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Fundamentals of Sheetmetal
Release 2000i2 T869-310-03

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Copyright
Fundamentals of Sheetmetal
COPYRIGHT 1989-2000 PARAMETRIC TECHNOLOGY CORPORATION. ALL RIGHTS RESERVED. This Fundamentals of Sheetmetal Training Guide may not be copied, reproduced, disclosed, transferred, or reduced to any form, including electronic medium or machine-readable form, or transmitted or publicly performed by any means, electronic or otherwise, unless Parametric Technology Corporation (PTC) consents in writing in advance. Use of the software has been provided under a Software License Agreement. Information described in this manual is furnished for information only, is subject to change without notice, and should not be construed as a commitment by PTC. PTC assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual. The software contains valuable trade secrets and proprietary information and is protected by United States copyright laws and copyright laws of other countries. Unauthorized use of the software or its documentation can result in civil damages and criminal prosecution. Pro/ENGINEER and Pro/MECHANICA are registered trademarks, and all product names in the PTC product family and the PTC logo are trademarks of Parametric Technology Corporation in the United States and other countries. All other companies and products referenced herein have trademarks or registered trademarks of their respective holders. US GOVERNMENT RESTRICTED RIGHTS LEGEND This Software and Documentation are provided with RESTRICTED RIGHTS. Use, duplication, or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software-Restricted Rights at 48 CFR 52.227-19, as applicable. Parametric Technology Corporation, 128 Technology Drive, Waltham, MA 02453 2000 Parametric Technology Corporation. Unpublished all rights reserved under the copyright laws of the United States. PRINTING HISTORY Document No. Date T869-310-03 09/22/00

Description Initial Printing of Fundamentals of Sheetmetal for Release 2000i2

Order Number DT-869-310-EN Printed in U.S.A

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Training Agenda
Fundamentals of Sheetmetal
Day 1
8:30-8:45 8:45-9:15 9:15-9:30 9:30-10:00 10:00-10:30 10:30-10:45 10:45-11:15 11:15-11:30 11:30-12:00 12:00-1:00 1:00-1:30 1:30-2:00 2:00-2:15 2:15-2:45 2:45-3:30 3:30-4:00 4:00-4:30 Welcome and Introduction Module 1 Introduction to Sheetmetal Design Module 2 Primary Walls Exercise Module 3 Secondary and Unattached Walls Break Exercise Module 4 Unbend, Bend Back, and Cuts Exercise Lunch Module 5 Notches and Punches Exercise Break Module 6 Sheetmetal Forms Exercise Module 7 Bend Features Exercise

Day 2
8:30-9:00 9:00-9:30 9:30-10:15 10:15-10:30 10:30-11:00 11:00-11:30 11:30-12:00 12:00-1:00 1:00-1:45 1:45-2:15 2:15-2:45 2:45-3:00 3:00-3:30 3:30-4:00 4:00-4:30 4:30-5:00 Review Module 8 Unbending Sheetmetal Geometry Exercise Break Module 9 Converting Solid Parts Exercise Module 10 Sheetmetal Drawings with Flat States and Bend Order Tables Lunch Exercise Module 11 Additional Features Exercise Break Module 12 Setting Up for Design Exercise Module 13 Interrogating the Sheetmetal Part Exercise

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Acknowledgments
The Pro/ENGINEER curriculum is a joint development effort between the courseware development teams at PTC and RAND Worldwide. Both companies strive to develop industry leading training material and in turn deliver it to you the customer.

PTC 128 Technology Drive Waltham, MA 02453 USA 1-781-398-5000 http://www.ptc.com

RAND Worldwide 5285 Solar Drive Mississauga, ON Canada L4W 5B8 1-877-726-3243 http://www.rand.com

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Table of Contents
Fundamentals of Sheetmetal
INTRODUCTION TO SHEETMETAL DESIGN 1-1

THE SHEETMETAL DESIGN ENVIRONMENT............................................................1-3 SHEETMETAL PARTS.....................................................................................................1-3


Features .............................................................................................................................. 1-3 Sheetmetal Part Display ..................................................................................................... 1-4 Orienting the Sheetmetal Part ............................................................................................ 1-4 Developed Length .............................................................................................................. 1-5

DESIGN APPROACH .......................................................................................................1-5 MODULE SUMMARY......................................................................................................1-9

PRIMARY WALLS

2-1

WALL TYPES....................................................................................................................2-3 CREATING THE FIRST WALL .......................................................................................2-3


Wall Feature Options ......................................................................................................... 2-3 Sketching Technique.......................................................................................................... 2-5

LABORATORY PRACTICAL ..........................................................................................2-7


EXERCISE 1: Creating the Cable Box Base ..................................................................... 2-7

MODULE SUMMARY....................................................................................................2-13

SECONDARY AND UNATTACHED WALLS

3-1

TYPES OF SECONDARY WALLS ..................................................................................3-3


Resulting Geometry ........................................................................................................... 3-6 Creating Other Walls ......................................................................................................... 3-7

CREATING UNATTACHED WALLS .............................................................................3-9


Merging Unattached Walls .............................................................................................. 3-10

SECONDARY WALLS WITH RELIEF .........................................................................3-10 LABORATORY PRACTICAL ........................................................................................3-13


EXERCISE 1: Adding Walls to the Cable Box Base....................................................... 3-13 EXERCISE 2: Adding Walls to the Tuner Cover ............................................................ 3-17 EXERCISE 3: Creating the Box ...................................................................................... 3-26 EXERCISE 4: Creating an Unattached Wall ................................................................... 3-35

MODULE SUMMARY....................................................................................................3-41

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UNBEND, BEND BACK, AND CUTS 4-1
THE UNBEND, REGULAR FEATURE........................................................................... 4-3 THE BEND BACK FEATURE ......................................................................................... 4-4 CREATING SHEETMETAL CUTS ................................................................................. 4-5
Dimensioning Scheme........................................................................................................4-6

LABORATORY PRACTICAL ......................................................................................... 4-7


EXERCISE 1: Unbend and Bend Back ..............................................................................4-7

MODULE SUMMARY ................................................................................................... 4-13

NOTCHES AND PUNCHES

5-1

INCREASING YOUR EFFICIENCY WITH SHEETMETAL NOTCHES AND PUNCHES.......................................................................................................................... 5-3


Creating a Punch or Notch UDF.........................................................................................5-3 Placing a Punch or Notch Feature ......................................................................................5-5

LABORATORY PRACTICAL ......................................................................................... 5-7


EXERCISE 1: Creating Notches in the Flat State of the Model.........................................5-7

MODULE SUMMARY ................................................................................................... 5-15

SHEETMETAL FORMS

6-1

CREATING FORM FEATURES ...................................................................................... 6-3 CREATING FORM PARTS.............................................................................................. 6-3


Creating Rips in the Geometry ...........................................................................................6-5 Using Multiple Forms on a Single Die Model....................................................................6-5 Using Multiple Forms on a Single Punch Model ...............................................................6-6

PLACING FORM FEATURES ......................................................................................... 6-7


Placing By Reference .........................................................................................................6-7 Copying the Geometry .......................................................................................................6-8

RETURNING THE MODEL TO THE FLAT................................................................... 6-8 LABORATORY PRACTICAL ......................................................................................... 6-9
EXERCISE 1: Forms for the Cover ...................................................................................6-9 EXERCISE 2: Placing a Die Form...................................................................................6-18

MODULE SUMMARY ................................................................................................... 6-21

BEND FEATURES

7-1

BEND FEATURES............................................................................................................ 7-3


Angle ..................................................................................................................................7-3 Roll .....................................................................................................................................7-3 Regular ...............................................................................................................................7-4 W/Transit (With Transition)...............................................................................................7-4

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Planar Bends ...................................................................................................................... 7-4

BEND LINES .....................................................................................................................7-5


Bend Line Adjustment ....................................................................................................... 7-7

LABORATORY PRACTICAL ..........................................................................................7-9


EXERCISE 1: Creating a Model in the Flat ...................................................................... 7-9

