field corresponding to the direction of the
Section Axis.
 Use the Offset Selected Face option. Select the desired face, then
provide a positive or negative value in the Distance input field.
 Use the Translate Placement Face option. Select a vector to define the
direction (which must be consistent with the direction of the Section
Axis), and provide a Distance value.
 Use the Translate Selected Face option. Select a face, select a
translation direction vector, and provide a Distance value.

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Bead

Target Body

This optional step allows you to specify the target body for the bead geometry if
the original placement face is off the body of the part. You must use this option
if you have selected a datum plane or single plane as the original placement
face.

NOTE Once selected, you cannot change the target body while
editing the bead parameters. ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

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Bead

Bead Type

The Type option in the Bead dialog allows you to preĆdefine bead parameters by
storing their information in the sheet metal standards file (see Lesson 1). When
no standards are defined, this option is grayed out and the system displays
default parameters for each bead structure.

The cross section of the bead is available in three different geometric shapes;
UĆshaped, VĆshaped, and circular. The pictorial icons presented on the Bead
dialog allow you to choose the desired shape.
ÏÏÏ
ÏÏÏ
12 Each pictorial icon depicts the geometric constraints required to parameterize
ÏÏÏ
ÏÏÏ
the specified bead structure. The changeable list below the pictorial icon
displays the parameter input fields for the selected bead cross section.

UĆshaped VĆshaped Circular

A complete shape can be derived for each bead type without specifying a value
for every given geometric constraint. Indeed, in some instances, too many
constraints are given and the system will warn you that the bead is
overĆparameterized and will ignore selective constraints while creating the
bead. You can see several combinations of constraints that are valid for creating
your bead by moving your cursor over the pictorial icon on the Bead dialog. The
displayed list gives the combinations of minimum parametric inputs necessary
to define the bead.

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Bead

Bead Terminology

The changeable display in the Bead dialog contains a list of the parametric
constraints of the given bead type. The terminology for these constraints is
described below.

UĆAWH,AwH,WwH

ÏÏÏ
ÏÏÏ
12
VĆAW,AH
ÏÏÏ
ÏÏÏ

CircularĆR,RH

Angle (A) - The taper angle for the sides of UĆshaped and VĆshaped beads.

Blend Radius - The radius value for the blend created between the placement
face and the walls of the bead. This parameter is only available for U and
VĆshaped beads.

End Cap Angle - The taper angle of the faces placed at the end of the
VĆshaped bead.

End Cap Radius - The radius value for the end caps of a Circular bead. The
value must be greater than or equal to the height of the bead.

Height (H) - The height (or depth) of the bead as measured from the
placement face.

Placement Width (W) - The width of the bead base without a Blend Radius.
This parameter is only available for U and VĆshaped beads.

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Bead

Radius (R) - For beads with UĆshaped cross sections, this is the radius on
either side of the top face. For beads with VĆshaped cross sections, this is the
radius at the top of the bead. For beads with Circular cross sections, this is the
radius of the cross section.

Secondary width (w) - The width of the UĆshaped bead top, or secondary, face.
This width can be measured either from the top face's theoretical intersections
with the bead's sides (Intersection Point), or from the tangents between the top
face and the bead's blended side edge (Tangent Point). The intersection points
are represented by the wider w" on the top face of the UĆshaped bead pictorial

ÏÏÏ
ÏÏÏ
12
icon. The tangent points are represented by the top face's narrower w". This
preference can be set in the Bead Options dialog which appears when you

ÏÏÏ
ÏÏÏ
choose the Options button.

Distance Tolerance This value is used to approximate curves created internally


to build the bead. If the bead fails to build, some type of error message may be
given to indicate the system was unable to create the curves In this case, a
looser tolerance might resolve the problem.

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Bead

Options

The Options button on the Bead dialog activates the Bead Options dialog. This
dialog lets you specify additional preferences for controlling the bead structure.
The availability of the listed options is based on the selected bead type specified
in the Bead dialog.

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

The Height for all three bead types can be specified as Constant or Law
Controlled. The height can be measured along the face normals or along the
section axis.

The Angle option appears for UĆshaped beads only. The Angle can be
measured from the section axis or from face normals.

The Secondary Width From options appear for UĆshaped beads only.
Secondary width can be measured either from the top face's theoretical
intersections with the bead's sides ( Intersection Point) or from the tangents
between the top face and the bead's sides (Tangent Point). Intersection Point is
represented by the wider w" dimension on the top face of the UĆshaped bead,
Tangent Point by the top face's narrower w" dimension.

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Bead

The End Cap options appear for all three types of constant shaped beads . End
caps can be defined for the Start, End or Both ends, or as None for no end caps.
End caps may be specified to fade into the placement face. A length for the end
caps may also be given which will define the distance used for fading the end
caps into the placement face.

Attach Bead appears for all three types of beads. If you decide to attach the
bead to a sheet body, the bead will be sewn to the sheet. If you attach the bead
to a solid body, it will be either united to or subtracted from the solid body,
depending on the direction of the section axis.

ÏÏÏ
ÏÏÏ
12 Hollow Bead appears for all three types of beads. If you attach the bead to a
ÏÏÏ
ÏÏÏ
solid body, the bead will remove volume from the face opposite the placement
face to maintain a constant thickness. This toggle is turned off and disabled if
Attach Bead is turned off. This has no effect on sheet bodies.

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Bead

Construction Tips
 You cannot create a bead of zero length, or with a closed or
selfĆintersecting centerline. Beads that end at the periphery of the face
can be created with some limitations.

Must be perpendicular to
the periphery with no end
cap on this end.

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

Acceptable Beads Unacceptable Beads

 Flat patterns generated from parts with bead features will show the
outline of the bead intersection with the surface of the part. It should
be noted that if a blend radius has been added to the bead, the outline
will be derived from the blend intersection with the placement face.
 Flat patterns generated for parts with unattached beads will not
produce a bead outline.

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Bead

Activity 12-1: Creating Beads

In this activity you will use different bead construction techniques to add
strength and functionality to a sheet metal part.

Step 1 Create a VĆshaped stiffening bead.

ÏÏÏ
ÏÏÏ
12
 Open the part smd_bead.

ÏÏÏ
ÏÏÏ  Make sure you're in the Modeling application.

 Make Layer 41 selectable. A series of three straight lines will


become visible. You may want to rotate the model for
another view of the three lines.

 Choose the Bead icon.

 Select the top surface as the Placement Face.

 Click MB2 to advance to the Centerline step.

 Select the left outer line as the centerline curve.

Select the upper


surface as the
placement face.

Select this outside line


as the centerline.

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Bead

Because the guide curve does not rest on the surface of the part
you will need to specify a Centerline Projection Vector such that
the guide curve will be projected onto the placement face.

 Click MB2 to advance to the Centerline Projection Vector

step.

 Choose the button below the Centerline Projection


Definition text and choose Specify New Vector...
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

 Choose the ZC Axis option. Notice that the centerline


projection vector points up and away from the part.

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Bead

 Choose the Cycle Vector Direction button to point the vector


down toward the part. (See diagram below.)

ÏÏÏ
ÏÏÏ
12  Choose OK.
ÏÏÏ
ÏÏÏ  In the Bead dialog, change the bead type to VĆshaped by
selecting the pictorial icon.

 Insert the following values:

 Radius = .50
 Blend Radius = Ignore this field for now.
 Height = 1.00
 Angle = 30
 Placement Width = 2.00
 End Cap Angle = 60

 Choose the Options button in the Bead dialog.

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Bead

 Set the End Cap option to Start.

 Ensure the Attach Bead and Hollow Bead options are ON.

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

 Choose OK to accept the options.

 Choose Apply to create the bead.


Because more information was given for the bead geometry than
was necessary, the system flashes a Note message indicating that
the specified height will be ignored when the width is given.

Step 2 Create a VĆshaped bead with a userĆdefined orientation.


 Choose WCS→Display to turn ON the WCS.

 Double-click on the WCS to enter into WCS Dynamics.

 Select the XC-YC rotation handle to rotate around the ZC


axis.

 Enter -60 degrees into the Angle input field and choose
MB2.

 With the Bead dialog still active, select the upper surface

again as the placement face.

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Bead

 Click MB2 to advance to the Centerline step.

 Select the right outer line as the centerline curve.

Select the upper


surface as the
Select this outside line
placement face.
as the centerline

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
 Click MB2 to advance to the Centerline Projection Vector

step.

 Choose the button below the Centerline Projection


Definition text and choose Specify New Vector...

 Choose OK to accept the previously defined vector direction


(should be -ZC, if NOT adjust it to point in that direction).
Now you'll reĆorient the section cut plane so that it's parallel to
the YCĆZC plane.

 Choose the Orientation Plane icon.

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Bead

 Choose the Orientation Plane Normal button in the Listing


Box.

 Choose Specify New Plane...

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

 Choose the Principle Plane option.

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Bead

 Choose the YCĆZC Plane option. Now you've defined the


plane at which the cross sections of the bead will be
generated along the centerline curve.

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
 In the Bead dialog, remove the Radius value by inserting a 0
in the input field.

 In the Bead Options dialog change the End Cap option to


None.

 Choose OK.

 You can leave the remaining parameters in place.

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Bead

 Choose Apply again to create the bead.


Shade your model and examine the ends of the two beads.
Notice the cross section of the second bead?

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

Step 3 Create a depression in the center of the part.


 In the Bead dialog, select the upper surface again as the

Placement Face.

 Click MB2 to advance to the Centerline step.

 Select the middle line as the centerline guide curve.

 Click MB2 to advance to theCenterline Projection Vector

step.

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Bead

 If necessary, adjust the Centerline Project Vector so that the


line is projected onto the placement face.

 Choose the Orientation Plane icon.

 Choose the Orientation Plane Normal button in the Listing


Box.

Change this option back to Normal to String...


ÏÏÏ


ÏÏÏ
12 Before you choose the bead type, you need to orient the bead
ÏÏÏ
ÏÏÏ
Section Axis such that a depression will be formed when the
bead is united with the part.

 Choose the Section Axis icon.

 Under the Section Axis text in the Bead dialog, choose


Reversed Face Normals.

 Change the bead type to Circular.

 Set the Radius equal to 6.00 and the Height equal to .20 .

 Choose the Options button.

 Turn OFF the Hollow Bead option.

 Choose OK to return to the Bead dialog.

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Bead

 Choose OK to create the depression. Examine your model.

Step 4 Create a bead on a flange surface.


Beads can move with a forming and unforming flange surface as
long as their centerline guide curves are associated to the flange
surface. The easiest way to accomplish this is to create a sketch
on the face of the flange surface and constrain it to static edges
of the flange surface. Such a sketch has been created for you on
Layer 21.
 Make layer 21 selectable and layer 41 invisible. ÏÏÏ
ÏÏÏ
12
 Create a hollow, circular bead using the middle line as a
guide curve. Set the Radius to 2.00 and the Height to .50 .
ÏÏÏ
ÏÏÏ
NOTE In theory, a single line cannot define a plane so you will
have to specify a Centerline Projection Vector to tell the
system how to project the curve onto the placement face.
You can specify a new vector" using the Two Points
method and select the control points of the flange edges
as shown below.

Use the flange edge


control points to specify
the Centerline Projection
Vector

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12-27
Bead

TIP Use Confirm Upon Apply to ensure it looks correct


before accepting your results.

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Step 5 Check the bead integrity.
If the sketch and bead were created correctly, the part will
unform and the bead will remain associated to the flange
surface.

 Choose the Form/Unform icon.

 Choose the Unform All button. The part will completely


unform.

 Reform the part using the Form All button.

EDS Unigraphics NX
12-28 Sheet Metal Design
Student Guide All Rights Reserved
Bead

Step 6 Create a UĆshaped bead on a flange surface.


We'll be placing a semiĆcircular bead around the hole, but we
must first create an associative guide curve.

 Choose Sketch icon.

TIP You may want to change your work layer before you
create the sketch.
ÏÏÏ
ÏÏÏ
12
 Select the upper surface of the flange with the hole cutout as
the sketch plane.
ÏÏÏ
ÏÏÏ
 Select the left end of the flange edge as the new horizontal
direction. (See figure below)

Select this face as


the Attachment
face

Select on this side for the


Horizontal Reference.

 Choose MB2 to create the sketch.

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12-29
Bead

 Create an arc with a 20 inch radius. Make the arc concentric


with the hole and constrain its endpoints so that they are
8.00 inches from each edge of the part.

ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

 Choose Finish and verify that it will unform with the


associated flange.

TIP You only need to unform the second flange to check


associativity.

If the sketch was constrained correctly it should move with the


flange. The sketch must be properly constrained before you
proceed to the next step or your model will fail to unform.
 Reform your part.
 Return to the Bead dialog.

 Select the upper surface as the placement face.

 Select the arc as the centerline curve.


Because an arc is a planar curve, it is not necessary to specify a
Centerline Projection Vector. The default should be adequate.

EDS Unigraphics NX
12-30 Sheet Metal Design
Student Guide All Rights Reserved
Bead

 Change the bead type to UĆshaped.


 Insert the following values:
 Radius = .30
 Blend Radius = .50
 Height = 1.00
 Angle = 30
 Placement Width = 5.00
 In the Options dialog, make sure that Attach Bead, Hollow
Bead, and Both End Cap options are selected.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ

 Choose OK to create the bead. Examine your model. Verify


that the bead unforms with the underlying flange.

