Sheetmetal Design using Creo Parametric

T3407-380-01
Course Objectives

In this course, you will learn how to:

n The Sheetmetal Design Process
n Sheetmetal Model Creation, Conversion, and Display
n Methods of Developed Length Calculation
n Primary Wall Features
n Secondary Wall Features
n Partial Walls
n Bend Relief
n Unbend and Bend Back Features
n Sheetmetal Bend Features
n Flat Patterns
n Sheetmetal Cuts
n Forms
n Notch and Punch Features
n Sheetmetal Environment Setup
n Sheetmetal Design Information Tools
n Sheetmetal Design Rules
Course Objectives

n Detailing Sheetmetal Designs

n Sheetmetal Design Project
Training Agenda

n Module 1: Introduction to the Creo Parametric Sheetmetal Design Process

n Module 2: Sheetmetal Model Fundamentals
n Module 3: Creating Primary Sheetmetal Wall Features
n Module 4: Creating Secondary Sheetmetal Wall Features
n Module 5: Modifying Sheetmetal Models
n Module 6: Sheetmetal Bends and Setting Up the Sheetmetal Environment
n Module 7: Special Sheetmetal Tools
n Module 8: Detailing Sheetmetal Designs
n Module 9: Design Project
Module 1 : Introduction to the Creo Parametric
Sheetmetal Design Process

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Create a primary flat wall as the base feature for a sheetmetal design.
n Create some simple secondary walls.
n Add a predefined notch and a predefined form to a sheetmetal model.
n Create a flat state for a sheetmetal model design.
n Create a drawing of the formed and flat state of a sheetmetal design.
Creo Parametric Sheetmetal Design Process

The typical sheetmetal design process can be summarized by five high-level steps.
n Primary Walls
n Secondary Walls
n Other Sheetmetal Features
n Flat States
n Detail Drawings Figure 1 – Primary Walls

Figure 2 – Secondary Walls Figure 3 – Other Sheetmetal Features

Figure 4 – Flat States Figure 5 – Detail Drawings

Module 2 : Sheetmetal Model Fundamentals

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Understand the thickness of a sheetmetal model, and how it is calculated from a driving surface.
n Describe how the wireframe display of a sheetmetal model's driving and driven surfaces are displayed.
n Define, understand, and change developed lengths in sheetmetal model designs.
n Control developed lengths with a K-factor, a Y-factor, or a bend table.
n Create new sheetmetal models in part or assembly mode.
n Create a new sheetmetal model by converting a solid model into a sheetmetal model.
Sheetmetal Model Fundamentals

It is important to understand some fundamental characteristics of the Sheetmetal mode in Creo

Parametric.
n Constant
thickness
n Driving
(green) and
offset (black)
sides
n Formed or
flat
n Developed
length
Figure 2 – Formed Model

Figure 1 – Wireframe
Display of Driving
(Green) and Offset
(Black) Sides Figure 3 – Flat Pattern
Understanding Developed Length

Creo Parametric can automatically calculate the developed length of most sheetmetal bends.
Developed Length (Bend Allowance) can be
determined by:
n System Equation (Y/K Factor)

n Provided Bend Tables (soft, medium and hard

materials) Figure 1 – Before Bend
n User-defined Bend Tables

n Entered Value

Applied to whole part or to individual features, as

necessary.
N is the Neutral Axis
L = (π/2 x R + y x T) θ/90
n L= Developed Length

n R = Inside Radius

n T = Material Thickness

n θ = Bend Angle (measured as angle of deflection)

n y = (π/2) * K

n K = δ/T Figure 2 – After Bend

Creating a New Sheetmetal Part in Assembly Mode

There are three methods for creating a new sheetmetal model. One method is to create a new
sheetmetal part in Assembly mode.

Figure 1 – Creating a New Component in an Assembly

Creating a New Sheetmetal Model in Part Mode

There are three methods for creating a new sheetmetal model. One method is to create a new
sheetmetal model in Part mode.

Figure 1 – Creating a New Sheetmetal Model in Part Mode

Converting Solid Models to Sheetmetal

There are three methods for creating a new sheetmetal model. One method is to convert a solid model
to a sheetmetal model.

Figure 1 — Conversion, Driving Surface, and Shell Dashboards

Module 3 : Creating Primary Sheetmetal Wall
Features

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Understand the difference between primary and secondary walls.
n Understand the difference between attached and unattached walls.
n Create flat primary walls.
n Create extruded primary walls.
n Create revolved primary walls.
n Create blend primary walls.
n Create offset primary walls.
n Understand other less common types of primary walls.
Understanding Sheetmetal Wall Features

A wall is any section of sheetmetal.