MODULE SUMMARY....................................................................................................7-21

UNBENDING SHEETMETAL GEOMETRY

8-1

UNBENDING GEOMETRY AFTER DEFINING THE MODEL ....................................8-3


Unbending Ruled Geometry: the Regular Unbend ............................................................ 8-3 Unbending Nonruled Geometry: the Cross Section Driven Unbend ................................. 8-3 Adding Tears to the Geometry: Ripping ............................................................................ 8-4

DEFORMATION AREAS .................................................................................................8-6 LABORATORY PRACTICAL ..........................................................................................8-9


EXERCISE 1: Creating a Regular Unbend Feature........................................................... 8-9 EXERCISE 2: Cross Sectional Unbend ........................................................................... 8-11 EXERCISE 3: Creating a Deformation Area ................................................................... 8-16

MODULE SUMMARY....................................................................................................8-21

CONVERTING SOLID PARTS

9-1

CREATING SHEETMETAL PARTS FROM SOLID PARTS .........................................9-3 CREATING A DEVELOPABLE PART............................................................................9-4 LABORATORY PRACTICAL ..........................................................................................9-7
EXERCISE 1: Converting a Sheetmetal Part..................................................................... 9-7 EXERCISE 2: Using the Sheetmetal Conversion Feature ............................................... 9-10

MODULE SUMMARY....................................................................................................9-15

SHEETMETAL DRAWINGS WITH FLAT STATES AND BEND ORDER TABLES

10-1

FLAT STATES.................................................................................................................10-3
Retrieving Instances......................................................................................................... 10-3

CREATING MULTI-MODEL DRAWINGS...................................................................10-4 DOCUMENTING THE BEND ORDER..........................................................................10-5 LABORATORY PRACTICAL ........................................................................................10-7
EXERCISE 1: Documenting the Model........................................................................... 10-7

MODULE SUMMARY..................................................................................................10-17

ADDITIONAL FEATURES

11-1

FLAT PATTERN .............................................................................................................11-3

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SOLID FEATURES......................................................................................................... 11-3
EDGE TREATMENTS....................................................................................................11-3

Using Projected Datum Curves ........................................................................................ 11-4 LABORATORY PRACTICAL ....................................................................................... 11-7
EXERCISE 1: Using a Projected Datum Curve to Create a Cut ......................................11-7

MODULE SUMMARY ................................................................................................. 11-13

SETTING UP FOR DESIGN

12-1

CALCULATING DEVELOPED LENGTH .................................................................... 12-3 SETTING UP A DEFAULT RADIUS ............................................................................ 12-7 SETTING DEFAULT FIXED GEOMETRY .................................................................. 12-7 LABORATORY PRACTICAL ....................................................................................... 12-9
EXERCISE 1: Calculating the Length of a Sheetmetal Part ............................................12-9 EXERCISE 2: Setting Up for Sheetmetal ......................................................................12-12

MODULE SUMMARY ................................................................................................. 12-19

INTERROGATING THE SHEETMETAL MODEL

13-1

SHEETMETAL INFORMATION................................................................................... 13-3


Measurement ....................................................................................................................13-3 Surface Analysis...............................................................................................................13-3 Sheetmetal Bend Reports .................................................................................................13-4 Sheetmetal Radii Reports .................................................................................................13-5

DESIGN RULES.............................................................................................................. 13-6


Establishing a Design Rule Table.....................................................................................13-6

LABORATORY PRACTICAL ....................................................................................... 13-9


EXERCISE 1: Using Sheetmetal Information Tools........................................................13-9

MODULE SUMMARY ................................................................................................. 13-13

ADDITIONAL EXERCISES

A-1

EXERCISE 1: Creating a Blended Primary Wall..............................................................A-3 EXERCISE 2: Creating a Flat Primary Wall.....................................................................A-6 EXERCISE 3: Creating a Swept Secondary Wall .............................................................A-8 EXERCISE 4: Creating a Twisted Secondary Wall ........................................................A-10 EXERCISE 5: Bend Line Adjustment.............................................................................A-13 EXERCISE 6: Creating an Edge Bend and a Rip............................................................A-18

SKETCHER BASICS

B-1

THE SKETCHER ENVIRONMENT ............................................................................... B-2


The Sketcher Interface....................................................................................................... B-2

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Intent Manager .................................................................................................................. B-3 Pop-Up Menus .................................................................................................................. B-4

SKETCHER MODE FUNCTIONALITY.........................................................................B-4


Sketcher Menus................................................................................................................. B-4 Specifying References....................................................................................................... B-5 Creating Geometry............................................................................................................ B-6 Dimensioning.................................................................................................................... B-7 Constraining.................................................................................................................... B-10 Additional Sketcher Tools .............................................................................................. B-11 SETTING SKETCHER PREFERENCES ...................................................................... B-14

SKETCHER PHILOSOPHY ...........................................................................................B-17


Rules of Thumb............................................................................................................... B-17

LABORATORY PRACTICAL .......................................................................................B-19


EXERCISE 1: Sketching Basics ..................................................................................... B-19 EXERCISE 2: Sketching in Steps................................................................................... B-25 EXERCISE 3: Sketching a Hexagon .............................................................................. B-30

MODULE SUMMARY...................................................................................................B-33

USING PTC.HELP

C-1

PTC HELP OVERVIEW...................................................................................................C-2 PTC HELP FEATURES....................................................................................................C-2 USING THE PRO/ENGINEER HELP SYSTEM .............................................................C-2
Getting Help While Performing a Task..............................................................................C-2

GETTING HELP THROUGH THE PTC HELP SIDEBAR.............................................C-3 PTC HELP MODULE LIST..............................................................................................C-4

PTC GLOBAL SERVICES: TECHNICAL SUPPORT

D-1

FINDING THE TECHNICAL SUPPORT PAGE.............................................................D-2 OPENING A TECHNICAL SUPPORT CALL ................................................................D-2
Opening a call via email: .................................................................................................. D-2 Opening a Call via Telephone:.......................................................................................... D-3 Opening calls on the PTC Web Site:................................................................................. D-3 Sending Data To Technical Support ................................................................................. D-3

CALL / SPR FLOW CHART AND PRIORITIES............................................................D-4 REGISTERING FOR ON-LINE SUPPORT.....................................................................D-5 ONLINE SERVICES.........................................................................................................D-6 FINDING SOLUTIONS IN THE KNOWLEDGE BASE ................................................D-6 GETTING UP-TO-DATE INFORMATION ....................................................................D-8 CONTACT INFORMATION............................................................................................D-8
Internet .............................................................................................................................. D-8

Telephone ..........................................................................................................................D-9

ELECTRONIC SERVICES ............................................................................................ D-13

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Module

Introduction to Sheetmetal Design


Using the functionality available with the Pro/SHEETMETAL module, you can capture your design intent by bending flat material into its final formed shape, as well as create a flat form for manufacturers to use to develop the actual model.

Objectives
After completing this module, you will be able to: List benefits of designing sheetmetal components using Pro/SHEETMETAL List specialized sheetmetal feature types Describe the display of a sheetmetal part Describe how to orient a sheetmetal part Describe the design approach for a sheetmetal part

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NOTES

THE SHEETMETAL DESIGN ENVIRONMENT


Using Pro/SHEETMETAL to generate sheetmetal components enables you to do the following: Design a sheetmetal part that defines the supporting structures in an assembly Add sheetmetal-specific features such as walls, bends, cuts, punches, notches, and forms to a model in either the formed or flat condition Control the developed length of the bends when creating a flat instance of the model Create flat patterns and flat states of the model geometry to reflect the manufacturing and design models Create bend order tables that define the bend order, bend radius, and bend angle used in the manufacturing process Document the design by generating production drawings of the flat model and design model, as well as bend order tables

SHEETMETAL PARTS
Features
Sheetmetal parts are created in Sheetmetal mode, Assembly mode as sheetmetal components, or from a regular Pro/ENGINEER part. When you create a new file, you can use a default template or choose one from a list of standard or user customizable templates. When you use a template that contains designated parameters, you are able to enter parameter values as you create the model. Templates also include default datum planes and a coordinate system, saved views, and default layers. Pro/ENGINEER offers specialized feature types for the sheetmetal design environment. They include the following: sheetmetal cuts notches punches bends unbends

Introducti on to Sh eetm etal D esig n

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bend backs forms walls Note:


Create features in an order that captures your design intent, not in the order in which you would manufacture the geometry.