Step 7 Close your part. Do not save.

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12-31
Bead

ÏÏÏ
ÏÏÏ
12 SUMMARY With the Bead feature you can create a variety
ÏÏÏ
ÏÏÏ
of bead shapes and sizes. Beads are fully
associative to their Placement Faces. When you
delete their parent feature, they will delete as
well. If sketches are used on the Placement
Face of the bead, the bead will also form and
unform to remain on their associated flange.

In this lesson you:


 Created UĆshaped, VĆshaped, and Circular
Beads.
 Created a bead with a parametrically
controlled guide curve (sketch).

EDS Unigraphics NX
12-32 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bridge

Sheet Metal Bridge


Lesson 13

PURPOSE Create contoured sheet metal surfaces (bridges)


between existing solid bodies using the Sheet Metal
Bridge feature.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create Sheet Metal Bridge surfaces


 Edit Sheet Metal Bridge surfaces
ÏÏÏ
ÏÏÏ
This section contains the following activity:
ÏÏÏ
13
ÏÏÏ
Activity Page
13-1 Sheet Metal Bridge Creation . . . . . . . . . . . . . . . . . 13-13

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13-1
Sheet Metal Bridge

The Sheet Metal Bridge Dialog


The Sheet Metal Bridge feature will allow you to create a contoured surface
between base and target solids. Sheet Metal Bridge is unique from the Flange
and General Flange feature since the bridge can be created between two
bodies, as opposed to an extension from a single body.

You can access the Sheet Metal Bridge dialog from Insert→Sheet Metal

Feature→Bridge or from the Sheet Metal Bridge icon in the Sheet Metal
Feature toolbar. To edit a Sheet Metal Bridge, use Edit→Feature or the Edit
Feature toolbar.

ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ

EDS Unigraphics NX
13-2 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bridge

You can use Sheet Metal Bridge to create single and double bend surfaces
between base and target solid bodies. During creation, the Sheet Metal Bridge
is constrained at the base and target profiles. During unforming, the Sheet
Metal Bridge behaves like the General Flange with distortion determined as an
extension from the base profile. The Sheet Metal Bridge supports the following
construction types:

 Tangent at Target - This construction type may be used to create a


Sheet Metal Bridge with a single bend when base faces/edges have
been selected along with either target faces or target
faces/edges/curves.
 Intersect Angle at Target - This construction type may be used to
create a Sheet Metal Bridge with a single bend when base faces/edges
have been selected along with either target edges/curves or target
faces/edges/curves.
 Z-Bend - This construction type may be used to create a Sheet
Metal Bridge with a double bend when base faces/edges have been
selected along with any combination of target faces/edges/curves.

ÏÏÏ
ÏÏÏ
Intersect Angle
ÏÏÏ
13
ÏÏÏ
ZĆBend Intersect Angle Tangent at Target
at Target

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Sheet Metal Bridge

Selection Steps
The Sheet Metal Bridge dialog, is a selection steps type of dialog. The icons at
the top of the dialog highlight as you progress through the bridge creation
process. You may also choose any icon at any time to specify, or reĆspecify,
information for that step of the process.

NOTE You can use expressions or arithmetic statements in the


Sheet Metal Bridge dialog, however, they will be
converted to their numeric equivalent upon execution of
the dialog.

Base Faces Target Profile


Base Profile Target Faces

ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ Base Faces
The Base Faces selection step lets you select either single or multiple faces to
define the tangency constraints at the base of the Sheet Metal Bridge feature.

The base faces define a G1Ćcontinuous region which is used to tangentially


constrain the construction of the Sheet Metal Bridge feature at the base. The
Sheet Metal Bridge feature requires you to selection at least one base face.

Base Profile
The Base Profile selection step lets you select either single or multiple edges to
define the boundary at the base of the Sheet Metal Bridge feature.

The base profile is defined by G1Ćcontinuous edges which are used to define
the bend/extension edge at the base end of the Sheet Metal Bridge feature. The
Sheet Metal Bridge feature requires you to select at least one base edge. In
addition, the base profile selection is restricted to the edges that define the
peripheral boundaries of the base faces selected.

EDS Unigraphics NX
13-4 Sheet Metal Design
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Sheet Metal Bridge

Target Faces

The Target Faces selection step lets you select either single or multiple faces to
define the tangency constraints at the target of the Sheet Metal Bridge feature.

The target faces define a G1Ćcontinuous region which is used to tangentially


constrain the construction of the Sheet Metal Bridge feature at the target. The
Sheet Metal Bridge feature does not require the selection of target faces.

Target Profile

The Target Profile selection step lets you select either single or multiple edges
or curves to define the boundary at the target of the Sheet Metal Bridge
feature.

ÏÏÏ
The target profile is defined by either a G1Ćcontinuous edges or curves. The
ÏÏÏ
Sheet Metal Bridge feature does not require the selection of a target profile. In
addition, the target profile selection is restricted to either the edges that define ÏÏÏ
13
ÏÏÏ
the peripheral boundaries of the target faces selected or curves that may be
projected to the surfaces of the target faces. If target faces are not selected, the
target profile may be any G1Ćcontinuous edges or curves.

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13-5
Sheet Metal Bridge

Construction Parameters

Flip Extension Direction

The Flip Extension Direction option lets you toggle the extension direction of
the Sheet Metal Bridge feature. There are two extension directions shown on
the display: one for the base profile and one for the target profile. The direction
of each extension can be flipped while in their respective selection steps.

ÏÏÏ Construction Type


ÏÏÏ
ÏÏÏ
13
ÏÏÏ
The Construction Type option lets you choose the type of Bridge you will
construct. Choose from Tangent at Target, Intersect Angle at Target, and
ZĆBend.

EDS Unigraphics NX
13-6 Sheet Metal Design
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Sheet Metal Bridge

A Bridge is built by creating section curves from the Base Profile to the Target
Profile. These section curves represent the top surface of the Bridge. The start
of these section curves are tangent to the Base Faces. Tangent at Target and
Intersect Angle at Target Bridges use section curves that contain a single bend,
whose angle is determined by the geometry. A ZĆBend Bridge contains two
bends of equal angles. See the figures below.

Base Faces Target Face

Intersect Angle
Target Faces

ZĆBend Intersect Angle Tangent at Target


at Target

Intersect Angle
ÏÏÏ
ÏÏÏ
The Intersect Angle is the angle between the Bridge surface and the Normal to
the Target Face, at the point where the Bridge surface intersects the Target ÏÏÏ
13
ÏÏÏ
Profile (see middle figure above). This value may be defined as follows:

 Constant - The Intersect Angle may be defined by a constant number


or expression. The value entered in the text field can be any valid
Unigraphics expression or arithmetic statement, however, they will be
converted to their numeric equivalent upon execution of the dialog.
 Law Controlled - The Intersect Angle may be defined using the Law
Subfunction.

NOTE The Intersect Angle parameter is only available when the


Intersect Angle at Target construction type has been
specified.

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Sheet Metal Bridge

Inside Radius

This parameter defines the Inside Radius of the Bridge feature. This value may
be defined similar to the Intersect Angle.

NOTE The Inside Radius must be specified regardless of any


other parametric or geometric input data.

Thickness

ÏÏÏ This parameter defines the Thickness of the Bridge feature. This value may be

ÏÏÏ defined similar to Intersect Angle and Inside Radius.

ÏÏÏ
13
ÏÏÏ

NOTE The direction of the Thickness may be specified either


Along Bend Direction or Opposite Bend Direction. The
default direction is Along Bend Direction.

EDS Unigraphics NX
13-8 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bridge

Bend Allowance Formula

This button displays the Bend Allowance Formula (BAF) dialog. You can
choose a bend allowance formula from the list or key in your own formula.
Toggle ON the Use Feature Standards option in the Sheet Metal Preferences
dialog to list the BAF's in the BAF dialog.

ÏÏÏ
Options ÏÏÏ
ÏÏÏ
13
ÏÏÏ
This button allows access to the settings for Global Parameters.

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Sheet Metal Bridge

Distortion Method

Area Preserve and R Value

You can specify an r value (average strain ratio or normal anisotropy) or choose
area preserve, which is equivalent to specifying an infinite r value. The r value is
a property of the material being formed and will affect how the Bridge is
mapped to other states. Higher r values represent higher resistance to thinning
when the material is being stretched or resistance to thickening when the
material is being compressed. The default value of 1.0 corresponds to a
homogeneous material.

ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ

EDS Unigraphics NX
13-10 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bridge

Construction Method

Unite

The Unite option controls how the Bridge feature unites with its construction
geometry. You may choose from None, Base, and Target. Because the creation
of a Bridge involves approximations, sometimes the Unite operation will fail.
You can improve the chances of success if you specify a tolerance that is no
more than 10 times the Modeling Distance Tolerance (found under
Preferences→Modeling in the Modeling application).

Tolerance ÏÏÏ
ÏÏÏ
This parameter defines the Tolerance that is used to construct the BĆSurface
Geometry of the Bridge feature. This value may be defined as follows:
ÏÏÏ
13
ÏÏÏ
 Constant - The Tolerance may be defined by a constant number or
expression. The value entered in the text field can be any valid
Unigraphics expression or arithmetic statement, however, they will be
converted to their numeric equivalent upon execution of the dialog.
 Inferred - The Bridge Tolerance is initially inferred from the
Modeling Distance Tolerance. However, the user may replace this
value with any valid Unigraphics expression or arithmetic statement, if
necessary.

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13-11
Sheet Metal Bridge

Construction Tips

To ensure the viability of a part, there are a few design requirements which
should be followed when creating sheet bridge features:

 Edit a Bridge as you would any feature. Note that during editing you
cannot change the Unite method.
 The resultant bridge faces will be comprised of trimmed BĆsurfaces.
This may present minor difficulties while attempting to dimension the
feature, or a section cut of the feature.
 The Construction Type does not allow for joining of the bridge, the
base and the target bodies. After creation if one solid body is desired,
an additional boolean operation must be performed to untie the
bodies together.
 A bridge feature can be unformed in some cases. If an unform
operation is done to a body where a boolean is done between the
bridge, base and target bodies, the bridge will unform from the Base

ÏÏÏ
feature only. If the Construction type was set to Target, the system will
error and return a warning message.
ÏÏÏ
ÏÏÏ
13
ÏÏÏ

EDS Unigraphics NX
13-12 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bridge

Activity 13-1: Sheet Metal Bridge Creation

In this activity you will create a bridge feature.

Step 1 Open the part smd_seedpart. Save this part as xxx_bridge


where xxx are your initials.

 Make sure you're in the Modeling application.

Step 2 Edit the Expressions as follows:

 Change T to .060.

 Change R to .125.

ÏÏÏ
Step 3 Create the base feature.
ÏÏÏ
 Create a block using the following parameters and locate it ÏÏÏ
13
ÏÏÏ
at (0,0,0).

 X Length = 6.00
 Y Length = 3.25
 Z Length = T

Step 4 Remove rectangular sections from the base feature.

 Create two Rectangular Pockets using the parameters


underlined below and locate the features according to the
figure on the next page. Use the top face as the Placement
Face and any edge parallel to the XCĆaxis of the WCS for the
Horizontal Reference.

 X Length = l (lower case L) = 2.50


 Y Length = w (lower case W) = 1.25
 Z Length = T

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Sheet Metal Bridge

Hint: Use Line onto Line and Point onto Line to position the
Rectangular Pocket.
For the second Rectangular Pocket, just use the expressions l, w
and T for the parameters.

Step 5 Add Flange features to the two inset faces.

 Choose the Flange icon and select the front bottom


edge of the inset face as the Bend Edge.
ÏÏÏ
ÏÏÏ  Enter the following parameters:
ÏÏÏ
13
ÏÏÏ  Width = .750 (change to Width Expression)
 Tangent Length = 1.25
 Inside Radius = R
 Positioning Method = Manual
 Locate the Flange by aligning the top edges and the far right
edges to the placement face.

EDS Unigraphics NX
13-14 Sheet Metal Design
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Sheet Metal Bridge

 Repeat the process for the opposite side. Use


Information→Feature to link the first Flange Width and
Length p" numbers to the new Flange (i.e. Width = p18).

 Unform the part and orient your view to the Top view.

Notice the Flanges stick out farther than the original edges of
the block.

ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
The next series of steps will lead you through the process of
associating the Tangent Length of the Flange with the original
edges of the base block.

Step 6 Edit the parameters of the Front Flange.


 Choose Information→Expression→List All and locate the
first p" value for a Bend Allowance Formula (e.g.
p22=(p21+(p17*0.44))*rad(p19)) and then close the
Information window.

 Choose the Edit Feature Parameters icon , select the


first flange, and choose OK.

 Change Tangent Length value to w-the p" number found in


the previous step (e.g. w-p22).

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Sheet Metal Bridge

This sets the Tangent Length so it is 1.25 (w) minus the Bend
Allowance Formula (p22).

 Choose OK to the Flange and Edit Parameters dialog


windows.

If you correctly set the second Flange's Tangent Length equal to


the first Flange's Tangent Length, you should see both flanges
change.

Step 7 Form your part and orient your view to the Trimetric view.

Step 8 Create the Bridge features.

 Choose the Sheet Metal Bridge icon.