Figure 1 – Primary Wall No References

Figure 2 – Secondary Wall Attached Along Green Edge

Figure 3 – Two Unattached Primary Walls Figure 4 – Secondary Wall Merged at Both Ends
Creating Flat Walls

A flat wall is a planar, unbent section of sheetmetal.

Figure 1 – Completed Flat Wall Figure 2 – Flat Wall Icon Location

Extruded Sheetmetal Wall Features

You can use the Extrude tool to create a primary wall feature.

Figure 1 – Competed Extruded Primary Wall

Revolved Sheetmetal Wall Features

You can use the Revolve tool to create a primary wall feature.

Figure 1 – Completed Revolved Wall Figure 2 – Revolved Wall Icon Location

Blend Sheetmetal Wall Features

Multiple sections can join together to create a Blend Primary Wall feature.

Figure 1 – Completed Blend Primary Wall Feature Figure 2 – Blend Wall Icon Location
Creating Offset Walls

You can use surfaces to create an offset wall feature.

Figure 1 – Surface Feature Figure 2 – Completed Offset Primary Wall

Sheetmetal Wall Sketching Tools

The Thicken option is available in Sketcher mode for sheetmetal features.

Figure 1 – Before Thicken Figure 2 – After Thicken

Advanced Primary Walls

There are many less common but often useful types of primary walls.

Figure 1 – Variable Section Sweep Figure 2 – Swept Blend

Figure 3 – Helical Sweep Figure 4 – From Boundaries

Module 4 : Creating Secondary Sheetmetal Wall
Features

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Understand the general characteristics and types of secondary walls.
n Create secondary flat walls.
n Create secondary flange walls.
n Create secondary extruded walls.
n Create secondary twist walls.
n Create secondary extended walls.
n Create secondary merge walls.
n Understand and create partial and overextended walls.
n Understand and apply the different types of relief to walls when necessary.
n Understand and use the different dashboard options that are available for flat and flange walls.
Understanding Secondary Walls

Secondary walls are dependent on at least one primary wall.

Figure 1 – Flat Figure 2 – Flange

Figure 3 – Extruded Figure 4 – Extend

Figure 5 – Twist Figure 6 – Merge

Creating Secondary Flat Walls

Secondary flat walls are planar walls that are attached to a straight edge of an existing wall.

Figure 1 – Rectangle Figure 2 – Trapezoid

Figure 3 – L Figure 4 – T
Using Flange Walls

A flange wall is a folded sheetmetal wall that is attached to straight or swept edges.

Figure 1 – I Figure 2 – Arc Figure 3 – S Figure 4 – Z

Figure 5 – Open Figure 6 – Flushed Figure 7 – C Figure 8 – Duck

Using Extruded Walls

You can use the Extrude tool to create extruded walls to handle special modeling requirements.
Extruded Walls
n For non-circular bends

n Constant thickness

– Thickness set by primary wall

n No automatic bends
Figure 1 – Elliptical Bend Example
n No automatic thickness side

n No automatic attachment

– Merge Wall tool necessary for attachment

Figure 2 – Wrong side Thickness

Figure 3 – Invalid Attachment

Wall Dashboard Options

Wall dashboard options enable you to fully capture your design intent in Creo Parametric sheetmetal
walls.
n Placement
n Shape/Profile
n Offset
n Relief
n Bend Allowance
n Properties
Thickness Side Figure 3 – Offset: Figure 4 – Offset:
n
Figure 1 – Offset: None Figure 2 – Offset: Add
Automatic By Value
to Part Edge
n Bend/No Bend
n Bend Radius
n I/O Bend Dimension
Using Partial and Overextended Walls

Partial walls are walls that do not extend to the end of the referenced edge or edge chain.
n Partial/Overextended Wall Definitions
n Creation Methods
n Bend Relief

Figure 1 – Full Wall

Figure 2 – Overextended Wall Figure 3 – Partial Wall

Understanding Relief

Bend reliefs and corner reliefs are often necessary when creating secondary walls.