Sheetmetal Part Display


A sheetmetal part appears with green and white surfaces with side surfaces in between to define depth. This enables you to visualize the part and geometry selection, since sheetmetal parts tend to be comparatively thin. Sheetmetal parts always have a constant thickness. Pro/ENGINEER creates the white surface by offsetting it from the green surface by the amount of the material thickness. The side (depth) surfaces do not appear until the part has been successfully regenerated.

Orienting the Sheetmetal Part


When orienting a sheetmetal part, the first selection must be a planar surface or a datum plane and the second selection may be an edge. (This way of viewing is available in all modes of Pro/ENGINEER.) You may also use the thin edge surfaces of the sheetmetal part for orienting. Using Query Select is the suggested method of selecting these thin surfaces.

Figure 1: Orienting a Sheetmetal Part

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Developed Length
Pro/ENGINEER automatically compensates for stretching that occurs in the area of a bend by taking into account the thickness of the sheetmetal, the radius of the bend, the bend angle, and other material properties. This enables you to capture your design intent through the creation of the formed sheetmetal model, but also enables you to create a flat form of the model for manufacturers to use to develop the actual model.

Figure 2: The Developed Length

DESIGN APPROACH
You can generate sheetmetal models at either the sheetmetal level or the assembly level, but the assembly level enables you to use the top-down design approach. The following is a typical design approach for creating sheetmetal parts at the assembly level: 1. Create the assembly by assembling all major components relative to each other. You can include simple supporting structures, or sheetmetal parts that are not completely defined at this time.

Introducti on to Sh eetm etal D esig n

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Figure 3: Assembly of Sheetmetal Components

2. Create or modify sheetmetal parts in Assembly mode using the internal components as references. This process will aid in creating support walls, form features for stiffening panels, and punches and notches for fastening the components.

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Cover created in assembly referencing internal components

Additional features added to complete cover in Sheetmetal mode

Figure 4: Modify Sheetmetal Parts in Assembly Mode

3. After the cabinet and supporting structures are defined relative to the internal components and each other, add any remaining components or features. 4. Create or select a bend table to provide material allowances when unbending the part. The bend table data will be used to ensure accurate flat pattern geometry of the sheetmetal part. 5. In Sheetmetal mode, create a bend order table to define the bending sequences for each part. 6. Add a Flat Pattern feature. This will create the flat pattern for manufacturing. Another option is to create a Flat State. 7. Create a family table for each sheetmetal part that includes at least two instances: the unbent flat pattern instance and the as

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NOTES

designed instance. These instances are automatically created using the Flat State option. 8. Document the parts by creating drawings. You can include both instances (that is, with a multi-model drawing). Show the dimensions for the as designed part and show/create dimensions for the flat pattern part. Add the bend order table as a note.

Figure 5: Drawing of Sheetmetal Part

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MODULE SUMMARY
In this module, you have learned about: The benefits of using Sheetmetal mode to design sheetmetal parts Display and orientation characteristics specific to sheetmetal parts A design approach for creating sheetmetal parts at the assembly level

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Module

Primary Walls
In this module, you will learn how to create primary walls. The first sheetmetal feature must be a wall.

Objectives
After completing this module, you will be able to: Create the primary wall in a sheetmetal model Use sketching techniques to create the section for a primary wall

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WALL TYPES
Pro/SHEETMETAL gives you the ability to create two types of walls: primary and secondary. Primary walls do not need another wall in order to exist. They can stand alone. A secondary wall, however, must be attached to another wall because it cannot exist independently; thus, it is always a child of another wall.

CREATING THE FIRST WALL


Wall Feature Options
To create any model in Pro/ENGINEER, you should start with three default datum planes. If you use one of the sheetmetal templates, the part will automatically include these. When creating sheetmetal geometry, you must add a wall as the next feature. The following options are available for creating walls:
Extrude

Sketches the side section of the wall and extrudes it to a specified depth, as shown in Figure 1.

Figure 1: Extruding to a Specified Depth

Revolve

Sketches the side section of the wall and revolves it about a centerline, as shown in Figure 2.

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Figure 2: Revolving about a Centerline

Uses parallel, rotational, or general blend feature forms to create a wall, as shown in Figure 3. For more information on blends, see Creating a Blend in PTC Help.
Blend

Figure 3: Using Blend Feature Forms

Sketches the boundaries of the wall in the Sketcher plane, as shown in Figure 4.
Flat

Figure 4: Sketching in a Plane


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Offsets from an existing surface, as shown in Figure 5. For more information on offset surfaces, see Creating Surfaces by Offsetting in PTC Help.
Offset

Figure 5: Offsetting from an Existing Surface

Advanced

Creates a wall by using datum curves, multiple trajectories, and so on.

Sketching Technique
When creating an extruded wall, you can insert bends to represent inside and outside radii. Usually, you dimension all bends in sheetmetal parts to the inside. To do this, you may need to use the Thicken option to thicken the material and dimension the offset edges, as shown in Figure 6.

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Figure 6: Thickening the Material

It is common practice to dimension sheetmetal walls to the mold line (the intersection of the flat wall extensions). To create this dimensioning scheme, you must add Sketcher centerlines and points while creating the wall section. You can then dimension to the Sketcher points, instead of the tangent points on the arc, as shown in Figure 7.

Figure 7: Defining a Mold Line

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LABORATORY PRACTICAL
Goal
The goal of this exercise is to create the primary wall of a sheetmetal part as an extruded wall.

Method
In this exercise, you begin developing the lower housing of a cable box. The section of the extruded wall will be thickened and the inside radii dimensioned.

EXERCISE 1: Creating the Cable Box Base

Figure 8: First Wall of Cable Box

Task 1.

Start the definition of a sheetmetal model.

1. Create a new part file and select Sheetmetal as the sub-type in the NEW dialog box, as shown in Figure 9. The Use default template option is selected so that the part uses the default sheetmetal template. 2. Type [CABLE_BOX_BASE] as the name and click OK .

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Sub-type selection

Figure 9: NEW Dialog Box

Task 2. plane.

Create an extruded wall on both sides of the FRONT datum

1. Click Feature > Create > Wall > Extruded > Done > Both Sides > Done . 2. Select datum plane FRONT as the sketching plane and datum plane TOP as the top reference. 3. Sketch the section as shown in Figure 10.

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Figure 10: The Dimensioning Scheme

Task 3. Change the dimensioning scheme so that the system dimensions the inside radius by thickening the geometry. 1. Click Sketch > Feature Tools > Thicken . 2. Click Flip or Okay to add material inside the sketched section. 3. Type [0.08] as the thickness. 4. Delete the existing radius dimension. 5. Add a radius dimension to the thicken line, as shown in Figure 11. This results in an inside radius. Tips:
Make sure that you pick the thicken arc, not the solid arc. Use Query Sel to make it easier.

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Dimension the thicken arc

Figure 11: Dimensioning the Thicken Line 6. Modify the radius dimension to [.13] and exit from Sketcher. 7. Extrude to a blind depth of [12]. The completed wall feature appears as shown in Figure 12.

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Figure 12: The Finished Base

8. Save the model and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: The first sheetmetal feature must be a wall. The section of a wall can be thickened so that inside radii are dimensioned. Centerlines can be used in the section of a wall to dimension to the mold line.

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Module

Secondary and Unattached Walls


After you create the base wall for a sheetmetal model, you can attach secondary walls to its edges. You can also create unattached walls and later merge the geometry.