ÏÏÏ
 Select the top face of the original block as the Base Face

ÏÏÏ
then choose MB2 to advance to the next selection step.

ÏÏÏ
13
ÏÏÏ Base Face

Base Profile

EDS Unigraphics NX
13-16 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bridge

 Select the top left edge of the front Rectangular Pocket


feature as the Base Profile edge as shown above and choose
MB2 to advance to the next selection step.

 Select the top faces of the front Flange feature, which


include the bend face and the web face, as the Target Faces
and choose MB2 to advance to the next selection step.

Target Profile

ÏÏÏ
ÏÏÏ
Target Faces ÏÏÏ
13
ÏÏÏ
 Select the left edges of the front Flange feature on the same
face selected in the previous step as the Target Profile.

 Set the Construction Type option to ZĆBend (ArcĆLineĆArc).

 Enter a value of .500 for the Inside Radius.

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Sheet Metal Bridge

 Choose Apply to create the feature.

 Repeat this process for the opposite side trying to follow the
steps in the Cue Line.
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
Step 9 Unform the Flange features.

 Choose the Form/Unform icon and select the two


Flange features.

 Choose the Unform Selected Features button. Notice the


resultant shape resembles a straight edge cut on both sides.

EDS Unigraphics NX
13-18 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bridge

NOTE Since the Flange feature drives the shape of the


SMBridge feature, you can unform the SMBridge feature
by unforming the Flange. We do not recommend using
the Unform All function for Sheet Metal Bridge Features.

Step 10 Optional: Edit the Width of the front Flange feature and
the Inside Radius of the SMBridge feature to test the
limitations of the feature.

Step 11 Choose File"Close"Save and Close.

ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ

EDS
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13-19
Sheet Metal Bridge

SUMMARY The Sheet Metal Bridge application provides


you with a way to join two solid bodies.

In this lesson you:


 Created and edited Sheet Metal Bridges

ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ

EDS Unigraphics NX
13-20 Sheet Metal Design
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Multibend Bracket

Multibend Bracket
Lesson 14

PURPOSE To see the advantages of using the Multibend Bracket


feature.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create and edit a multibend bracket

This section contains the following activity:

Activity Page
14-1 Creating a Multibend Bracket . . . . . . . . . . . . . . . . 14-10

ÏÏÏ
ÏÏÏ
14
ÏÏÏ

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14-1
Multibend Bracket

The Multibend Bracket Dialog

The Multibend Bracket enables you to create a fully associative sheet metal
bracket defined from user selected reference geometry. Select 3D reference
geometry to define a set of planes. Using bend parameters that you define, the
Multibend Bracket unfolds this reference geometry into a base plane. Use the
Sketcher to develop a sketch of the unformed bracket outline based on this
unfolded reference geometry. The system extrudes the sketch into a solid and
applies the appropriate bends.

You can access the Multibend Bracket dialog from Insert→Sheet Metal

Feature→ Multibend Bracket or by selecting the Multibend Bracket icon


from the Sheet Metal Feature toolbar. To edit a Multibend Bracket, use
Edit→Feature or the Edit Feature toolbar.

Tree
List

ÏÏÏ
Bend
Tools

ÏÏÏ
14
ÏÏÏ
Outline
Tools
for
Sketching

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14-2 Sheet Metal Design
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Multibend Bracket

Selection Steps

The Multibend Bracket dialog is a Selection Steps dialog. This dialog is unique
in that there is only one step on the dialog, (which has no bitmap).

Tree List

The tree list controls the target for each action within the Multibend Bracket
dialog. Selecting geometry defines the plane for the highlighted node. In
addition, functions such as Add Bend, Delete Bend, and set Inner Radius
applies to the highlighted node. You can reach the Add Bend and Delete Bend
functions by clicking the right mouse button on the node.

Right mouse button


on the node for
additional functions

Base Plane

Select geometry to define a plane for the highlighted node on the tree list. The
position and orientation of the planes will determine the angle and location of
ÏÏÏ
each bend. You must select sufficient geometry to define a plane.
ÏÏÏ
14
Each piece of selected reference geometry is unfolded onto the base plane for ÏÏÏ
inclusion in the sketch. When a face is selected, the edges of the face are
unfolded to the base plane. No geometry is unfolded when a datum plane,
datum axis, or CSYS is selected. All selected geometry is, however, used to
define the location and angle of the bend. If you select a CSYS, the XY plane
defines the reference geometry plane. Errors will occur if you select insufficient
geometry to define a plane, or geometry that does not define a single plane.

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14-3
Multibend Bracket

Add Bend

This function adds a new bend to the tree list. The new bend node will be a
child of the highlighted node. You can only add a bend node if a base plane has
been defined for the parent node. Select reference geometry to define the
plane for the bend. Specify a bend radius and bend allowance formula. If
desired, specify an offset from the plane. Add additional bends as necessary.
Bends can be added to any node in the tree list by selecting the node in the tree
list that is to be the parent of the new bend node.

Add Intersection

This function adds a new intersection node to the tree list. The new node will
be the child of the highlighted node. You can only add an intersection node if a
plane has been defined for the parent node. The intersection line between the
current plane and its parent plane will be included as a reference in the sketch.

Reverse Material Direction

This function is used to change the material direction for the highlighted node.
The material direction also defines the direction of a positive offset. You can
only reverse the material direction if a plane has been defined for the node.

ÏÏÏ
ÏÏÏ
14
ÏÏÏ Delete Bend

This function deletes the highlighted bend node, and all of its children, from
the tree list. All data associated with these nodes is lost. You cannot delete the
base plane.

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14-4 Sheet Metal Design
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Multibend Bracket

Bend Allowance Formula

You can choose a Bend Allowance Formula by pressing this button. The Bend
Allowance Formula dialog is displayed below. You can select the Bend
Allowance Formula (BAF) from the list or you can enter the BAF in the text
field.

If Use Global is turned ON in global parameters for Bend Allowance Formula,


this option will be removed from the General Flange dialog.

Offset

You can offset the plane defined for the highlighted node from the selected
geometry using the Offset value. A positive offset value is always in the
ÏÏÏ
direction of the material direction vector. You cannot set an offset value until a
ÏÏÏ
14
plane has been defined. The value may also be an expression.
ÏÏÏ
If you have Preferences"Sheet Metal"Use Feature Standards turned ON, the
button on each field will give you a list of standard acceptable values.

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Multibend Bracket

Inner Radius

This field sets the inner radius for the highlighted bend node. The inner radius
must be a positive value or expression. You cannot set an inner radius value
until a plane has been defined. The base plane does not have an inner radius.

If you have Preferences"Sheet Metal"Use Feature Standards turned ON, the


button on each field will give you a list of standard acceptable values. This field
is not available if you have enabled a global inner radius value.

Intersection Thickness

This field defines the thickness of the intersection node. The intersection node
is treated a having two sides, separated by the given thickness value. The
Multibend Bracket feature determines which sides of the adjacent planes will
contact each other. In cases where you want to find intersections between
planes within one Multibend Bracket, (for example to avoid intersecting
bends), you should make the intersection thickness the same as the material
thickness.

ÏÏÏ
ÏÏÏ
14
ÏÏÏ

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14-6 Sheet Metal Design
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Multibend Bracket

Adjacent Face

The Adjacent Face button is only available for bend nodes that are defined
using the Attachment Edge selection filter. By default, the plane defined for an
attachment edge is that of the adjacent planar face that yields the smaller
thickness. The system will highlight the attachment face. Press the Adjacent
Face button to select the plane of the other adjacent face.

Sketch Tools

After all bends have been specified, the Sketch Tools must be accessed to
define the sketch. This function unfolds the selected reference geometry into a
sketch, and then invokes a subset of the normal Sketcher dialog. This dialog
lets you edit the hidden sketch that belongs to the Multibend Bracket. You ÏÏÏ
cannot create a new sketch or substitute an existing sketch. ÏÏÏ
14
ÏÏÏ
Upon completing the sketch, exit the Sketch Tools dialog to return to the
Multibend Bracket dialog.

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14-7
Multibend Bracket

Options

The Select only coplanar objects toggle allows you to only select objects that lie
in a single plane. Set the toggle OFF if you need to select any reference
geometry regardless of the plane. Objects that do not lie in the plane will be
projected into the reference plane.

Set the Global Parameters toggle ON to use the global preference settings for
Material Thickness, Inner Radius and Bend Allowance Formula. These settings
are only available if the global preferences are set appropriately. If you turn
OFF the toggle, the global value will not be used for that field.

Editing Multibend Brackets

Editing a Multibend Bracket is very similar to creating a Multibend Bracket. To


edit a Multibend Bracket, use Edit→Feature or the Edit Feature toolbar. Upon
entering the dialog, you can change bend parameters, add or delete bends, and
ÏÏÏ edit the sketch.
ÏÏÏ
14
ÏÏÏ If you add a new bend, the model will update when you enter the sketcher. Be
aware that if you delete faces and edges (due to deleting a bend or editing the
sketch) downstream features could be affected.

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Multibend Bracket

Construction Tips
 A Multibend Bracket will update if any of its parents (features,
expressions, geometry) change. In some cases, editing the geometry
that the bracket is associative to, by a significant amount, can cause
the Multibend Bracket to fail upon update. Many times what you will
find is that the sketch that controls the outline of the bracket has had
one of the dimensions reapplied in an alternate solution". If the
bracket fails to update, simply edit the Multibend Bracket feature,
enter the Sketch Tools dialog and apply an Alternate Solution to
resolve any incorrect dimension(s).
 The Multibend Bracket creates bend centerlines for each bend node.
Since these lines are used as application curves for hidden Sheet Metal
Bend features, all rules associated with that feature apply. At least
part of the bend centerline must lie within the outline of the sketch
geometry. The bend centerline must not extend past the outline such
that when it is projected onto the extruded sketch, it will yield two
curves. The system will center each bend centerline based on the
position on the first reference object selected.
 The Sketch Tools dialog allows you to create or edit the sketch that
defines the outer perimeter of a Multibend Bracket feature. Since the
sketch will be extruded, it is important to make sure there are no gaps
in this perimeter. When you leave the Sketch Tools dialog, the system
will extrude the sketch. If the extrusion failed, you will be shown the
location of possible gaps in the outline. Reenter the Sketch tools to
correct these gaps.
 Use the Sketch Tools dialog to edit the sketch of a Multibend Bracket
feature. While editing, note that you cannot delete active sketch curves
that are part of the extrusion. To delete these curves, first change them
to reference geometry using the "Convert To/From Reference" ÏÏÏ
function. Then exit the Sketch Tools dialog to cause the Multibend ÏÏÏ
14
Bracket to update. You may then reenter the Sketch Tools dialog to
delete the unused sketch curves.
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Multibend Bracket

Activity 14-1: Creating a Multibend Bracket

In this activity you will create a multibend bracket around an existing solid
body.

Step 1 Open and examine the assembly.

 Open the part smd_multibnd_brkt_2 and Save As


***_multibnd_brkt_2.

ÏÏÏ Ensure you're in the Modeling application.


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14
ÏÏÏ Step 2 Establish the parameters for the bracket.

 Choose Tools"Expressions...

 Choose the T variable and change the value to .080 .

 Choose the R variable and change the value to .080 .

 Choose OK.

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Multibend Bracket

Step 3 Set the sheet metal preferences for the part.

 Choose Preferences→Sheet Metal...

 Select aluminum in the Part Materials window.

 Toggle ON Use Feature Standards.

 Choose the Global Parameters button.

 Toggle ON Use Global Thickness.

 Set the Thickness option to Use Expression.

 Enter T for the Thickness expression.

 Toggle ON Use Global Bend Radius.

 Enter R for the Bend Radius expression.

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 Toggle ON Use Global for Bend Allowance Formula. No


changes to the default are required.

ÏÏÏ
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14  Confirm your settings and choose OK twice.

ÏÏÏ Step 4 Create the Multibend Bracket.

NOTE Consider turning OFF the Assembly and Model


Navigators to take full advantage of the graphics screen.

 Change the work layer to 22 and choose the Multibend

Bracket icon.

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Multibend Bracket

 Select the top face as the BASE_PLANE.

Select this face

 If needed, choose Reverse Material Direction


to flip the vector so it points upward.

 Choose the Add Bend icon.

TIP Another way to add a bend is by placing the cursor


over the BASE_PLANE node in the tree listing,
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selecting MB3 and choosing Add Bend.
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Multibend Bracket

 Select the bottom edge of the boss, as shown, for the


reference geometry.

NOTE Consider turning OFF shading.

Material direction

Select this edge

 If needed, choose Reverse Material Direction


to flip the vector so it points in the direction shown above.

 Highlight the BASE_PLANE at the top of the Multibend


Bracket dialog. This is necessary because the next flange
ÏÏÏ needs to be created off of the same base plane.
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ÏÏÏ

 Choose the Add Bend icon.

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Multibend Bracket

 Select the front face of the solid for the reference geometry.

Select this face

 If needed, choose Reverse Material Direction


to flip the vector so it points in the direction shown above.

 Enter .030 for an Offset value.

 Highlight the BASE_PLANE at the top of the Multibend


Bracket dialog again.

 Choose the Add Bend icon.


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Multibend Bracket

 Select the back face of the solid for the reference geometry.

Select the
back face

 If needed, choose Reverse Material Direction


to flip the vector so it points in the direction shown above.