Figure 1 – No Bend Relief Figure 2 – Rip Bend Relief Figure 3 – Stretch Bend Relief

Figure 4 – Rectangular Bend Relief Figure 5 – Obround Bend Relief

Figure 6 – No Corner Relief Figure 7 – V Notch Corner Relief Figure 8 – Circular Corner Relief

Figure 9 – Rectangular Corner Relief Figure 10 – Obround Corner Relief

Creating Twist Wall Features

Twist walls enable you to create spiraling or coiling sections of sheetmetal.

Figure 1 – Twist Wall (Developed State)

Figure 2 – Twist Wall (Flat State)

Extending and Trimming Walls

You can use extend and trim walls to lengthen or shorten existing walls.
n Extending an edge.
– Extend an edge by distance or reference plane.

n Extending an edge with Adjacent Surface and

Along Boundary Edge options. Figure 1 – Extending an Edge
– Create a sharp edge or blend the boundary edge.

n Using Extend to “trim” an edge.

– Remove material by using the Extend tool.

Figure 2 — Extend Adjacent Surface and Along Boundary Edge Figure 3 — Using Extend to “Trim” an Edge
Using the Merge Feature

A merge wall combines two or more unattached walls into one contiguous piece of sheetmetal.
Merge Wall Feature Requirements Creation Elements
n Touching and Tangent n Basic Refs

n Driving Sides Match n Merge Geoms

n Merge Edges

n Keep Lines

Figure 1 – Tangent Lines Shown as Phantom Lines: Before Merge Figure 2 – Tangent Lines Shown as Phantom Lines: After Merge
Module 5 : Modifying Sheetmetal Models

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Create angle and roll type bends.
n Apply the Regular, Transition, and Planar options for bends.
n Unbend models with the Unbend tool.
n Reform models with the Bend Back tool.
n Use the Flat Pattern tool.
n Flatten undevelopable geometry using deform areas.
n Remove material from a model using cuts.
n Use punches and dies to form your models.
n Flatten form geometry.
n Create rips to help flatten unbendable geometry.
n Create notches and punches to remove material and create relief.
n Create edge bends on sharp corners.
n Create corner relief.
Creating Bend Features

A bend feature adds a bend to a flat section of the part.

Types of Bend Features:
n Angle Bend

n Roll Bend

Figure 1 – Angle Bend

Figure 2 – Angle Bend From Edge Figure 3 – Roll Bend

Adding Transition to Bends

A transition deforms the surface between a bend and a section of the model that is to remain flat.
n Sketch bend line.
n Sketch transition area.

Figure 1 – Original Model with Roll Bend

Figure 2 – First Transition Added Figure 3 – Second Transition Added

Creating Planar Bends

A planar bend is formed around an axis perpendicular to the driving surface and sketching plane.
Bend around axis normal to driving surface and
sketch plane.
n Bend Tables not applicable.

n Sketch bend line.

n Angle or Roll type.

Figure 1 – Angle Planar Bend

Figure 2 – Roll Planar Bend Figure 3 – Completed Bends

Creating Unbend Features

You can unbend both a wall and a bend as long as the material is developable and able to unbend.
n Unbend types:
– Unbend

• All surfaces and bends or specific areas.

• Rip out deformation areas.
• Optional relief geometry.
• Flatten all forms.
– Cross Section Driven Figure 1 – Original Model
• Select or sketch the Xsec curve.
– Transitional

Figure 2 – Selected Xsec Curve and Resulting Unbend Figure 3 – Sketched Xsec Curve and Resulting Unbend
Creating Bend Back Features

You create the bend back feature to return an unbent feature to its original condition.
n Set the part default fixed geometry in the tool.
n Bend back all bends or select specific areas.
n Use the Bend Control tab to set which contours
are bent back or kept flat.
Figure 1 – Original Model

Figure 2 – Unbend and Extrude Feature Figure 3 – Bend Back: Default and Keep Contour
Creating Flat States

A flat state refers to the creation of a flat and formed version of the part model.
n Create flat states using the following methods:
– Family tables
– Part simplified representations.
Figure 1 – Family Table Method
– Wildfire flat state functionality.

Figure 2 – Formed and Flat State Figure 3 – Simplified Representation Method

Previewing and Creating Flat Patterns

A flat pattern is similar to unbending all walls, except that it always remains as the last feature in the
model tree.
n Flat Pattern Preview:
– Show or hide.
– Flat pattern feature does not need to be created.
– Bounding box dimensions.

n Flat Pattern:
– System unbends all geometry.
– Flat pattern feature added to end of model tree. Figure 1 – Default Model and Flat Pattern
– Always at the end of the model tree.