Objectives
After completing this module, you will be able to: Create an attached secondary wall along the complete length of the primary wall edge Create an attached secondary wall partially along the primary wall edge Create relief for secondary walls Create unattached walls and merge the geometry

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NOTES

TYPES OF SECONDARY WALLS


You can create several different types of secondary walls by sketching the bend in the wall or automatically creating a bend along the attachment edge. Using the No Radius and Use Radius options, you can create flat, extruded, partial, and swept secondary walls.
Flat, No Radius

Sketch the boundaries of the wall attached to the selected edge. The new wall is automatically created parallel to the adjacent wall, as shown in Figure 1 and Figure 2.

Figure 1: Flat, No Radius

Figure 2: A Wall Partially Along the Edge

Extruded, No Radius

Sketch the side section of the wall that will be extruded along the attachment edge. You determine if the bend is created when sketching the section, as shown in Figure 3.

Figure 3: Extruded, No Radius

Se conda ry and Un atta ched Wall s

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NOTES

If you sketch an arc to define the bend, you must sketch it tangent to the attachment edge and adjacent to the green or white surface, as shown in Figure 4.

Figure 4: Ensuring Tangency

You can also partially extrude the wall along the selected edge using the blind depth option and by defining a sketching plane partially along the edge.
Swept, No Radius

You can attach the wall to a nonlinear edge, but the edge must consist of all tangent entities, as shown in Figure 5. The green or white surfaces of the attachment edge do not necessarily have to be planar. For more information on sweeps, see Creating a Sweep in PTC Help.

Figure 5: Swept, No Radius

You can define the sketching plane at a specific angle through a selected attachment edge and then define a radius for the desired bend at the attachment edge, as shown in Figure 6.
Flat, Use Radius

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Figure 6: Flat, Use Radius

Extruded, Use Radius

You can sketch the side profile of the wall with a specified angle and then define the radius of the bend, as shown in Figure 7. This bend deforms a portion of the existing attachment wall.

Figure 7: Extruded, Use Radius

You can also partially extrude a wall along an edge using a blind depth and relief, as shown in Figure 8.

Figure 8: Using Make Datum and Depth Option Blind

Se conda ry and Un atta ched Wall s

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NOTES

You can sketch the section for the wall, and then specify the radius, as shown in Figure 9. With the Use Radius option, you cannot enter a wall angle that is greater than 180 to the adjacent green or white surface of the attachment edge.
Swept, Use Radius

Figure 9: Swept, Use Radius

Resulting Geometry
The Use Radius option produces different results, depending on the attachment edge that you select, as shown in Figure 10 and Figure 11. If you attach the geometry to an edge that is going to be the outside edge of the wall, the length of the original wall does not change. However, if you attach it to the inside edge, the wall extends a distance beyond the length of the original wall that is equal to the thickness of the geometry.

Attached to inside edge

Attached to outside edge

Figure 10: Extruded Walls

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Figure 11: Flat Walls

When creating a flat wall, Pro/ENGINEER also enables you to automatically miter a corner by sketching outside the attachment edge and aligning to an existing wall, as shown in Figure 12. You must add rip relief at the attachment edge.

Aligned to inside edge

Figure 12: Mitered Corner

Part and Feature Bend Tables


When creating a wall with the Use Radius option, you must specify whether you want to use a part bend table or a feature bend table. Bend tables control the developed length of the bends. Using the Part Bend Tbl option, you can use a single table to control all of the bends on the entire model.

Creating Other Walls


A twist takes the form of an extension to a straight edge on an existing planar wall. It can be rectangular or trapezoidal. It has an axis running through it center, perpendicular to the attach edge and it can be twisted around the axis by a specified amount, as shown in Figure 13. You cannot use a radius with the twist wall type. You can unbend a twisted wall using

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the Unbend and Regular options. You can also add more walls to the end of the wall. To generate the twisted geometry, you must specify the following values: Point of attachment Width at the start Width at the end Length Twist angle Developed length

Figure 13: Twisted Wall

To create an extended wall, you can extend the existing green surface of a wall up to an existing planar surface or to a specified distance. Using this technique, you can close gaps between walls in the geometry by extending up to the inside or outside surfaces of the wall, as shown in Figure 14. You cannot use a radius with the extended wall type.

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Open corner

Extended to the inside surface

Extended to outside surface

Figure 14: Closing Gaps between Walls by Extending

CREATING UNATTACHED WALLS


After you add the first wall of the model, you can create additional unattached walls using the same methods. Figure 15 shows a primary wall with an unattached wall. The Unattached option enables you to capture the intent of the model with greater flexibility by enabling you to concentrate in more than one area on the model. Once you have created the walls, you can use an unattached or secondary wall to bridge the gap and then merge the geometry.

Figure 15: Unattached Wall

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Merging Unattached Walls


To successfully merge an unattached wall with an unattached or secondary wall, the wall geometry must be tangent to the wall with which you are merging it. Also, the corresponding green side of the unattached wall must be adjacent to the green side of the adjacent wall. You can change this, if necessary, by using the Swap Side element, as shown in Figure 16.

Figure 16: Matching the Side

SECONDARY WALLS WITH RELIEF


When creating walls or bends that require relief, the system provides an automatic relief function. The choices are as follows:
No Relief

Attach the wall without reliefs.

StrtchRelief

Use material stretching to provide bend relief at the wall attachment points, as shown in Figure 17. The system prompts for the width and angle of the stretch relief.

Figure 17: Stretch Relief

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Rip relief

At the wall attachment points, rip the existing material normal to the edge and back to the tangent line as shown in Figure 18.

Figure 18: Rip Relief

RecRelief

At the wall attachment points, apply a rectangular cut by defining its width and depth, as shown in Figure 19.

Figure 19: Rectangular Relief

ObrndRelief

- At the wall attachment points, apply an obround cut by defining its width and depth, as shown in Figure 20.

Figure 20: Obround Relief

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LABORATORY PRACTICAL
Goal
The goal of this exercise is to create secondary walls with relief, when necessary and create unattached walls that are eventually merged with existing geometry.

Method
In the first exercise, you will create secondary walls using different types of automatic relief. In the second exercise, you will create secondary walls and create additional extruded and extended walls to close gaps in the geometry. In the third exercise, you will create a new part using several different techniques to construct the walls. In the fourth exercise, you will create two unattached walls in a part and merge them to complete the geometry.

EXERCISE 1: Adding Walls to the Cable Box Base

Figure 21: Cable Box Base

Task 1. Create a Flat, Use Radius wall with obround relief on one end of the cable box base. 1. Open CABLE_BOX_BASE.PRT. If you did not complete the base of the cable box, open SECONDARY_CABLE_BASE.PRT. 2. Click Feature > Create > Wall > Flat > Use Radius > Done .

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3. Click Part Bend Tbl > Done/Return > Inside Rad > Done/Return . 4. Pick the lower green edge to attach the wall as shown in Figure 22.

Attach to the green lower edge

Figure 22: Attaching the Wall to the Lower Edge

5. Click Done to use the default bend angle of 90 degrees. 6. Click Okay to accept the viewing direction. 7. Sketch the section as an open section consisting of three lines as shown in Figure 23.
Align the endpoint to the edge

Figure 23: Sketching an Open Section

8. Exit Sketcher when the section is complete and orient to the default view. 9. Click w/Relief > Done . A point on the attachment edge highlights at the end of the new wall. 10. Click ObrndRelief > Done for the first end of the wall.

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11. Click Enter Value and type [0.20] for the reliefs width. 12. Click Tan To Bend . 13. Define the same relief for the other end of the wall. 14. Type [0.13] for the bend radius value. Click OK in the dialog box. The part should appear as shown in Figure 24.

Figure 24: Flat Wall with Obround Relief

Task 2.

Create another wall on the other end of the part.

1. Create a similar flat wall on the opposite end of the cable box. Use obround relief on both ends of the wall. Make this wall reference the first flat wall (that is, no dimensions are required for the second flat wall). The part should appear as shown in Figure 25.