 Enter .030 for an Offset value.

 Highlight the BASE_PLANE at the top of the Multibend


Bracket dialog. Once again this is necessary because the next
flange needs to be created off of the same base plane.

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 Choose the Add Bend icon.

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Multibend Bracket

 Select the three edges, as shown below, for the reference


geometry.

Select the three


bold edges

 If needed, choose Reverse Material Direction


to flip the vector so it points in the direction shown above.

NOTE You can review your geometry selection for each bend by
highlighting the applicable bend node (e.g. BEND_01) in
the tree listing.

Step 5 Create an intersection curve.

 Highlight BEND_01 at the top of the Multibend Bracket ÏÏÏ


dialog. ÏÏÏ
14
ÏÏÏ
 Choose the Add Intersection icon.

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Multibend Bracket

 Select the face shown below for the reference geometry.

Select this
face

 If needed, choose Reverse Material Direction


to flip the vector so it points in the direction shown above.

Since we only selected the bottom edge of the boss for the
reference geometry we can use the Add Intersection option to
imprint" a curve onto the BEND_01 face for reference.

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Step 6 Create the outline for the bracket.

 Choose the Sketch Tools icon.

 Make all layers but the work layer invisible.

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Multibend Bracket

 For clarity purposes, Blank the objects shown below.


(Edit"Blank"Blank...)

Blank these
objects

NOTE The reference geometry is added to the sketch as

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Extracted Curves and are made reference (grey and

ÏÏÏ
phantom font). They can be converted to active for use in
the outline if desired. 14
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 Fit the view.

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Multibend Bracket

 Using the Profile icon freehand sketch the " shape


shown below.

NOTE Make sure all lines created are horizontal and vertical. If
necessary, apply geometric constraints of horizontal or

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vertical to capture the constraints.

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ÏÏÏ Step 7 Constrain the bracket outline.

 Choose the Constraints icon.

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Multibend Bracket

 Apply Collinear constraints to the pairs of curves shown


below.

1 2

Some of the geometry has been removed for clarity.

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ÏÏÏ
 Choose the Dimensions icon.

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 Create the dimensional constraints shown below.

Intersection curve
2.000

1.500 1.000

0.500 0.500

1.000

0.500

0.125

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Multibend Bracket

 Create the circle to the dimension shown below on both


sides. If necessary, apply concentric geometric constraints to
the extracted circles to align the arc centers.

∅ 0.625

Some of the geometry has been removed for clarity.

 Create the slot shape to the dimensions shown below.

0.625
0.3125

0.5625

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1.125

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Some of the geometry has been removed for clarity.

NOTE Make sure that the radius is tangent to both sides of the
vertical lines. If necessary, apply a tangent geometric
constraints to capture the intent.

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Multibend Bracket

 Check to see if the Status Line states that the Sketch is fully
constrained. If it does not indicate how many constraints are

left choose the Dimensions icon again.

 Choose Edit→Blank→Unblank All of Part.

 Choose the Finish Sketch icon.


This will force the multibend bracket to update, the sketch and
datums will disappear, the sketch will be extruded into a solid
and bend features will be applied to the part. Once the update
is finished, the bracket should look like the one below.
 Shade and rotate the part to examine the bracket.

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ÏÏÏ  If necessary, orient the view to Trimetric.

 Choose OK in the Multibend Bracket dialog.


This will force the multibend bracket to finish the creation
process establish the feature.

Step 8 Edit the base solid to test the associativity of the bracket.

 Choose the Model Navigator icon.

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Multibend Bracket

 Place your cursor on the SIMPLE_HOLE(6) feature and


press MB3.

 Choose Edit Positioning.

 Choose Edit Dimension.

 Select the vertical dimensions and edit the value to 1.25 .

 Choose MB2 three times to accept the change and update


the model.

 Choose the Model Navigator icon.

 Place your cursor on the BOSS(5) feature and press MB3.

 Choose Edit Positioning.

 Choose Edit Dimension.

 Select the vertical dimensions and edit the value to 3.00 .

 Choose MB2 three times to accept the change and update


the model.

NOTE In some cases, editing the model a significant amount can


ÏÏÏ
cause the Multibend Bracket to not update properly.
ÏÏÏ
14
Many times what you will find is that the sketch that
controls the outline of the bracket has had one of the ÏÏÏ
dimensions reapplied in an alternate solution". If the
bracket fails to update, simply edit the Multibend Bracket
feature, enter the Sketch Tools dialog and apply an
Alternate Solution to resolve any incorrect dimension.

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Multibend Bracket

 Shade and rotate the part to examine the bracket.

Step 9 Choose File"Close"Save and Close.

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Multibend Bracket

SUMMARY The Multibend Bracket feature creates an


associative bracket that moves with the
respectively referenced geometry. It is
comprised of formable features so it can be
unformed.

In this lesson you:


 Created and Edited a Multibend Bracket
 Worked in an assembly environment.

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Multibend Bracket

(This Page Intentionally Left Blank)

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Sheet Metal Bracket

Sheet Metal Bracket


Lesson 15

PURPOSE Create and edit sheet metal brackets using the Sheet
Metal Bracket utility.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create and edit brackets

This section contains the following activity:

Activity Page
15-1 Bracket Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18

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Sheet Metal Bracket

The Sheet Metal Bracket Utility

The sheet metal Bracket is a utility you can use to create a bracket from
reference geometry. It is a collection of features.

Each bracket consists of a Base Pad, created by an Extrude feature and a


Flange or General Flange feature built off the Base Pad. One or more Sheet
Metal Cutout features then trim the flange to size. The Sheet Metal Cutout is
built to match input reference points. The resulting bracket will align with the
reference geometry. It is possible to build subsequent flanges off of existing
bracket geometry.

The flanges and general flanges created by the Sheet Metal Bracket utility can
be formed and unformed as any other flange feature.

To edit a bracket, you must edit the individual features that make up the
bracket. A bracket is not associative to its reference geometry.

You can access the Sheet Metal Bracket dialog from Insert→Sheet Metal

Feature→Bracket or by selecting the Sheet Metal Bracket icon in the


Sheet Metal Feature toolbar. To edit a Sheet Metal Bracket, use Edit→Feature
or the Edit Feature toolbar.

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Sheet Metal Bracket

The Sheet Metal Bracket Dialog

Once you bring up the Sheet Metal Bracket dialog, you will see and have access
to the following menus:

Bracket
parameters

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Sheet Metal Bracket

Selection Steps
There are four choices for geometry selection. They are Base Face, Base
Clearance Points, Reference Face, and Reference Clearance Points.

Clearance Reference Face


Points
Flange
Base Pad
Clearance Base Face
Circles

Flat Pattern under Finished bracket


construction

Base Face

The first selection step leads you to pick the Base Face. The Base Face is a
single face used to construct the bracket Base Pad. The Base Face must be
planar. You may set the Filter to allow the selection of a Plane, Face, or Datum
Plane.

Base Clearance Points

The second step allows you to select Clearance Points on the Base Face. This
step is optional. If you don't select any geometry, the Pad Length parameter
will define the Base Pad dimension.

ÏÏÏ
ÏÏÏ
The system uses the Clearance Points to define the outline of the Base Pad.
There may be no more than two Base Clearance Points. Use the filter to allow
15
ÏÏÏ
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the selection of existing Points, an Edge, a Curve, or an Arc Center.

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Sheet Metal Bracket

The selection of Points or Arc Centers causes the system to define a Clearance
Circle for each selection. If you select a curve, the system will construct a
Clearance Circle at each end point. The system will construct the Base Pad
outline tangent to the Clearance Circles.

If you select an Edge for this step, the Base Pad edge will coincide with the
selected edge. No Clearance Circles will be applied.

Reference Face

The third selection step lets you pick the Reference Face. This face defines the
mating surface for the bracket flange. The Reference Face must intersect the
plane of the Base Face. This will generate the Intersection Curve. If the
intersection curve is linear, a Flange feature is constructed. If the intersection
curve is nonlinear, a General Flange feature is constructed. When a General
Flange is built, it will approximate the Reference Face using linear cross
sections. The initial bracket width is the length of the intersection curve.

NOTE One of the benefits of the Bracket feature over the


Multibend Bracket feature is the ability to select a
non-planar face for a reference face.

You may set the Filter to allow the selection of a Plane, Face, or Datum Plane.

The bend direction of the Flange is determined from the pick point on the
Reference Face. The Flange will always bend toward the pick point.

Reference Clearance Points

The fourth selection step allows you to select Clearance Points on the
Reference Face. This step is optional. If you don't select any geometry, the
Flange Length parameter will define the Flange contour length.

The system uses the Clearance Points to define the outline of the Flange. There
may be no more than two Reference Clearance Points. Use the Filter to allow
ÏÏÏ
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15
the selection of existing Points, an Edge, a Curve, or Arc Centers. ÏÏÏ
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Sheet Metal Bracket

The selection of Points or Arc Centers causes the system to define a Clearance
Circle for each selection. If you select a curve, the system will construct a
Clearance Circle at each end point. The system will construct the Flange
outline such that it is tangent to the Clearance Circles.

If you select an Edge for this step, the Flange edge will coincide with the
selected edge. No clearance circles will be applied.

Parameters

The following parameters define the overall dimensions of the bracket. After
building the Base Pad and Flange, you will be given the opportunity to edit the
outline.

If you have Preferences"Sheet


Metal"Use Feature Standards
turned ON, the arrow button on each
field will give you a list of standard
acceptable values.

Reverse Material Direction

Upon selecting a Base Face and Reference Face, the system will display two
vectors that indicate the material direction of the bracket. The bracket faces
will align with the Base and Reference Faces, however, you can choose to align
on the bracket inner or outer faces. Switch between the two using the Reverse
Material Direction button

Clearance Distance

The Clearance Distance defines the radius of the Clearance Circles. This

ÏÏÏ
parameter has two effects. Since the bracket outline is tangent to these curves,
it defines the minimum distance of the Clearance Point to the edge of the
ÏÏÏ
15 bracket. It also defines the corner radius (if the Add Rounded Corners option is
ÏÏÏ
ÏÏÏ
enabled).

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Sheet Metal Bracket

Material Thickness

A bracket is constructed from an Extrude feature and a Flange or General


Flange. The Material Thickness is used as the extrusion distance and the
Flange thickness.

Bend Radius

The Bend Radius is the constant inside radius of the Flange or General Flange
feature.

Pad Length

The Pad Length defines the distance from the Intersection Curve to the
opposite edge along the Base Face. This parameter is only used if no Base
Clearance Point geometry is selected.

Flange Length

The Flange Length defines the contour length of the Flange or General Flange
feature. This parameter is only used if no Reference Clearance Point geometry
is selected.

Offset Distance

When you specify an Offset Distance, the resulting Flange or General Flange
will be offset from the Reference Face, by the given distance. With offset
distance, you can allow room for the bend to go around an outside corner or
provide for a shim under the reference flange.

Chordal Tolerance

ÏÏÏ
The Chordal Tolerance defines how closely the resulting General Flange will
match a non-planar Reference Face along the Bend Edge. The General Flange
is built from section curves. This parameter controls the number of sections ÏÏÏ
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Linear Tolerance

The Linear Tolerance defines how closely the resulting General Flange will
match a non-planar Reference Face. The General Flange is built from section
curves, each consisting of an arc and a line. This parameter controls the
maximum distance between the Reference Face and the General Flange face.

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Sheet Metal Bracket

Bend Allowance Formula

You can choose a Bend Allowance Formula by pressing this button. The Bend
Allowance Formula dialog is displayed. You can select the Bend Allowance
Formula (BAF) from the list or you can enter the BAF in the text field.

Add Rounded Corners

The Add Rounded Corners toggle lets you create a bracket in which the corners
are constructed from the Clearance Circles. The default is "ON".

NOTE When this option is "OFF" the bracket outline is created


using lines that are tangent to the Clearance Circles. It is
possible that these tangent lines could intersect a
considerable distance from the bracket, or even be
parallel. This can cause undesirable effects when the
outline is applied. For this reason, we recommend the use
of this option whenever possible. You can reduce such
problems by increasing the Bracket Margin under
Preferences→Sheet Metal.

Options

You can toggle the Global Parameters ON and OFF here. Global Parameters
are selectable only if the options are ON in the Sheet Metal Preferences.

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Sheet Metal Bracket

Create or Unite

After you press OK or Apply on the main dialog, you will be asked if a new
body should be created for the Base Pad or it if should be United to some
existing body. You may use the Unite option to build a single bracket that
consists of several Flanges. After choosing one of these options, the system will
build the Base Pad and the Flange or General Flange features. It will then
unform the Flange and allow you to edit the bracket outline.

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Sheet Metal Bracket

Edit Outline

After the system builds the bracket and unforms the Flange, you are given the
opportunity to edit the bracket outline. The default outline extends from the
Clearance Circles to the ends of the Base Face ć Reference Face intersection
curve. You may edit each intersection curve end point independently. The end
points are labeled "Point 1" and "Point 2". The buttons on the Edit Outline
dialog refer to Edit Point1 and Edit Point2 respectively.

While editing one of the intersection curve end points, a temporary point
marker will indicate the new position of the point. When you press OK, the
outline will update. If you press Back, the geometry you created will be
removed, and control will return to the main dialog.