Figure 2 – Creating a Flange Figure 3 – Flat Pattern Updates to Flatten Flange

Creating Split Area Features

Deformation areas stretch to help you unbend a sheetmetal part.

n You can create deform areas using the Split Area
tool.
– Sketch the deformation area.
– Control the normal direction to Driven or Offset surface.
– Control the Projection Direction.
Figure 1 – Original Model: System Detects Deformation During
– Define which side of the sketch receives the new id.
Unbend (But Cannot Extend to Model’s Edge)

Figure 2 – Select Existing Surface Patch (Deformation Undesirable) Figure 3 – Select Deformation Area (Deformation Isolated)
Sheetmetal Cuts

Sheetmetal cuts are created normal to the part surface while solid cuts are created normal to the
sketch plane.
Types of Cuts
n Sheetmetal Cut

– Solid
– Thin

n Solid Cut

Figure 1 – Cut Normal to Surface

Figure 2 – Cut Normal to Sketch Figure 3 – Thin Sheetmetal Cut

Die Form Features

Your sheetmetal models can be formed using dies.

Die form features:
n Represents the forming geometry surrounded by
a bounding plane.
n Uses assembly-type constraints to determine the
Figure 1 – Die Reference Model
location.
n Uses reference parts to create Die Forms.

Figure 2 – Wall Formed with Die

Punch Form Features

Your sheetmetal models can be formed using punches.

Assemble with Dashboard
n On Surface Csys

n Interfaces
Figure 1 – Punch Reference Model
n Constraints

Options
n Auto-Round Edges

n Exclude Surfaces
Figure 2 – Wall Formed with Punch
n Merge or Inheritance
Utilizing Punch Model Annotations

Define Punch Model annotations to speed up placement.

n Punch Model annotation type
– Predefine surfaces to remove

Figure 1 – Creating Annotation Figure 2 – Punch Model Created

Flattening Forms and Unstamping Edges

Form features can be flattened using the Flatten Form tool.

n You can flatten all valid forms in the model at once.
n Rounds and chamfers are unbent using the
Unstamp Edge tool.
Figure 1 – Original Model (Unbent)

Figure 2 – Form Flattened and Reference Patterned Figure 3 – Unstamping an Edge

Creating Rip Features

You can add rips to your models to help flatten otherwise unbendable geometry.
n Edge Rip:
– Define sets.
– Define edge treatment and gap setting per set.
– Edge trimming.

n Surface Rip: Figure 1 – Creating an Edge Rip

– Define sets.
– Action-object workflow enables auto-complete.

n Sketched Rip:
– Internal or external sketch.
– Flip sketch projection direction.
– Other options.

Figure 3 – Creating a Sketched Rip

Figure 2 – Creating a Surface Rip Feature

Notches and Punches

You use notches and punches as templates to cut and relieve sheetmetal walls.
Punches and notches are used to create cuts and
capture manufacturing information.
n Notches are placed on edges.

n Punches are placed in the middle.

Figure 1 – Notch Used for Relief

Figure 2 – Punch Used to Create Holes

Creating Edge Bends

An edge bend converts non-tangent edges to bends.

n Default bend radius set to thickness.
n Define sets of edge bends.
n Create partial edge bends.
n You can select non-linear edges.

Figure 1 – Formed Part with Sharp Edges

Figure 2 – Part with Two Edge Bend Sets Figure 3 – Partial Edge Bend Applied
Creating Corner Relief

Corner relief helps prevent unwanted deformation by controlling the sheetmetal material behavior.
n Five types of corner relief:
– V Notch (default)
– No Relief
– Circular
– Rectangular Figure 1 – V Notch Relief
– Obround

n Four methods:
– Create the corner relief as a feature.
– Create default relief automatically while unbending.
– Setup default relief for all corners.
Figure 2 – No Relief

– Define relief in a Conversion feature.

Figure 3 – Circular Relief Figure 4 – Rectangular Relief Figure 5 – Obround Relief

Patterning Walls

You can now pattern walls using direction and reference patterns.
n Pattern Flat or Flanged
– Use Direction Pattern

n Can Reference Pattern Figure 1 – Original Model

Figure 2 – Flat Wall Patterned Figure 3 – Flange Wall Reference Patterned

Mirroring Walls

You mirror sheetmetal walls to create symmetric models.

n A mirrored wall is its own feature.
– Dependent by default
– Can make section independent
– Can redefine independently

Figure 1 – Original Model

Figure 3 – Second Mirror Created

Figure 2 – First Mirror Created
Module 6 : Sheetmetal Bends and Setting Up the
Sheetmetal Environment

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Create features in the proper order to achieve appropriate dimensioning results.
n Define and adjust bend lines.
n Define and adjust bend allowances using bend tables.
n Define default fixed geometry.
n Define flat states.
Bend Line Adjustments

You can control the location of a bend feature by adding a Bend Line Adjustment (BLA).
The bend line location can be adjusted.
n Use the equation: BLA = L - (R+T).