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Figure 25: Completed Cable Box Base

2. Save the model and erase it from memory.

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EXERCISE 2: Adding Walls to the Tuner Cover

Figure 26: Secondary Walls Added to Tuner Cover

Task 1. Create a flat wall on one end of the part that does not extend past the existing wall. 1. Open TUNER_COVER.PRT. 2. Click Feature > Create > Wall > Flat > Use Radius > Done . 3. Click Part Bend Tbl > Done/Return > Inside Rad > Done/Return . 4. Pick the edge indicated in Figure 27.

Pick the upper white edge

Figure 27: Attachment Edge for Flat Wall


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5. Click 90.000 > Done . 6. Click Okay for the direction of viewing the sketching plane. 7. Sketch an open section in which the endpoints pass through the Sketcher points provided by the system. Align the horizontal edge to the lower surface of the existing side wall, as shown in Figure 28.
Section sketched to Sketcher points

Align to bottom surface of wall

Figure 28: Open Section for Flat Wall

8. When finished sketching, exit from Sketcher. 9. Use rip relief at both ends of the wall. 10. Type [.05] as the bending radius value. 11. Click OK . The model should appear as shown in Figure 29. Task 2. Create an extruded wall on the other end of the model.

1. Click Create > Wall > Extruded > Use Radius > Done . 2. Click Part Bend Tbl > Done/Return > Inside Rad > Done/Return . 3. Click One Side > Done . 4. Pick the edge to attach the wall, as shown in Figure 29.

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Pick here on the white edge

Figure 29: Selection Edge for Extruded Wall

5. Click Default > Flip to define the sketching plane and viewing direction. 6. Sketch the section as shown in Figure 30. Make sure that the endpoint passes through the Sketcher point provided by the system. Align the other end to the edge of the existing wall.

Align endpoint to edge

Sketched line

Figure 30: Section for Extruded Wall

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7. Finish the wall definition using rip relief on both ends and type [.05] as the bending radius value. The part should appear as shown in Figure 31. The walls that you just created look identical.

Figure 31: Flat and Extruded Walls

Task 3.

Extend the flat wall to the outside of the side walls.

1. Click Create > Wall > Extend > Done . 2. Pick the edge shown in Figure 32 as the edge to extend. 3. Click Query Sel to pick the hidden inside surface of the side wall to define the extension distance.

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Pick hidden inside surface Pick this edge

Figure 32: Defining the Geometry to Extend

4. Click OK . The part should appear as shown in Figure 33.

Figure 33: Completed Extension

5. Create another wall extension on the other end of the flat wall using the references shown in Figure 34.

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Extend the wall to this surface

Pick this edge

Figure 34: Defining the Second Wall Extension

Task 4. Use Extruded walls to create tabs on the back wall of the model to close the gap. 1. Click Create > Wall > Extruded > No Radius > Done . 2. Use a part bend table to drive the bend geometry and extrude one side of the sketching plane. 3. Pick the attachment edge as shown in Figure 35.

Pick this hidden edge for attachment (inside edge)

Figure 35: Specifying the Attachment Edge


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4. Click Default > Okay to define the sketching plane and viewing direction. 5. Sketch a section consisting of a line and a tangent arc, as shown in Figure 36. Use the dimensioning scheme shown.
Tangent arc Line

Figure 36: Section for Extruded Wall

6. Finish the definition of the wall. It should appear as shown in Figure 37 (as viewed from the underside of the part).

Figure 37: Tab Created as an Extruded Wall

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7. Add another extruded No Radius wall to the other side of the wall to fully close up the cover. The completed part should appear as shown in Figure 38.

Figure 38: Completed Part

Task 5. Determine if any of the walls that you created overlap in the unbent state of the model. 1. Click Create > Unbend > Regular > Done and pick the top surface of the cover to remain fixed. 2. Click Unbend All > Done . 3. Click OK to complete the feature. The unbent state of the model should appear as shown in Figure 39. If any of the walls overlap, they are highlighted in red.

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Surface to remain fixed

Figure 39: Unbent State

4. Save the part and erase it from memory.

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EXERCISE 3: Creating the Box

Figure 40: Completed Model

Task 1.

Create a new sheetmetal part.

1. Create a new sheetmetal part called BOX. 2. For the first sheetmetal feature, create an extruded wall using the section shown in Figure 41, sketched on the TOP datum plane.

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Figure 41: Section for Base Wall

3. Click Thicken on the pop-up menu to thicken the sketch. Type [0.12] as the inside wall value to maintain the proper dimensioning scheme. Make sure that the 0.35 dimension belongs to the inside (thickened) portion. 4. Extrude the wall to a blind depth of [10.00]. Task 2. Create three flat secondary walls attached to the base wall.

1. Create a flat wall using the Use Radius , Part Bend Tbl , and Inside Rad options. 2. Pick the green edge indicated in Figure 42 to attach the wall.

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Attach wall to the green edge

Figure 42: Attaching the Wall

3. Use the default bend angle of 90 degrees. 4. Sketch the wall as shown in Figure 43. After finishing the sketch, click No Relief and type [0.10] as the bend radius.

Figure 43: First Secondary Wall

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5. Create another flat wall so that it closes off the end of the box and Pro/ENGINEER miters the corner automatically. Use the Use Radius , Part Bend Tbl , and Inside Rad options. Use the default bend angle of 90 degrees. Pick the edge shown in Figure 44.

Attachment edge (white edge)

Figure 44: Creating Another Flat Wall

6. Sketch the section for the wall, as shown in Figure 45. You do not need to add dimensions, but add the appropriate references. Notice that the side of the sketch crossing the bend is beyond the Sketcher point. Pro/ENGINEER, therefore, miters both walls at this corner.

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Right vertex of edge

Figure 45: Sketching Second Wall to Create a Miter

7. After finishing the sketch, click W/Relief and use the Rip relief option for the right vertex, as shown in Figure 45. Type [0.35] as a bend radius. 8. Create another flat wall for the other end of BOX.PRT. Use the default bend angle of 90 degrees. Pick the white edge indicated in Figure 46.

Attachment edge (white edge)

Figure 46: Creating a Flat Wall for the Other End of BOX.PRT

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9. Sketch the wall using the section shown in Figure 47. After finishing the sketch, click No Relief and type [0.10] as the bend radius.

Figure 47: Sketching the Flat Wall

Task 3. wall.

Create a secondary wall that is partially extruded along the base

1. Create an extruded wall using the Use Radius , Part Bend Tbl , and Inside Rad options. 2. Click One Side > Done . 3. Pick the green edge as shown in Figure 48.

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Pick this green edge to attach wall

Offset the datum plane from datum plane RIGHT

Figure 48: Offsetting Datum Point

4. Click Make Datum and create a datum plane Offset from datum plane RIGHT by [2.0]. 5. Flip the viewing direction. Keep in mind that the direction of viewing for the wall is also the direction of feature creation. 6. Click Default on the SKET VIEW menu to define the orientation. 7. Sketch the section as shown in Figure 49.

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Figure 49: Sketching the Partial Wall

8. After completing the sketch, click W/Relief and use the Rip Relief option on each end of the wall. 9. Type [0.10] as the bend radius value. Do not click OK yet. 10. Click the optional Depth element in the dialog box, then click Define . 11. Type a Blind depth of [1.5]. 12. Click OK to complete the feature. The wall should appear as shown in Figure 50.

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Figure 50: Partial Wall Feature with Rip Relief

Task 4.

Redefine the wall to change the relief from rip to stretch.

1. Redefine the last wall and click Relief in the dialog box. 2. Click w/Relief > Done > StrtchRelief > Done . 3. Type [0.25] as a stretch relief value and [45] as an angle for both ends. Notice the changes that occur where the partial wall meets the base feature wall, as shown in Figure 51.

Figure 51: Partial Wall Feature with a Stretch Relief

4. Save the part and erase it from memory.

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EXERCISE 4: Creating an Unattached Wall

Figure 52: Custom Shield

Task 1.

Open the part and use the surface geometry to create two walls.