You are given several editing methods:

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Normal to Curve

The Normal to Curve option moves the intersection curve end point to a position on a line
tangent to the Base Face Clearance Circle and normal to the intersection curve. The tangent
line on the Flange side will meet that point, but it might not be normal to the curve. This
option is not available if there are no Clearance Points on the Base Face. In the figure
below, the original outline is shown as a solid line and the modified outline is shown as a
dashed line.

Flange Side

Intersection
Curve
Original
Outline

Base
Face
Base Face
Clearance
Circles

Normal to Curve

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Between Circles

The Between Circles option moves the intersection curve end point to lie on a
line tangent to the Clearance Circles from the Base Face to the Reference Face.
This option is not available if there are no Clearance Points. In the figure
below, the original outline is shown as a solid line and the modified outline is
shown as a dashed line.

Original
Outline

Flange Side

Intersection
Curve

Base Face
Clearance
Circles

Base Face

Between Circles

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Along Vector

The Along Vector option lets you choose the direction of the outline on the Base
Face. The system presents the Vector Constructor dialog. You may select any
vector. The system will project the vector onto the base face plane and move the
intersection curve end point to lie on a line that is parallel to the specified
vector and tangent to the Base Face Clearance Circle. The tangent line on the
Flange side will meet that point. If the specified vector and tangent line does
not intersect the Base Face ć Reference Face intersection curve, an error is
given. In the figure below, the original outline is shown as a solid line and the
modified outline is shown as a dashed line.

Original
Outline

Vector

Base Face
Clearance
Circles

Base Face

Along Vector

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Drag Point

The Drag Point option lets you interactively drag the intersection curve end
point along the curve. The point starts at one end of the intersection curve (0%
or 100%) and can be moved by adjusting the slider to a point anywhere along
the curve. You can also enter a percentage of the arc length or an actual arc
length. It is not possible to extend beyond the original intersection curve
endpoints.

Drag Point

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Point Constructor

The Point Constructor option lets you pick any point in space to serve as the
intersection curve end point. The system will project the point onto the
intersection curve in a direction normal to the curve, then create a line from
that point tangent to the Clearance Circles. In the figure below, the original
outline is shown as a solid line and the modified outline is shown as a dashed
line.

Point in Space

Original
Outline

Point in Space

Point Constructor

Reset

The Reset option is a convenience function that simply moves the intersection
curve end point to its original position.

Creation of a Sheet Metal Cutout

Press OK or Apply on the Edit Outline dialog to complete the construction of


the Bracket. The system creates a Sheet Metal Cutout feature to define the
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outline and then forms the Flange or General Flange feature.
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Sheet Metal Bracket

Construction Tips

MultiĆflanged Brackets

It is possible to make a bracket that contains multiple flanges. The procedure is


identical to that of a singleĆflange bracket, however, you must unite the Base
Pad of the second bracket to the Base Pad of the first bracket. In order to build
the second Base Pad to the proper size, you could select an edge from the first
Base Pad in the Base Clearance Points selection step.

If you select the web of an existing flange as the Base Face, the system will
create the Base Pad using Sketch, Bounded Plane, and Thicken features. This is
necessary to make the Base Pad follow the Base Face as it forms and unforms.

Editing Sheet Metal Brackets

A Sheet Metal Bracket is not a feature, but a collection of features, thus, each
feature must be edited independently. The Flange and General Flange features
are not associative to the Reference Face. Further, the Sheet Metal Cutout is
not associative to the Clearance Points. However, the curves that define the
initial Base Pad shape may be edited if desired. Also, the curves that define the
Sheet Metal Cutout may be modified. Either set of curves may be added to a
sketch for better parametric control of the outline, however, keep in mind the
feature creation hierarchy when trying to add the curves to a sketch.

Bracket Margin

During construction of a bracket, the system creates a base pad trimmed to the
proper size. The original base pad's size is determined by the intersection curve
and the clearance distance dimension. The Bracket Margin value is a
percentage that increases these dimensions. It only affects the size of the
original base pad and not the final bracket. You should increase this margin if
the Bracket outline curves do not lie entirely on the base pad. There may be a
need to increase the margin if you have Add Rounded Corners turned OFF.
You can access the Bracket Margin in Preferences→Sheet Metal.

NOTE If desired, the bracket margin can also be changed in the


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ug_smd.def default file.
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Activity 15-1: Bracket Creation

In this activity you will create and edit sheet metal brackets.

Step 1 Open the part smd_bracket. Save this part as


xxx_bracket where xxx are your initials.

Step 2 Change the default material for the part.


 Make sure you are in the Modeling application.

 Choose Preferences→Sheet Metal...

 Select aluminum in the Part Materials window.

 If necessary, toggle ON Use Feature Standards.

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 Choose OK to accept the preference settings.

Step 3 Identify the mating surfaces and clearance objects of the


bracket.

 Choose the Sheet Metal Bracket icon.

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Sheet Metal Bracket

 Select the top of the horizontal solid the Base Face.

Base Face

 Click MB2 to advance to the Clearance Points step.

 Change the filter pulldown to Arc Center.

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 Select the left and right holes on the Base Face as your Base
Face Clearance Points.

Base Face
Clearance
Points

 Click MB2 to advance to the Reference Face step.

 Select the front face of the other solid as your Reference


Face.

Reference
Face

 Click MB2 to advance to the Clearance Points step.

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Sheet Metal Bracket

 Again, change the filter pulldown to Arc Center.

 Select the left and right holes on the Reference Face as your
Reference Face Clearance Points.

Clearance
Points

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15
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ÏÏÏ
EDS Unigraphics NX
15-22 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bracket

Step 4 Establish the size parameters of the bracket.

 Change the parameters of the bracket to match the values


shown below.

NOTE Use the Standard arrows to help define valid size


parameters. If the values shown are not available type
them in.

Use
Standard
arrows

 Choose OK.

 Change your work layer to 42. This is to place the bracket


curves on a separate layer.

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15
ÏÏÏ
ÏÏÏ
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Sheet Metal Bracket

Step 5 Create the flat pattern.

 Choose Create in the dialog to create the flat pattern.

Now you will adjust the flat pattern by moving the end points.

 Choose the Edit Point1 icon.

The Editing Options dialog offers you several options to move


point 1.

 Choose the Between Circles option.

ÏÏÏ
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15
ÏÏÏ
ÏÏÏ
 Choose OK.

EDS Unigraphics NX
15-24 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bracket

 Choose the Edit Point2 icon.

 Choose the Between Circles option.

 Choose OK twice.

Step 6 Clean up your screen.

 Move the bracket to layer 15.

 Make layer 15 your work layer, layer 41 selectable and layer


42 invisible. This will display points at the hole centers and
open a new layer for your bracket.
ÏÏÏ
ÏÏÏ
15
 Shade your model by selecting the Shaded icon.
ÏÏÏ
ÏÏÏ
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Sheet Metal Bracket

Notice the new bracket is without fastener holes. You will need
to add them.
 Return your model to wireframe by selecting the Wireframe

icon.

Step 7 Copy the mating holes from the reference solid onto the
reference flange of your new bracket.
 Choose Edit→Copy Feature...
 Select SIMPLE_HOLE(1) in the filter window.

This hole will highlight

Reference
Flange

 Choose OK.
 Choose Edit→Paste.

 Change the Expression Transfer Mode to Link to Original.

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15
ÏÏÏ
ÏÏÏ
EDS Unigraphics NX
15-26 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bracket

 Select the top surface of the Reference Flange as the Trim


Face.

 Select the back surface of the Reference Flange as the


Planar Placement Face.

 Choose OK.

 Choose the Point onto Point icon.

 Select the point at the center of SIMPLE_HOLE(1).

Select this point

Reference
Flange

 Repeat the Copy/Paste using SIMPLE_HOLE(2) and its


corresponding point.

Step 8 Copy the mating holes from the base solid onto the base
pad of your new bracket.
 Choose Edit→Copy Feature...

 Select SIMPLE_HOLE(6) in the filter window.

Base Pad

This hole will


highlight
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Sheet Metal Bracket

 Choose OK.

 Choose Edit→Paste.

 Select the top surface of the Base Pad as the Trim Face.

 Select the bottom surface of the Base Pad as the Planar


Placement Face.

 Choose OK.

 Choose the Point onto Point icon.

 Select the point at the center of SIMPLE_HOLE(6).

Select this point

To get:

 Repeat the Copy/Paste using SIMPLE_HOLE(7) and


SIMPLE_HOLE(8) and their corresponding points.

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15
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EDS Unigraphics NX
15-28 Sheet Metal Design
Student Guide All Rights Reserved
Sheet Metal Bracket

 Make layer 41 invisible. Your finished part should look like


the one below:

Step 9 Choose File"Close"Save and Close.

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15
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Sheet Metal Bracket

SUMMARY The Sheet Metal Bracket utility combines the


functions of extrusion, flange, and sheet metal
cutout to create brackets with a variety of edge
styles.

In this lesson you:


 Created a sheet metal bracket
 Edited sheet metal brackets
 Added holes to sheet metal brackets
The edges of your bracket can be normal to the intersection
curve, tangent to the clearance circles, parallel to a vector or
lined up with a point in space.

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15
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EDS Unigraphics NX
15-30 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

Flat Pattern ÏÏÏ


Lesson 16
ÏÏÏ
ÏÏÏ
16
ÏÏÏ

PURPOSE To create, edit, and annotate different sheet metal flat


patterns.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Create flat patterns


 Change preferences for flat patterns and flat
pattern annotations
 Edit and update flat pattern displays.

This section contains the following activities:

Activity Page
16-1 Creating a Simple Flat Pattern Drawing . . . . . . . 16-12
16-2 Creating a Flat Pattern Drawing Assembly . . . . . 16-27

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Flat Pattern

ÏÏÏ The Sheet Metal Design Flat Pattern function allows for the creation of a 2D
ÏÏÏ wireframe profile of an unformed 3D part that accounts for material

ÏÏÏ
16
ÏÏÏ
deformation and elongation. Whereas the Part In Process function operates
only on sheet metal features, the Flat Pattern operation works on any solid or
sheet body, with or without sheet metal features, and independent of associated
forming tables.

NOTE If the part is a sheet body, the thickness of the part is set
to zero and the default Bend Allowance Formula (BAF)
used by the Flat Pattern function does not affect the
resultant flat pattern wireframe profile.

Three different mathematical solving methods are employed to map the model
geometry into the flat pattern definition. With these solvers, the user has the
control to specify which faces of a part are flattened and how they are flattened.
The generated flat pattern is associated to the model geometry and will update
when the model geometry changes.

NOTE The flat pattern profile has a oneĆway associativity to its


defining 3D part. Changes in the model geometry will be
reflected in the flat pattern definition. Changes in the flat
pattern profile will not be reflected in the 3D model
geometry.

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16-2 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

The Flat Pattern Dialog ÏÏÏ


ÏÏÏ
To enter the Flat Pattern function you must be in the Sheet Metal Design
application. The Flat Pattern dialog is presented when you choose Tools→Flat
ÏÏÏ
16
ÏÏÏ
Pattern.

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16-3
Flat Pattern

ÏÏÏ Creating a Flat Pattern


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
When you enter the Flat Pattern function for the first time, you are prompted
to select a starting face. Once you select a face on the active part, the system
automatically traverses the face and all adjoining faces on the same side of the
part, and then calculates the flat pattern definition for its given face.

Once part face identification is established, the Apply or OK buttons becomes


active. Simply choosing either of these buttons will create the flat pattern, with
the group name, on the layer specified within the Flat Pattern dialog. This
automated capability allows you to quickly create a flat pattern with a minimal
amount of effort.

You may traverse a solid body at any time while in the Flat Pattern module,
even if a flat pattern already exists, by simply selecting another start face.
Depending on your flat pattern preferences, the system will either allow you to
create a new flat pattern, or will attempt to replace the existing one.

Updating a Flat Pattern

If the Auto Update option in the SMD Flat Pattern Preferences dialog is toggled
ON, the flat pattern geometry will update whenever you enter or exit the Sheet
Metal Design application. If you disable the Auto Update option, you must
manually update the flat pattern using the Apply button in the Flat Pattern
dialog. When the flat pattern is updated, either automatically or manually, only
the master flat pattern for the active body is changed.

NOTE When the flat pattern is updated, any associated objects


(such as Drafting objects) will maintain their associativity
to any curve geometry that didn't change.

The Apply button is always active whenever a flat pattern already exists for the
active body. This allows you to reĆassign a mathematical solver to any selected
face Then you can update the flat pattern at any time while in the Sheet Metal
Design application, even if Auto Update is ON.

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16-4 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

Name and Layer


ÏÏÏ
ÏÏÏ
You may enter a name and layer designation for the flat pattern in the
respective input fields at any time prior to creating the flat pattern. Or you may
ÏÏÏ
16
ÏÏÏ
accept the default values shown which are set within the Preferences→SMD
Flat Pattern dialog. If you are creating multiple flat patterns, each flat pattern
must have a unique name.

NOTE If you create multiple flat patterns, only the most recent
flat pattern maintains associativity with the part. This is
called the master flat pattern.

Traverse Body

If a flat pattern already exists for the active body, then the Traverse Body option
becomes available. If Auto Update is turned OFF, you can use the Traverse
Body to reĆtraverse the solid body to find any new part faces and reĆcreate the
flat pattern definition.