Figure 1 – Original Bend Line Location

Figure 2 – Relation to Control the Bend Line Location Figure 3 – Bend Line Adjusted
Using Bend Tables for Bend Allowances

You can use bend tables, instead of the system default equation, to calculate the developed lengths of
bends.

Figure 1 – A Typical Bend Table

Fixed Geometry

You can specify a default reference for the fixed surface for unbend and bend back features.
You do not have to select the fixed side after setting
default fixed geometry.
Applies to:
n Unbend features

n Bend Back features Figure 1 – Surface Selected as Fixed Geometry

Figure 2 – Unbend Uses Fixed Surface Figure 3 – Bend Back Uses Fixed Surface
Module 7 : Special Sheetmetal Tools

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Review sheetmetal reports in text and HTML format.
n Set and review the effects of design rules.
n Edit and assign sheetmetal defaults and parameters.
n Retrieve an existing set of sheetmetal defaults and parameters.
n Use the Create Conversion tool to flatten an otherwise undevelopable model.
Info Tools and Reports

Reports provide information about bends, radii, bend tables, and design rules for your model.
Two types of reports
n Text

n HTML

n Controlled by config.pro option info_output_format

Figure 1 – HTML Report Excerpt

Design Rules

Design rules are geometric standards for your design.

A Rule table contains the design standards.
n MIN_DIST_BTWN_CUTS

n MIN_CUT_TO_BOUND

n MIN_CUT_TO_BEND

n MIN_WALL_HEIGHT

n MIN_SLOT_TAB_WIDTH

n MIN_SLOT_TAB_LENGTH

n MIN_LASER_DIM

Figure 1 – MIN_CUT_TO_BEND Figure 2 – MIN_CUT_TO_BOUND

Defaults and Parameters

Sheetmetal defaults can be customized.

Defaults are managed through the Model Properties dialog box.

Figure 1 – Model Properties

Using Conversion Features

You can use the Conversion tool to make undevelopable parts developable when you convert an
existing model to a sheetmetal model.
n The Conversion tool enables you to define:
– Edge Rips
– Rip Connects
– Edge Bends
– Corner Reliefs
Figure 1 – Original Model

Figure 2 – Conversion Feature Created Figure 3 – Creating a Flat Pattern

Module 8 : Detailing Sheetmetal Designs

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Add the flat and formed views to a drawing using multi-model drawings and flat states.
n Apply dimensions using the Auto Ordinate tool.
n Create bend line notes.
n Define the bend order sequence and create the bend order table.
Adding the Flat and Formed States

Flat states enable you to add the fully formed and fully flat views of your designs to a drawing.

Figure 1 – Formed Model Figure 2 – Flat State

Figure 3 – The Drawing

Auto Ordinate Dimensions

You can quickly create ordinate dimensions in a view.

You use the Auto Ordinate command to create ordinate dimensions automatically.
n Select the surfaces to dimension.

n Select edge, curve, or datum as the baseline.

Figure 1 – Selected Surfaces

Figure 2 – Ordinate Dimensions

Bend Line Notes

A bend line note describes the basic information about the bend type, bend direction, and bend angle.
Bend line notes describe:
n Bend Type

n Bend Direction

n Bend Angle

– Measured as deflection from the flat.

Figure 1 – Bend Notes

Bend Order Tables

The bend order table is used to document the bend order for manufacturing.
n Bends are added in sequence to match the manufacturing
process.
n Multiple bends can be added to a given sequence.

Figure 1 – Bent Part

Figure 2 – Sequence 1 and 2 Figure 3 – Sequence 3 and 4

Module 9 : Design Project

Sheetmetal Design using Creo Parametric

Objectives

After completing this module, you will be able to:

n Design sheetmetal parts using the top-down design approach.
n Apply the skills you learned in this course to real-world design projects.
Designing a Stapler

Project – Designing a Stapler

Figure 1 – Stapler Components

Figure 2 – Fully Assembled Model