1. Open CUSTOM_SHIELD.PRT. 2. Click Feature > Create > Sheet Metal > Wall > Offset > Done . 3. Pick the surface on the right-hand side, as shown in Figure 53.
Pick this surface from which to offset

Figure 53: Pick Right-Hand Surface

4. Type [0] as the offset value. 5. If necessary, flip the arrow outward (to the right), as shown in Figure 54. Click Okay.

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Figure 54: Offset Direction

6. Type [.05] as the thickness and click OK . 7. Create an unattached offset wall on the other side. Notice that the Unattached option is automatically selected when you click Offset . Type [0] as the offset value and add the thickness to the outside (to the left), as shown in Figure 55.

Figure 55: Direction of Offset

8. Blank the SURFACES layer. Task 2. Create an unattached flat wall that spans the gap between the two offset walls. 1. Click Create > Wall > Flat > Unattached > Done . 2. Pick the FRONT datum plane as the sketching reference. Flip the arrow outward as shown in Figure 56. 3. Pick the TOP datum plane as the top reference.

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Figure 56: Sketch Viewing Direction

Note:
Keep in mind that the direction of viewing is also the direction in which Pro/ENGINEER adds the material thickness.

4. Pick the top datum planes and the two vertical surfaces as references for the section, as shown in Figure 57.
Pick these surfaces as references

Figure 57: Section References

5. Sketch a horizontal centerline along the TOP datum plane. 6. Sketch a rectangle, symmetric about the centerline, where the vertical edges lie on the referenced surfaces, as shown in Figure 58. Complete the feature when finished sketching.

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Figure 58: Section for Flat Wall

Task 3.

Merge the three walls.

1. Click Create > Wall > Merge > Done . 2. Pick the bend surface on the first wall and click Done Sel > Done Refs . 3. Pick the front flat surface and click Done Sel > Done Refs again. 4. Click OK in the dialog box.

Pick these surfaces to merge

Figure 59: Merging the Flat Wall with the First Offset Wall

5. Create another merge feature for the other offset wall on the left side (Figure 60).

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Figure 60: Finished Model

6. Save the part and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: When creating some secondary wall types, you have the option of having the system automatically apply a radius at the attachment edge. The Use Radius option produces different results depending on the attachment edge selection. You can extrude secondary walls partially along an attachment edge by using the optional Depth element. Unattached walls enable you to concentrate on more than one area of the model. Automatic relief can be added to walls when necessary.

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Module

Unbend, Bend Back, and Cuts


It is easier to create sheetmetal parts in a completely bent condition; however, some features must be created in a flat state. Combinations of unbend and bend back features enable these features to be created effectively.

Objectives
After completing this module, you will be able to: Create unbend features Create bend back features Create sheetmetal cut features

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THE UNBEND, REGULAR FEATURE


The unbend, regular feature will unbend the curved surfaces of the part created by walls and bend features. If all bends are selected, a flat pattern of the part is automatically generated. You are prompted to pick a plane or edge to remain fixed while the part is being unbent. It is good practice to always pick the same plane or edge each time an unbend or bend back feature is created. This will keep the part in a consistent orientation.

Original model

Unbend selected

Unbend all

Figure 1: Unbend Sheetmetal Geometry

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THE BEND BACK FEATURE


The bend back feature may be used to return an unbent feature to its original condition. When you create a bend back feature, you can specify contours to remain fixed (that is, unbent) by picking on the edge of that contour.

Figure 2: The Bend Back Feature

Notes:
When a sheetmetal wall overlaps and intersects in the unbent position, the system highlights it and issues a warning.

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CREATING SHEETMETAL CUTS


A sheetmetal cut feature enables you to create Thru All and Thru Next cuts. The techniques for creating the cuts are the same as in Part mode. Unlike the solid cut, the sheetmetal cut always removes material normal to the green or white side of the model in order to emulate most sheetmetal manufacturing processes. The solid cut removes material normal to the sketching plane.

Solid cut

Sheetmetal cut projected on the white side

Sheetmetal cut projected on green side

Figure 3: Removing Material Using a Sheetmetal Cut

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Dimensioning Scheme
Features may be added to the sheetmetal part while the part is in any design condition (that is, completely bent, completely unbent in its flat condition, or at any stage in-between). It is easiest to design sheetmetal parts in the completely bent condition. When creating features in the unbent stages, care must be taken when picking sketcher references. See the example in Figure 4.

Cut created before bend

Cut created after bend and unbend features

When bend is created, new surfaces result. Cut section stays in old surface location.

When bent back, cut section stays with cut feature. The cut could have been created in the bent state.

Figure 4: Creating a Cut in the Flat Condition

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LABORATORY PRACTICAL
Goal
The goal of this lab is to create sheetmetal cuts across bent geometry that result in flat contours.

Method
In this exercise, you create a wall with two bends. An unbend feature is created followed by two sheetmetal cuts. A bend back feature is then created, but with two contours remaining flat.

Figure 5: Sheetmetal Cuts with Flat Contours

EXERCISE 1: Unbend and Bend Back


Task 1. Create a new sheetmetal part.

1. Create a new part called BEND_BACK using the default template. 2. Create an extruded wall using the dimension scheme shown in Figure 6 (use an equal length constraint for the horizontal segments). Create the wall on both sides of the datum plane. Type a blind depth of [6.0].

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Figure 6: Extruded Wall

Task 2.

Create an unbend feature.

1. Click Feature > Create > Sheet Metal > Unbend > Regular > Done . 2. Pick the surface shown in Figure 7 as the one to remain fixed while unbending.

Pick this surface to remain fixed

Figure 7: Surface to Remain Fixed during Unbend

3. Click Unbend All > Done and click OK in the dialog box.

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Task 3.

Create a Thru Next, Thin Cut on the part.

1. Click Feature > Create > Sheet Metal > Cut > Extrude > Thin > Done . 2. Sketch on the large top face of the part as shown in Figure 8.

Pick this surface as the sketching plane

Figure 8: Sketching Plane for Cut

3. Sketch the cut as shown in Figure 9.

Figure 9: Section for Cut

4. Add the thickness to the outside of the cut. Type a thickness value of [0.3]. 5. Click Thru Next for the depth of the cut. The completed feature should appear as shown in Figure 10.

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Figure 10: First Cut Feature

6. Create a similar cut through the bend on the other side of the part as shown in Figure 11.

Figure 11: Second Cut Feature

Task 4.

Create a Bend Back feature.

1. Click Feature > Create > Sheet Metal > Bend Back . 2. Pick the surface shown in Figure 12 to remain fixed.
Pick this surface to remain fixed

Figure 12: Surface to Remain Fixed during Bend Back

3. Click BendBack Sel > Done . 4. Pick the two surfaces shown in Figure 13.

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Pick these two surfaces for the Bend Back feature

Figure 13: Select References for Bend Back

5. After picking the two surfaces, click Done Sel > Done Refs . 6. Type [yes] at the prompt for the contour to remain flat. 7. Type [yes] for the second contour. The part should appear as shown in Figure 14.

Figure 14: Completed Part

8. Save the part and erase it from memory.

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MODULE SUMMARY
In this module, you have learned: Selected curved surfaces created by wall and bend features can be unbent. An unbent surface can be returned to the bent condition using an bend back feature. Sheetmetal cuts can be created Thru All or Thru Next. Sheetmetal cuts always remove material normal to the green or white surface of the model. If a contour partially intersects a bend that is being bent back, the system prompts you as to whether you want this contour to remain flat

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Module

Notches and Punches


Notches are used to relieve material that interferes with bending in places such as the corners of flanges. Punches are templated cutouts. Punches and notches are manufacturing operations. In Pro/ENGINEER they are created using cuts and user-defined features (UDF); in manufacturing, each punch or notch has a specific tool that defines its shape. Punches and notches can be used to create cuts and capture manufacturing information such as the tool name.

Objectives
After completing this module, you will be able to: Create user-defined features Create notch and punch features using user-defined features

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INCREASING YOUR EFFICIENCY WITH SHEETMETAL NOTCHES AND PUNCHES


Figure 1 shows examples of notches and a punch that can be defined with user-defined features (UDF). A UDF consists of selected features, all their associated dimensions, any relations between the selected features, and a list of references for placing the UDF on a part. For more information on UDFs, see creating a UDF in PTC Help.