You must be careful, however, since this function wipes out any manual
modifications you have made to the flat pattern. It will identify mathematical
solvers for all the faces just as it did during the original traversal. If you had
reĆassigned a mathematical solver to an existing face, you must repeat this
procedure again after reĆtraversing the solid body.

Once the body has been reĆtraversed, you must use the Apply button to update
the flat pattern geometry.

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16-5
Flat Pattern

ÏÏÏ Unform and Form Sheet Metal Features


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
These two options allow you to unform and form the sheet metal features on
the active body.

In cases where you have deformed features that pass into or thorough bends, it
is recommended that you completely unform all sheet metal features before
creating a flat pattern. Ambiguity in the flat pattern definition and loss of
deformation characteristics embedded in the sheet metal feature will then be
avoided.

The state of the part body will be saved when you create the flat pattern. Then,
whenever the flat pattern is updated, and if Auto Update is ON, the part will
automatically revert to the original flat pattern creation state upon entering the
Sheet Metal Design application.

NOTE Currently, accurate flat pattern geometry can only be


created for parts in a fully formed or fully unformed state.

Change Body

You may only work with one solid or sheet body at a time. If you wish to create
or update a flat pattern for a different body in your partfile, you must choose
the Change Body button and select the different body.

Bend Allowance Formula

You can choose a desired Bend Allowance Formula to be applied to a body that
does not contain sheet metal features from the Flat Pattern dialog. If no BAF is
selected, the default BAF will be used as specified in the Sheet Metal
Preferences dialog (under the Global Parameters button).

NOTE Parts that contain sheet metal features will always use the
BAF assigned to each feature at the time of creation. In
order to change this BAF you must edit each features
BAF. In cases where it is desired to change all the BAF
assigned to a part it is recommended that you use the Use
Global option for Bend Allowance Formula in the Global
Parameters dialog.

EDS Unigraphics NX
16-6 Sheet Metal Design
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Flat Pattern

Traverse Control Algorithm


ÏÏÏ
ÏÏÏ
Traverse Control refers to the method by which the system identifies the faces
of a part to be flattened. Four methods are available; Sheet Metal, Generic,
ÏÏÏ
16
ÏÏÏ
Woven, and None. If the Sheet Metal or Generic methods are used, the system
automatically finds all of the faces on the same side of the part as the initial flat
pattern base, or start, face. If Woven or None is used, only the start face of the
part is identified; no traversal of the part occurs. Different flat pattern creation
requirements may warrant the use of the different Traverse Control Algorithms:

 Sheet Metal Ć Choose the Sheet Metal traversal algorithm for parts
that reflect a formable manufacturing process, and typically exhibit a
uniform thickness.
 Generic Ć When flat representations are required for parts where the
concept of thickness does not apply, better results are obtained with
the Generic algorithm.
 Woven Materials Ć This method is used when you want to flatten a part
made of woven materials such as composites. With this method only
the selected start face is flattened.

NOTE See Appendix B for more information and an activity on


this Algorithm.

 None Ć Choose None when you want to flatten only the start face or a
subset of faces of the body. You may then select additional faces to
flatten using the appropriate Layout Option. You must insure that the
additional faces you select are connected somehow to the start face.
Specifying None will also prevent traversal of the part during
automatic update.

Location

Previously only available on Preferences"SMD Flat Pattern, the Location


window is now also available on the Flat Pattern dialog. This option allows you
to locate the flat pattern from the WCS or the Start Position on the Start Face.

NOTE When the Location option is set to WCS the Orientation


Vector Layout Option becomes available.

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Flat Pattern

ÏÏÏ Layout Options


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
Distortion Faces Projection Faces

Additional Curves
Area Preserving
Faces

Features
Starting Position Cutting Edges
Orientation Vector

The Layout Options provide a means to interrogate the traversed part faces to
identify and add, change, or remove the mathematical solver which was
automatically assigned to the face. These options also provide the capability of
defining cut edges, projecting extraneous curve geometry onto the flat pattern,
respecifying the starting position and orientation for flat pattern generation,
and identifying faces defined by sheet metal features in the part.

Area Preserving Faces

This icon, when selected, highlights all the faces in the traversed part which are
assigned the Area Preserving mathematical solver. This solver preserves the
area of the face upon creation of the flat pattern definition. Most faces in a part
are assigned this solver.

While the class selection dialog is displayed, you may select additional part
faces to which this Area Preserving solver will be assigned, or you may deselect
highlighted faces by using the Shift key and selecting the face.

NOTE Only one solver method may be assigned to a face at a


time. If a face is already assigned a mathematical solver,
you can change the assigned solver by reselecting the face
with any of the other mathematical solver icons selected.
Doing this will automatically remove the old solver and
assign the new one.

EDS Unigraphics NX
16-8 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

ÏÏÏ
Distortion Faces ÏÏÏ
For some extreme bend geometry, faces of the part actually distort upon
ÏÏÏ
16
ÏÏÏ
forming (A toroidal face is an example of a face that will distort upon forming).
For these faces, an area preserving solver is not desired. A more realistic
solution may be obtained using the Distortion solver. Faces which must stretch,
compress, or buckle are good candidates for the Distortion solver.

The Distortion Faces icon behaves in the same manner as the Area Preserving
icon. Once selected, all affected faces will highlight. You may add or delete
highlighted faces using the class selection dialog.

NOTE When a distorted face is flattened, it may stretch or


compress. This stretching or compressing continues
through the part until the part edge is reached.
Therefore, when a distortion solver is assigned to a face,
you must make sure that the face is at the edge of the
part, or next to a set of distortion faces at the edge of the
part.

Projection Faces

This solver is used to project its assigned face onto the flat pattern plane
without distorting adjacent faces. Bead faces are examples of projectionĆtype
faces.

NOTE Currently, the Projection solver only functions if an Area


Preserving face is beneath the projected faces. This
allows the Projection solver to map the flat pattern curves
of the projection faces onto the underlying faces. Hollow
beads, punched, and semiĆpierced features are currently
unsupported projectable features.

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Flat Pattern

ÏÏÏ
ÏÏÏ Cutting Edges
ÏÏÏ
16
ÏÏÏ In some cases, adjacent faces in the body are not intended to be adjacent in the
flat pattern. Unforming your part before allowing a traversal to occur will
prevent most of this type of flat pattern ambiguity. For parts with nonĆsheet
metal features, the Cutting Edges option allows you to identify the separation
edge between these faces. Thus the system will not attempt to create a
continuous flat pattern profile of the adjacent faces.

NOTE If you reĆtraverse a part with established cutting edges,


you will have to reĆidentify these edges.

Cutting Edges

Additional Curves

In addition to the normal curves that are created for the flat pattern, you may
use this option to select additional curves, edges, or points and add them to
your flat pattern definition. The selected geometry is first projected to the body
of the part, and then created with the flat pattern profile.

NOTE If you unform a part before creating a flat pattern, make


sure your additional curves will project onto the correct
face of the part. Or add the curves after the flat pattern is
created and the part is reĆformed.

EDS Unigraphics NX
16-10 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

ÏÏÏ
Features ÏÏÏ
This option, when selected, will highlight all the faces of sheet metal features
ÏÏÏ
16
ÏÏÏ
identified during traversal of the part.

Start Position

The start face is defined as the first face you select to begin the traversal
operation. With the appropriate preference setting, the flat pattern geometry
will be created coĆplanar with the start face. The Start Position is the point on
the start face, as given by the cursor selection point, from which all material
distortion will radiate. Selecting this icon will allow you to change the start
position on a face. By changing a start position location you can modify the
distortion profile reflected in a Woven Materials generated flat pattern.

NOTE To reselect a new start face simply select another face.


The system will reĆtraverse the part and allow you to
either replace the existing flat pattern or create a new
one.

Orientation Vector

The Orientation Vector button allows you to specify the orientation of the flat
pattern when using the WCS location method. Choose the orientation using the
standard Vector Constructor dialog. The selected vector, projected to the start
face, will align with the XĆaxis of the start face.

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16-11
Flat Pattern

ÏÏÏ Activity 16-1: Creating a Simple Flat Pattern Drawing


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
In this activity you will create a flat pattern drawing within the part file. You
will also see how the flat pattern geometry can be updated while in the Drafting
application.

Step 1 Create a flat pattern.

 Open the part smd_flange_complete.

 Choose Application→Sheet Metal→Design...

 Choose Tools→Flat Pattern...

Since the part has a couple deformed features that pass


through bends we must first unform the part.

 Choose the Unform Sheet Metal Features button in the Flat


Pattern dialog to completely unform your part.

Notice the Cue line directs you to select a starting face for
the flat pattern.

 Select the top face of the body of the part as the start face.

Select the top face


as the start face.

 Change the Layer field in the Flat Pattern dialog to 161 and
choose Apply.

 Choose the Form Sheet Metal Features button in the Flat


Pattern dialog to completely form your part.

EDS Unigraphics NX
16-12 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

ÏÏÏ
ÏÏÏ
ÏÏÏ
16
ÏÏÏ

Step 2 Create a flat pattern drawing.

 Enter the Drafting application.

 Change your work layer to 101.

 Choose Drawing→Edit and change your drawing size to


B Ć 11 X 17 .

 Choose OK to save the change and close the window.

 Make all layers invisible, then make layer 161 selectable.

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Flat Pattern

ÏÏÏ  Choose Drawing→Add View and place the Top view in the
ÏÏÏ center of the drawing.
ÏÏÏ
16
ÏÏÏ  Choose Cancel in the Add View dialog.

 Use Insert→Dimension→Horizontal,
Insert→Dimension→Vertical and Insert→Dimension→Hole
to add the following dimensions to your drawing:

NOTE You may have to change the Text Placement option to


Manual Placement - Arrows In to get the dimension
locations shown below.

Step 3 Edit your part.


 Return to the Modeling application and make layer 1
selectable.

 Unform all of the flanges.

 Choose the Edit Feature Parameters icon.

EDS Unigraphics NX
16-14 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

 From the Edit Parameters dialog, select


ÏÏÏ
S22_HOLE:SKETCH(22) and choose OK.
ÏÏÏ
 Change the diameter to 1.00 . ÏÏÏ
16
ÏÏÏ
 Choose OK twice to update the part.

 Form all of the flanges.

 Again, choose the Edit Feature Parameters icon.

 From the graphics window, select the squaredĆoff flange on


the left side of the part (Watch the Status Line).

Select this flange


to edit.

 Choose OK.

 Change the Inside Radius value to .25 .

 Choose OK twice to update the part.

Step 4 Update the flat pattern and the drawing.


When a change is made to a simple part, you can update the flat
pattern geometry directly from the Drafting application.

NOTE The Auto Update option in the SMD Flat Pattern


Preferences dialog must be toggled ON for this type of
flat pattern update to occur. By default, this option is
always toggled ON.

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Flat Pattern

ÏÏÏ  Enter the Drafting application.


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
 Choose Drawing→Update Views...

 Choose the Top view from the listing box.

 Choose OK. Notice that the flat pattern geometry and the
bottom dimensions updated to reflect the part changes.

Dimensions
have changed.

Step 5 Close your part. Do not save.

EDS Unigraphics NX
16-16 Sheet Metal Design
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Flat Pattern

Flat Pattern Preferences ÏÏÏ


ÏÏÏ
Flat pattern preferences can be established while in the Sheet Metal Design
application. Selecting Preferences→SMD Flat Pattern activates the SMD Flat
ÏÏÏ
16
ÏÏÏ
Pattern Preferences dialog.

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Flat Pattern

ÏÏÏ Name and Layer


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
These preference settings provide the default name given to the flat pattern
group entity, and the default layer on which the flat pattern objects will reside.

Chord and Angle Tolerance

These preference settings can be used to override the modeling default chord
and angle tolerances for deriving curves from solid edges. Typically the default
modeling tolerances are sufficient.

NOTE If you reduce the tolerance value below the model


default, it may result in slower system performance.

Orientation

You can orient the flat pattern relative to the work coordinate system (WCS)
and place it on the XCĆYC plane, or you can use the start face (Start Position)
to designate the flat pattern orientation and placement plane.

NOTE Although the flat pattern can be placed on the XCĆYC


plane, its orientation is governed by the UĆV vector
orientation of the start face surface. It is recommended to
use the WCS→Orient option to orient the WCS to
absolute before creating a flat pattern.

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16-18 Sheet Metal Design
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Flat Pattern

Output Objects ÏÏÏ


ÏÏÏ
This section of the SMD Flat Pattern Preferences dialog is used to specify what
type of objects are created in the flat pattern. ÏÏÏ
16
ÏÏÏ
Curve Set
This option is used to determine what type of curves can appear in the flat
pattern profile. Lines, Lines/Arcs, or Lines/Arcs/Splines are the available curve
types.

NOTE If only Lines/Arcs are specified then all BĆsurface edges


will be approximated by lines and nonĆconcentric arc
segments. If Lines/Arcs/Splines are specified, then
BĆsurface edges will be approximated by splines.

Bend Tangent Curves


This option is used to turn ON or OFF the output of bend tangent lines in the
flat pattern. Bend tangent lines are defined by the intersection between the
bend segment and the web segment of a flange.

Bend Center Curves


This option is used to turn ON or OFF the display of a line centered between
the two bend tangent lines.
Bend Tangent Line

(Body) (Web)

Bend Center Line

NOTE Once Tangent Curves or Centerline Curves are turned


ON or OFF the flat pattern must be updated to see the
affect of the preference changes.

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Flat Pattern

ÏÏÏ Auto Update


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
The Auto Update option enables or disables automatic flat pattern update when
entering or exiting the Sheet Metal Design application. Turning this option
OFF is similar to turning ON Suppress View Update in the Drafting
Application. Careful consideration should be taken because there are no out
of date" labels that identify an out of date flat pattern. Turning Auto Update
OFF can make the process of changing the model faster when switching back
and forth between Sheet Metal Design and other applications.

Distortion Constraint

When a distortion type of face (e.g. a toroidal face) has two unbounded edges,
this option is used by the system to determine which open edge of the distorted
face will be the controlling edge.

NOTE This option is currently unavailable.

Allow Multiple Flat Patterns

This option, when toggled ON, allows for multiple flat patterns to be created
for the active body. Only the newest flat pattern maintains associativity to the
body.

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16-20 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

Use Bend Allowance Formula


ÏÏÏ
ÏÏÏ
This toggle turns ON or OFF the use of the BAF during flat pattern creation
Turning OFF the BAF is useful when the part has nonĆuniform thickness, or
ÏÏÏ
16
ÏÏÏ
when you just don't want the BAF included in calculating the developed length
of the faces.

Geodesics Algorithm

This option lets you control the Geodesics Algorithm used to split each face
into small segments. Each algorithm yields an approximation. If one algorithm
doesn't produce a desirable flat pattern, try another one. Parametric is the
default and should give the best results in most cases. The Knights algorithm
can be used as an alternative. The Projection algorithm was the default for all
flat patterns prior to V16. Generally, this method is the least accurate of the
three.

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Flat Pattern

ÏÏÏ Flat Pattern Annotation


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
The Flat Pattern Annotation dialog, located within the Sheet Metal Design
application under Tools→Flat Pattern Annotation, allows you to edit display
properties of the flat pattern wireframe geometry, and annotate the flat pattern
with text callouts.

Edit Display Dialog

The Edit Display dialog allows you to selectively edit the layer, color, line font
and width of each type of existing flat pattern object. If multiple flat patterns
exist within the partfile, the class selection dialog will be presented, thus
allowing you to select the objects you wish to modify. Once an object has been
edited, all subsequent flat pattern objects of this type will be created with the
specified edits.

EDS Unigraphics NX
16-22 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

Text Callout Dialog


ÏÏÏ
ÏÏÏ
Text Callout allows annotation of the flat pattern within the Sheet Metal Design ÏÏÏ
16
application. The text created interrogates the geometry selected, but is not
associative, therefore, if changes are made to the flat pattern the text callouts
ÏÏÏ
will need to be updated manually. Text or labels can also be added using the
Annotation Editor in the Drafting application. These can be made associative
by using the Expression option in the Annotation Editor (e.g. Bend Radius
parameter).

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Student Guide
16-23
Flat Pattern

ÏÏÏ Flat Pattern Annotation Preferences


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
You can modify the display of a flat pattern object before it is created using the
Annotation Preferences dialog found under Preferences→Flat Pattern
Annotation.

With this dialog you can specify the default color, line font, and width for each
type of flat pattern entity.

EDS Unigraphics NX
16-24 Sheet Metal Design
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Flat Pattern

Flat Pattern Information ÏÏÏ


ÏÏÏ
While in the Sheet Metal Design module, you have the option of listing the flat
pattern information associated with the solid or sheet body. When you choose
ÏÏÏ
16
ÏÏÏ
Information→Flat Pattern, the class selection dialog displays allowing you to
select a solid or sheet body. The information for the flat pattern associated with
the selected body is displayed in the information window. An example is shown
below.

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Student Guide
16-25
Flat Pattern

ÏÏÏ Construction Tips


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
 To create a complete flat pattern of a solid or sheet body, all defining
part geometry must be properly connected by either relative
positioning or boolean operations.
 Flat pattern curves are automatically grouped upon creation. Thus the
flat pattern group can be manipulated in the same way as any group
entity. However, if the flat pattern group is deleted then the curves in
the group are also deleted. Ungrouping operations will also cause flat
pattern curves to be deleted.
 The Flat Pattern traversal function requires that the starting face be
an areaĆpreserving type of face. This means that in order to create a
flat pattern using the standard Sheet Metal traversal algorithm, there
must be at least one areaĆpreserving face in the solid or sheet body.
 A flat pattern can be generated for a solid or sheet body which does
not contain sheet metal features. However, if the part contains an
unmodeled bend (i.e. a sharp edge depicting the transition from one
face to another), the resultant flat pattern will have varied dimensions
depending on which side of the model is selected as the start face. To
create a flat pattern with the expected developed length, you must
blend the transition edge.

EDS Unigraphics NX
16-26 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

Activity 16-2: Creating a Flat Pattern Drawing Assembly ÏÏÏ


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
In this activity you'll create an assembly file which will contain flat pattern
geometry and drawing data for a sheet metal part.

Step 1 Add the sheet metal component to your partfile.


 Open the part smd_fp_dwg.

 Toggle ON the Assemblies application.


 Choose Assemblies→Components"Add Existing or choose

the Add Existing Component icon.


 In the Select Part dialog, choose the Choose Part File button.
 Select the smd_fp file.
 Choose OK.
 From the Add Existing Part dialog, verify the Reference Set
is set to BODY.
 Ensure the Layer options are set to Original.
 Choose OK in the Add Existing Part dialog and in the Point
Constructor dialog locate the component at an origin of 0, 0,
0.

EDS
All Rights Reserved
Sheet Metal Design
Student Guide
16-27
Flat Pattern

ÏÏÏ Step 2 Set up your flat pattern default preferences.


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
 Enter the Sheet Metal Design application.

 Choose Preferences→SMD Flat Pattern...

 Verify the Output Objects Curve Set is on the Lines/Arcs


option.

 Choose OK to save the preference settings and close the


dialog.

EDS Unigraphics NX
16-28 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

Step 3 Set up your flat pattern annotation default preferences.


ÏÏÏ
ÏÏÏ
 Choose Preferences→Flat Pattern Annotation...
ÏÏÏ
16
ÏÏÏ
 Change the Bend Center Lines Color option to Cyan and the
Line Font option to CenterĆline.

Cyan

 Choose Apply.

 Change the Type field to Bend Tangent Lines. Set the Color
to Blue and the Line Font option to Phantom.

 Choose Apply.

 Change the Type to Exterior Edges and set the Color to


Yellow.

 Choose Apply.

 Change the Type to Interior Cutouts and set the Color to


Yellow.

 Choose OK to accept the preference settings and close the


dialog.

EDS
All Rights Reserved
Sheet Metal Design
Student Guide
16-29
Flat Pattern

ÏÏÏ Step 4 Create the flat pattern.


ÏÏÏ
ÏÏÏ
16
ÏÏÏ
 Choose Tools→Flat Pattern...

 Change the Layer option to 161.

 Select the top face of the body of the part as the start face.
Accept the selection if necessary.

Select this face as the


start face

Note the status line indicates Unigraphics is identifying faces to


flatten.

 Check which faces have been identified as area preserving

faces by selecting the Area Preserving Faces icon.

NOTE Area preserving faces will highlight on the unformed


model.

 Choose Cancel to close the class selection dialog.

 Check for distortion faces by selecting the Distortion Faces

icon.

Since no faces highlighted, the system did not allocate the


distortion solver to any surface of the part. Choose Cancel to
close the dialog.

EDS Unigraphics NX
16-30 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

ÏÏÏ
 Choose the Projection Faces icon. ÏÏÏ
Since no faces highlighted, the system did not allocate the
ÏÏÏ
16
ÏÏÏ
projection solver to any surface of the part. Choose Cancel to
close the dialog.

 Choose Apply on the Flat Pattern dialog to generate the flat


pattern geometry.

 Blank the solid body and review the flat pattern geometry
from the top view. Note the color and font of the flat pattern
objects.

Step 5 Add curve geometry to the flat pattern.

 Unblank your solid model if necessary.

 Return to the trimetric view, if necessary.

EDS
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Sheet Metal Design
Student Guide
16-31
Flat Pattern

ÏÏÏ  Make layer 41 selectable. Notice that points are now visible
ÏÏÏ on the return flanges of the part.
ÏÏÏ
16
ÏÏÏ  Choose the Additional Curves icon.

 Select all four points and choose OK.

 Choose Apply. The curves should now be reflected on your


flat pattern.

NOTE Your part must be in the formed state if you wish the
curves to be reflected accurately on the flat pattern. If the
part was in the unformed state, the curves would have
been projected onto the wrong surface of the part.

Step 6 Create a flat pattern drawing.


By design, whenever you add or update flat pattern geometry to
a drawing, the system will automatically reĆtraverse the
associated solid or sheet body and will regenerate the flat
pattern geometry. If you wish to avoid this process, make sure
the Auto Update option in the SMD Flat Pattern Preferences
dialog is toggled OFF before adding or updating drafting views.

 Choose Preferences→SMD Flat Pattern...

 Toggle OFF the Auto Update option.

 Choose OK.

 Change your work layer to 101.

 Enter the Drafting application.

 Change your drawing size to B - 11 X 17 (Drawing→Edit).

 Make layers 1 and 41 invisible and leave layer 161 selectable.

EDS Unigraphics NX
16-32 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

 Add a Top view to your drawing and center it.


ÏÏÏ
ÏÏÏ
 Add the following annotations and dimensions to your flat
pattern: ÏÏÏ
16
ÏÏÏ

Step 7 Edit the sheet metal part.

 Return to the Modeling application.

 Make layer 1 selectable.

 Using the Assembly Navigator make the component your


work part (double-click on it).

 Choose the Edit Feature Parameters icon.

EDS
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Sheet Metal Design
Student Guide
16-33
Flat Pattern

ÏÏÏ  Change the Contour Length of the middle flanges to 1.20 .


ÏÏÏ
ÏÏÏ
16
ÏÏÏ

Change the contour


length of the middle
flanges

 Make the smd_fp_dwg file the work part.


At this point, if Auto Update was activated, you could enter the
Drafting application and the flat pattern geometry would
automatically update. But remember, you don't want to
reĆtraverse the part, so you have to manually update the flat
pattern.
 Enter the Sheet Metal Design application.

NOTE You do not have to unform your part to update the flat
pattern.

 Activate the Flat Pattern dialog from the Tools pulldown


menu.

 Choose Apply to update the flat pattern.

 Unform your part and verify that the flat pattern profile
updated correctly.

Step 8 Return to your drawing and update your view boundary.

 Return to the Drafting application.

EDS Unigraphics NX
16-34 Sheet Metal Design
Student Guide All Rights Reserved
Flat Pattern

 Choose Drawing→Update Views...


ÏÏÏ
ÏÏÏ
 Choose the Top view from the listing box and choose OK.
ÏÏÏ
16
ÏÏÏ
 If any dimensions or annotations loose associativity, you can
reĆassociate your drafting objects using the Edit→Drafting
Object Associativity and Edit→Leader functions.

Step 9 Close your part. Do not save.

EDS
All Rights Reserved
Sheet Metal Design
Student Guide
16-35
Flat Pattern

ÏÏÏ
ÏÏÏ
ÏÏÏ
16
ÏÏÏ
SUMMARY The activities in this lesson demonstrated the
application of the Flat Pattern features
available in Unigraphics.

In this lesson you:


 Applied the various Layout Options
 Created a flat pattern using the Sheet Metal
algorithm
 Created a flat pattern using the Woven
Material algorithm

EDS Unigraphics NX
16-36 Sheet Metal Design
Student Guide All Rights Reserved
Additional Projects

Additional Projects
ÏÏÏ
Appendix A
ÏÏÏ
A
ÏÏÏ
ÏÏÏ
The following pages contain part drawings for the assembly shown below which
you may use to practice the skills you've learned within this manual. Please
refer any questions you may have regarding this material to your instructor.

EDS Sheet Metal Design


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A-1
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

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A-2 Sheet Metal Design


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Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

EDS Sheet Metal Design


All Rights Reserved Student Guide
A-3
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

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A-4 Sheet Metal Design


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Unigraphics NX
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

EDS Sheet Metal Design


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A-5
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

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A-6 Sheet Metal Design


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EDS
All Rights Reserved
Unigraphics NX
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

EDS Sheet Metal Design


All Rights Reserved Student Guide
A-7
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

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A-8 Sheet Metal Design


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EDS
All Rights Reserved
Unigraphics NX
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

EDS Sheet Metal Design


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A-9
Additional Projects

ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

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A-10 Sheet Metal Design


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EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

Sheet Metal Part in Process


Appendix B

PURPOSE To form Sheet Metal parts in increments to simulate


the manufacturing process. ÏÏÏ
ÏÏÏ
ÏÏÏ
B

OBJECTIVES
ÏÏÏ
Upon completion of this lesson, you will be able to:

 Create, edit, and manipulate Part in Process


features.
 Manipulate and execute bend operation groups
using the Part In Process dialog.
 Create a drawing using your Part in Process
information.