Notches

Punch

Figure 1: Sheetmetal Notches and Punch

To create a notch or punch UDF, you use the following parameters that are specific to sheetmetal design and manufacturing: A coordinate system to locate tooling for automated punch and notch operations A specific tool ID to specify the proper tool for the manufacturing operation A single sheetmetal cut feature, as shown in Figure 2.
The cut remains normal to surfaces in the bend

Figure 2: Using a Notch UDF

Creating a Punch or Notch UDF


Use the following steps to create a notch or punch UDF: 1. Create a simple sheetmetal part to serve as a reference part.
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2. Create a cut feature. Sketch the desired section for Punch or Notch. Be sure to include the coordinate system. When you are aligning and dimensioning, keep in mind the convenience of eventual placement of the UDF. Notes:
If a notch is intended to relieve material in bend areas, create a bend and unbend it. When sketching the cut, align its sides to the bend edges. If you can set up relations for the feature (for example, the overall cut height is always 1.2 of the side height), do so; it reduces the number of variable dimensions you have to type every time when placing the punch/notch.

3. Click Feature > UDF Library. The UDF menu appears. 4. Click Create , then type the name of the UDF. The UDF OPTIONS menu appears. 5. Click Stand Alone > Done . (Punch and notch UDFs can only be Stand Alone.) 6. The system prompts you to indicate whether you want to include the reference part. If the part is simple, type [Y]; otherwise, type [N]. The UDF:<UDFNAME>, STANDALONE dialog box appears. 7. The UDF FEATS menu appears with Add pre-selected. This, in turn, brings up the SELECT FEAT menu. Pick the cut feature, then click Done > Done/Return . 8. Type [Y] when the system prompts you to indicate whether you are defining this UDF for a punch or a notch feature. Note:
If a coordinate system is not included in the feature, the UDF creation is aborted at this point.

9. In response to the system prompt, type the tool name. 10. The SYMMETRY menu appears to define the symmetry of the tool relative to the feature coordinate system. Click one of the options.

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11. Continue with the process by responding to prompts for the reference geometry, selecting variable dimensions, and so on. 12. Click OK in the dialog box. The system creates and stores the UDF. 13. Click Done/Return in the UDF menu. Notes:
All punch/notch UDF feature attributes, including Tool Name and Symmetry flags, can be redefined after the UDF has been placed on the base part by clicking Feature > Redefine and picking the UDF feature. When you are creating a table-driven punch/notch group, you can modify any instance Tool Name in the table.

Placing a Punch or Notch Feature


1. Click Notch or Punch from the SHEETMETAL menu. 2. Select the UDF from the OPEN dialog box. 3. Specify whether the reference part should be retrieved or not. The GROUP ELEMENTS dialog box appears. 4. The SCALE menu appears. Click one of the first two options, then click Done . 5. The DISP OPTION menu appears. Click one of the first three options, then Done . 6. The SEL REF menu appears. Place the UDF by selecting placement references.

Consider Design Intent When Using Notch Relief


When you actually create a sheetmetal part, you add the notch relief before bending. However, you can capture your design intent more accurately by creating the part in the formed state. Instead of adding relief and then creating the wall, you should focus on dimensioning the walls to preserve your design intent. Using this method, you can increase your regeneration speed by suppressing the notches since the walls are not children to those entities.

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LABORATORY PRACTICAL
Goal
The goal of this lab is to use UDFs to simplify the creation of multiple notch features and to incorporate non-constant wall thickness into a sheetmetal part.

Method
In the first exercise, you create a cut that is used to define a UDF. That UDF is then used to define notch features in the flat state of another part. In the second exercise, you show the varying thickness of a part by placing a UDF.

EXERCISE 1: Creating Notches in the Flat State of the Model


Task 1. Define the notch by creating a sheetmetal cut.

1. Open SQUARE_NOTCH_REF.PRT.
Surface to remain fixed

Figure 3: SQUARE_NOTCH_REF.PRT

2. Create a Regular, Unbend All feature. Pick the top surface of the part to remain fixed, as shown in Figure 3. 3. Create a sheetmetal cut using the top surface of the bend as the sketching plane and the edge surface of the bend as the bottom reference, as shown in Figure 4.

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Sketching plane Bottom reference plane

Figure 4: References for Sheetmetal Cut

4. Specify references as shown in Figure 5.

Specify this vertical tangent line as a reference

Specify these horizontal and vertical bend axes as references

Figure 5: Sketching the Cut

5. Sketch horizontal and vertical centerlines along the bend axes. 6. Sketch a rectangle as shown in Figure 5. No other alignments are required.

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7. Sketch a coordinate system at the intersection of the two centerlines. 8. When finished sketching, exit from Sketcher. Remove the material from the inside of the section, and create the feature using the Thru All depth option. 9. Click OK . The part should appear as shown in Figure 6.

Figure 6: Completed Cut

Task 2.

Define a UDF from the finished cut.

1. Click UDF Library > Create and type [square_notch]. 2. Click Stand Alone > Done . 3. Type [yes] to include the reference part. 4. Pick the square cut that you just created. 5. Click Done Sel > Done > Done/Return . 6. Type [Y] to confirm that you are defining a UDF for a notch. 7. Type [square] as the tool name. 8. Click Both to have the tool symmetric about both axes. 9. Type prompts for the five references, as shown in Figure 7. Before typing each prompt, make sure that the appropriate entity highlights on the screen. When you have finished, click Done/Return > OK .

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Vertical bend axis Vertical bend tangent edge

Placement plane

End surface Horizontal bend axis

Figure 7: Defining a UDF from the Cut

10. Save the model and close the window. Task 3. Place the UDF on the tuner cover model to create notch relief at the corners. 1. Open TUNER_COVER.PRT. If you did not complete the secondary walls on the part, retrieve NOTCH_TUNER_COVER.PRT. The part opens in the unbent state as shown in Figure 8.

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Figure 8: TUNER_COVER.PRT

2. Click Feature > Create > Notch . 3. Select the SQUARE_NOTCH.GPH file that you just created. Retrieve reference part, if you wish. 4. Click Same Dims > Done > Normal > Done . This defines the group to have the same dimensions as the UDF and displays them so they may be modified. 5. Respond to the prompts by specifying the appropriate references, as shown in Figure 9, for the lower, right-hand corner of the part. Click Done to finish. The notch feature should appear as shown in Figure 10.

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NOTES Vertical bend axis

Vertical bend tangent edge

Horizontal tangent edge

Placement plane

Perpendicular end surface

Figure 9: Adding the Square Relief

Figure 10: Defining the Notch

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6. Add the notch relief to the other three corners on the part.
Add the other three notches

Fixed surface for bend back

Figure 11: Adding Notch Relief to Other Corners

Task 4. Now that you have added the relief, bend back the model to its formed state. 1. Bend back the entire part. It should appear as shown in Figure 12.

Figure 12: The Completed Part

2. Save the model and erase it from memory.


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MODULE SUMMARY
In this module, you have learned that: Notches and punches are created by first defining a UDF. A simple sheetmetal part can be used to define the notch or punch UDF. A coordinate system must be included in the UDF if it is to be used as a notch or punch UDF.

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Module

Sheetmetal Forms
In this module, you learn how to complete a forming operation to plastically deform a sheetmetal model. Plastic deformation changes the material properties of the metal as it flows under the force of the forming operation.

Objectives
After completing this module, you will be able to: Create form features Create form parts Place form features Use solid features to show edge treatments Create a flatten form feature

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CREATING FORM FEATURES


To create a form feature, you use reference geometry. You can create two types of sheetmetal forms: die and punch. A die form represents the forming geometry (convex or concave) surrounded by a bounding plane. The surface that surrounds the forming geometrythe base planemust be planar, and the base plane must completely surround the forming geometry. You can reference multiple die forms from a single model. A punch form represents only forming geometry, using the entire model to form the sheetmetal part.