This section contains the following activities:

Activity Page
B-1 Creating a Process . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
B-2 Generate Family Members for Model States . . . . B-28
B-3 Adding Part in Process States to a Drawing . . . . . B-32

EDS Sheet Metal Design


All Rights Reserved Student Guide
B-1
Sheet Metal Part in Process

The next series of lessons will focus on the manufacturing processes supported
within the Sheet Metal Design application.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

Within the Sheet Metal Design application, Flat Pattern, Wireframe Flattening,
Flat Pattern Annotation, and Part in Process functions are available to support
manufacturing requirements for part definition and fabrication. This lesson
content will focus on Part in Process processes only.

B-2 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

Part In Process

When you enter the Sheet Metal Design application, the Part In Process dialog
appears.

NOTE If you happen to open a part that does not contain a solid
or sheet body, the Wireframe Flattening dialog will
appear instead of the Part In Process dialog.

ÏÏÏ
The Part In Process dialog allows you to manipulate and execute groups of
operations on sheet metal features. This tree list dialog makes it easy to
ÏÏÏ
ÏÏÏ
B
manipulate individual sheet metal features or groups of sheet metal features.
You can add entire Processes, Groups, or Features to customize this dialog to
ÏÏÏ
define the state of your part at any stage of your entire process.

This is a standard tree list dialog. You can use the plus and minus signs to
expand and collapse the tree. You can also right click on any node in the tree
and get a menu that is specific to the type of node on which you clicked. In
addition, you can do a slow double-click on any Process, Group, or Features to
rename it.

Listing
Box

While in the Sheet Metal Design application, the Part In Process dialog can
also be accessed through Tools→Part In Process.

EDS Sheet Metal Design


All Rights Reserved Student Guide
B-3
Sheet Metal Part in Process

Process

You can use a Process to define all of the stages that your part goes through
from blank to fully formed product. The two default states of Unform and
Form All in Part can be accessed at any time. You can execute either of these at
any time by simply double clicking on the name (node). Execute the Unform
All in Part node to see the fully unformed state of the model. Execute the Form
All in Part node to see the creation or "as designed" state of the model.

ÏÏÏ If you click MB3 on the SMD Process node, you will see the Process Menu

ÏÏÏ
ÏÏÏ
B
show below. You can use this menu to Unform, Form, Add a new Process or
Group, or to Delete a Process. A Process is a collection of Groups, similar to a

ÏÏÏ station in a forming shop. A Group is a collection of Feature operations


performed at that station. A Feature is a defined state of a sheet metal feature
in the model.

Unform Process

Adding a Process means adding a new root node on the tree list. This Process
can be used to contain new Groups, which in turn contain new Feature nodes.

NOTE You cannot Unform a Process if there are no Process


nodes in the tree list.

B-4 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

Form Process

Adding a Process means adding a new root node on the tree list. This Process
can be used to contain new Groups, which in turn contain new Feature nodes.

NOTE You cannot Form a Process if there are no Process nodes


in the tree list.

ÏÏÏ
Add Process ÏÏÏ
ÏÏÏ
B
Adding a Process means adding a new root node on the tree list. This Process
can be used to contain new Groups, which in turn contain new Feature nodes.
ÏÏÏ

Add Group

Adding a Group will add a new Group named "New Group" to the tree list
under the current Process. This Group can then be used to contain a set of
Feature nodes.

Delete Process

Deleting a Process deletes all of the Feature and Group nodes under the
Process as well as the Process itself.

NOTE You cannot Delete a Process if there are no Process


nodes in the tree list.

EDS Sheet Metal Design


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B-5
Sheet Metal Part in Process

Group

When you click MB3 on a Group, you will see the Group Menu shown below.
You can use this menu to Unform, Form, Execute, Add a new Group or
Feature, or Delete a Group.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

Unform Group

Unforming a Group means setting all of the features in the model to the fully
unformed state for each Feature node within the Group.

Form Group

Forming a Group means setting all of the features in the model to the fully
formed state for each Feature node within the Group.

Execute Group

Executing a Group means setting all of the features in the model to the states
defined for each Feature node within the Group.

Add Group

Adding a Group means adding a new Group node on the tree list. This Group
can be used to contain new Feature nodes.

B-6 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

Add Features

Adding a Feature means defining a state for a given sheet metal feature in the
model and then adding a Feature node into the tree list under the current
Group. You must select one or more sheet metal features in the graphics
window before you selected Add Feature.

Delete Group

ÏÏÏ
Deleting a Group deletes all of the Feature nodes under the Group as well as
the Group itself. ÏÏÏ
ÏÏÏ
B
ÏÏÏ

EDS Sheet Metal Design


All Rights Reserved Student Guide
B-7
Sheet Metal Part in Process

Feature

When you choose the Add Features node under a Group, you are defining the
state of that sheet metal feature in the model at this point in the Process. The
dialog boxes that you will see depend on the currently selected sheet metal
feature.

Bridge and Bend

ÏÏÏ These two features are the easiest features for which to define states. Both of
ÏÏÏ
ÏÏÏ
B
these features can only be either fully formed or fully unformed. The dialog
that is presented to you when you select a sheet metal Bridge or Bend feature is
ÏÏÏ shown in the figure below. You simply check whether the feature is formed at
this stage in the Process.

Flange and Inset Flange

It is also easy to define a state for Flanges and Inset Flanges. These two
features simply require that you enter an angle to define how far the feature is
bent at this stage in the Process.

Process Angle

The process angle is an angle, either positive or negative, simulating an


intermediate state of the flange. Negative angular values can be used to
indicate a back bend, and angular values larger than the design angle can be
used to simulate over forming.

B-8 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

General Flange

The General Flange is the most complex feature for which to define a state.
The General Flange has five methods that can be used to define a completely
new shape for the feature. This new shape can be used to represent a complex
die forming operation or hydroform operation. The five methods are
Parameters, Build to Sections, Build to Faces, Punch Vector, and Surface
Extension. You can change from one method to another simply by selecting the
appropriate icon at the top of the dialog. The dialog boxes for these methods
are nearly identical to those used to create and edit the General Flange. The
dialog for Parameters method is shown below. ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

EDS Sheet Metal Design


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B-9
Sheet Metal Part in Process

Surface Extension

The Surface Extension method is only available in the General Flange State
dialog. This method causes the underlying surface to be created as a tangential
extension to the target face. You do not need to specify any additional
parameters. If the target face(s) were planar, the resulting General Flange
State would be planar as well.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
Edge Constrains

ÏÏÏ The Edge Constraints option allows you to specify how the three edges of the
General Flange not attached to the target face will deform. The two side edges
are selectable only if the deformation algorithm for the General Flange is set to
BiĆdirectional. If this is the case, the far edge will only be selectable when the
side edges are constrained.

The different types of edge constraints are:

 None Ć No additional constraints are placed on the edges other than


the original distortion constraint applied during the flange creation.
 Along Section Ć This constraint will cause the edge to behave much as
if the Along Section distortion option was used during the creation of
the General Flange. The length of the edge will vary according to
adjustments made for distortion.
 Along Profile Ć With this option, you will be prompted to select a string
of curves, edges or faces along which the flange edge will lie. Again,
the length of the edge will vary according to adjustments made for
distortion.
 To Profile Ć This option functions in the same manner as Along Profile,
but the flange edges will match the length of the profile string.

B-10 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

BiĆDirectional deformation
at each edge of the
flange.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
General Flange with BiĆDirectional
distortion and no edge constraints.
ÏÏÏ

Outer edge is still


distorted.

Inside edge follows


the profile of the
adjacent edge.

General Flange with BiĆDirectional distortion


and Along Profile edge constraints.

EDS Sheet Metal Design


All Rights Reserved Student Guide
B-11
Sheet Metal Part in Process

Activity B-1: Creating a Process

In this activity you will define the manufacturing bend process for the part
shown below.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Step 1 Open the partfile smd_pip and save it as xxx_pip where
xxx are your initials.

Step 2 Create the first process in the Part in Process dialog.


 Choose Application→Sheet Metal→Design...
The Part in Process dialog will appear.

 DoubleĆclick MB1 on the Unform All in Part node to fully


unform your part.

B-12 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

NOTE You can also use MB3 on the node and choose Execute.

 Slowly doubleĆclick MB1 on the SMD Process node and


change the name to Process 1 and press Enter.

 Slowly doubleĆclick MB1 on the New Group node and


change the name to Stage 1 and press Enter.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

 From the graphics window, select the inner back flange


features. The Status line should read INSET_FLANGE(6),
(7) or (8) as you select each feature.

Select these
flanges

EDS Sheet Metal Design


All Rights Reserved Student Guide
B-13
Sheet Metal Part in Process

 From the Part in Process dialog, click MB3 on the


Stage 1 node and choose Add Features.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Notice that the Process Angle dialog appears.

 Enter 30 in the Process Angle field and choose OK.

 Another Process Angle dialog appears, enter 30 again for the


remaining two inset flanges.

Step 3 Create the next bend sequence.

B-14 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

 Click MB3 on Process 1 or Stage 1 node and choose Add


Group.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

 Slowly doubleĆclick MB1 on the New Group node and


change the name to Stage 2.

EDS Sheet Metal Design


All Rights Reserved Student Guide
B-15
Sheet Metal Part in Process

 From the graphics window, select the outer back flange


features. The Status line should read FLANGE(9), (10) or
(11) as you select each feature.

Part has been rotated 1805 for clarity

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ Select these
flanges

 Click MB3 on the Stage 2 node and choose Add Features.

 Enter 30 in the Process Angle field for all three features.

B-16 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

Step 4 Create a new process.

 Click MB3 on the Process 1 node and choose Add Process.

 Slowly doubleĆclick MB1 on the SMD Process node and


change the name to Process 2 and press Enter.

 Slowly doubleĆclick MB1 on the New Group node and


change the name to Stage 3 and press Enter.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

 From the graphics window, select the inner front flange


features. The Status line should read FLANGE(12) or (13) as
you select each feature.

Select these
flanges

 Click MB3 on the Stage 3 node and choose Add Features.

 Enter 45 in the Process Angle field for both flanges.

Step 5 Insert a group.

EDS Sheet Metal Design


All Rights Reserved Student Guide
B-17
Sheet Metal Part in Process

 Slowly doubleĆclick MB1 on the Stage 3 node and change the


name to Stage 4.

 Click MB3 on the Stage 2 node and choose Add Group from
the popĆup menu.

 Change the name of the New Group to Stage 3.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

 Select the right and left flange features from the graphics
window. The Status line should read SMBEND(20) or (21)
as you select each feature.

Select these
flanges

B-18 Sheet Metal Design


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All Rights Reserved
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Sheet Metal Part in Process

 Click MB3 on the Stage 3 node in the Part in Process dialog


and choose Add Features.

Notice the Form/Unform dialog box appears. This appears


because the feature selected was a Sheet Metal Bend
feature, which can only be shown in the fully formed or
unformed condition. A Bridge feature would present the
same dialog.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
 Toggle ON the option to Form Feature SMBEND for both
features.

Step 6 Edit a sequence.

 Select the curved flange feature from the graphics screen.

Select this
flange

EDS Sheet Metal Design


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B-19
Sheet Metal Part in Process

 Click MB3 on the Stage 4 node and choose Add Features.

Notice the General Flange State dialog appears. This


appears because the feature selected was a General Flange
feature, which can have various properties edited in a
forming operation. We will only adjust the bend angle.

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

 Enter 45 in the Angle field and choose OK.

B-20 Sheet Metal Design


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Sheet Metal Part in Process

ÏÏÏ
ÏÏÏ
ÏÏÏ
B
 DoubleĆclick on the Form All in Part node to completely ÏÏÏ
form your part.

Step 7 Save your part. You will be working with this part in the
next activity.

EDS Sheet Metal Design


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B-21
Sheet Metal Part in Process

Working in Assemblies

Because of the inherently dynamic nature of sheet metal parts, using them in
assembly applications presents some unique concerns. Unlike typical modeling
features, sheet metal features must alter their shape states upon command by
external sources (e.g. Form and Unform operations). Thus a dependency is
established between sheet metal component parts and the assembly models
which contain them.

ÏÏÏ At any assembly level model, it is possible to place the sheet metal component
ÏÏÏ
ÏÏÏ
B
in an intermediate or unformed state. When the assembly partfile is saved, the
system will attempt to also save the sheet metal component part in its altered

ÏÏÏ state. If a user does not have write access to the component part, then an error
message will be produced, the component partfile save operation will abort, and
the user can continue to save the assembly partfile only.

If the user does have write permission to the sheet metal component partfile,
then the system will successfully save the component part in its altered state.
This state is then reflected everywhere the component is used. Subsequent
problems, such as failed mating constraints, can then occur while accessing
other assemblies. To avoid such problems, it is strongly recommended that you
always place the sheet metal component part in its fully formed state before
saving any partfile.

B-22 Sheet Metal Design


Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

Creating Process Drawings

The Part in Process operation is the only method by which you may place a
sheet metal part in a semiĆformed state. To help prevent inadvertent component
geometry changes from occurring when Part in Process data is saved, it is
possible to create a separate assembly file to contain the Part in Process data.

If you wish to create a manufacturing process drawing which depicts


intermediate states of the part, then it is necessary to create the Part in Process
drawing utilizing an assembly partfile. The best results are achieved by creating
ÏÏÏ
associative copies of the sheet metal part, as placed in its intermediate states.
This process can be accomplished by utilizing the Part Family option under ÏÏÏ
ÏÏÏ