Die form

Punch form

Figure 1: Forms

CREATING FORM PARTS


The form model can be a solid part or another sheetmetal part, but you should start the creation of both types of form models using default datum planes. To make it easier to place the form, the datum planes should intersect at the center of the form feature. If you use a sheetmetal model, the sheetmetal to be formed should conform to the green side of the sheetmetal component. When creating a form model, keep in mind the following: Any convex surface must have a radius that is larger than the thickness of the sheetmetal or equal to zero if the form is mated to the sheetmetal geometry.

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NOTES Convex radius greater than thickness

Figure 2: Convex Surface

Any concave surface must have a radius that is larger than the thickness of the sheetmetal or equal to zero if the form is aligned to the sheetmetal geometry.
Must have radius greater than thickness

Figure 3: Concave Surface

The form can contain a combination of convex and concave geometry, creating hollows. However, the hollows in the form must not drop below the base plane or mating surface.

Hollow above base plane

Figure 4: Hollows

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The model can contain a coordinate system that you can reference to determine where a forming die should strike the part in the manufacturing process.

Creating Rips in the Geometry


Some forming operations consist of two tasks: plastically deforming the sheetmetal and actually cutting the sheetmetal. Figure 5 shows an example of a cooling fin that is cut through the side of the sheetmetal housing. You can represent the shearing of the material by excluding surfaces from the form when you place it on the sheetmetal model.
Excluded surface

Figure 5: Shearing Material

Using Multiple Forms on a Single Die Model


In some cases, it may be more convenient to store multiple forms on a single form die model, as shown in Figure 6. For Pro/ENGINEER to distinguish one set from another, however, you must specify a seed surface to gather all surfaces that are surrounded by the base plane to create the form geometry, as shown in Figure 7. You must select the seed surface in all die forms, even if there is only one set of form geometry.

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Figure 6: Using Multiple Forms in a Single Die Model


Seed surface

Base plane

Figure 7: Specifying a Seed Surface

Using Multiple Forms on a Single Punch Model


To reduce the number of models stored for punch forms, you can create the punch model with two sides, as shown in Figure 8. The system enables you to select one side or the other, with respect to the mating surface that you use in the punch model.

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Figure 8: Using Both Sides of a Punch Model

PLACING FORM FEATURES


When placing a form feature, you should consider the design intent, particularly in terms of how the form feature references other features in the model, as well as how it is referenced when you place it. The system uses assembly type constraints to determine the location of the form feature on the model. If you move a feature that the form references, the system updates the forms location parametrically.

Placing By Reference
You can place a form feature so that it references the original forming model at all times. If the original form model changes, the geometry on the sheetmetal part also changes. If the sheetmetal model cannot find the referenced form model, the system freezes the geometry on the component.

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Copying the Geometry


When you do not want to associate the geometry of the form to the reference model, you can place the form model by copying all of the form geometry into the sheetmetal model. This copy operation creates a completely independent version of the form geometry; therefore, when you make a change to the form, the system does not reflect it in the component.

RETURNING THE MODEL TO THE FLAT


In some cases, you may have to return a sheetmetal model to its original flat state after you have placed it. To do this, you can use the Flatten Form option to flatten the form geometry in the model.

Figure 9: Flattening the Form

Note:
You should use the Flatten Form option as a tool to create the flatten form feature, not to reduce regeneration time.

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LABORATORY PRACTICAL
Goal
The goal of this lab is to reference geometry in another model to create form geometry in a sheetmetal part.

Method
In the first exercise, you are going to use two different form models to create geometry in a sheetmetal part. The part will then be unbent and the Flatten Form option will then be used to flatten the form geometry. In the second exercise, you get additional practice by placing a die form that represents louvers on a part for ventilation.

EXERCISE 1: Forms for the Cover

Figure 10: Form Geometry

Task 1.

Create the formed feature for the recess on the cover part.

1. Open COVER.PRT. 2. Open FORM1.PRT. This part was created in Part mode and represents the die that creates the recess. Close this window and activate the COVER part window. 3. Click Feature > Create > Form . Accept the defaults of Die and Reference in the OPTIONS menu.

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4. Select FORM1.PRT for the referencing geometry. The form part opens in a second window along with a component placement window. 5. Mate the front of the form and the green underside surface on the cover part, as shown in Figure 11. 6. Align Offset DTM1 (yellow side) on the form part and the right side wall of the cover, as shown in Figure 11. Type [-4.33] as the offset value. 7. Mate Offset DTM2 (yellow side) on the form part and the bottom end surface of the cover, as shown in Figure 11. Type a value of [-6.33].
Mate front of form to underside of cover

Mate Offset DTM2 and end surface of cover by -6.33

Align Offset DTM1 and right-hand side of cover by -4.33

Figure 11: Assembling the Form to the Cover

8. The Message Window prompts, Form feature can now be placed. Click Show Placement to preview the placement of the form, then click Done to complete the placement.

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9. Pick the front surface of the form as the boundary plane, as shown in Figure 12. Pick one of the rounds that touch the bounding plane as the seed surface.
Boundary Plane Seed Surface

Figure 12: Seed and Boundary Surfaces

10. Click Preview > OK to place the form. The part should appear as shown in Figure 13.

Figure 13: Completed Form Feature

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Task 2.

Create the rectangular cut.

1. Create the rectangular cut shown in Figure 14. Locate the cut from the same end and side surfaces used to locate the form feature.

Figure 14: Section for Cut

Task 3. Create the knock-outs on the side of the box as a pattern of form features. 1. Click Feature > Create > Form > Die > Reference > Done . 2. Select KNOCK_OUT_FORM.PRT as the reference part. 3. Place the form on the cover by using the assembly constraints as shown in Figure 15 and Figure 16.

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Mate this surface to the side surface of the cover

Mate Offset DTM3, yellow side, 2.00 from the back side of cover

Mate Offset DTM1, yellow side, -1.25 from the top of cover

Figure 15: Form Assembly References


Back Side Top Surface

Side Surface

Figure 16: Form Placement Preview

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4. Pick the bounding plane and the seed surface as shown in Figure 17. 5. Select the optional Exclude Surf element in the FORM dialog box and click Define . 6. Pick the six surfaces shown in Figure 17 to remove from the form feature.

Boundary Surface Exclude Surfaces

Exclude Surfaces

Seed Surface

Figure 17: Boundary, Seed, and Exclude Surfaces

7. Click Ok . The part should appear as shown in Figure 18.

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Figure 18: Completed Form Feature

8. Click Pattern and pick the form feature. 9. Pick the 2.00 dimension as the dimension to increment in the first direction. 10. Type an increment value of [2.50]. 11. Click Done and type [4] as the total number of instances. 12. Click Done when asked for the second direction. The part should appear as shown in Figure 19.

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Keep this surface fixed during the unbend

Figure 19: Patterned Form Features

Task 4.

Unbend the geometry.

1. Create an unbend feature with the surface shown in Figure 19 remaining fixed. As shown in Figure 20, the form geometry is not flattened.

Figure 20: Unbent Geometry

2. Click Create > Flatten Form .

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3. Select the optional Form element in the dialog box and click Define . 4. Pick the recess created with the FORM1.PRT part. 5. Click Done Sel > Done Refs . 6. Click Ok . The form feature is flattened. 7. Use the same method to flatten the first knock-out (the pattern leader). 8. Create a reference pattern to flatten the remaining knock-outs. The part should appear as shown in Figure 21.

Figure 21: Flattened Forms

9. Save the part and erase it from memory.

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EXERCISE 2: Placing a Die Form

Figure 22: Ventilation Louvers

Task 1. Add the form model as a reference die form, pattern the form, and mirror the part. 1. Open BOX.PRT. If you did not complete the secondary wall exercise for the box, open FORM_BOX.PRT. 2. Add the FORM_LOUVER.PRT form model as a Die by Reference. Locate the form as shown in Figure 23. Exclude the surface to create a vent opening.

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Seed surface

Boundary plane

Align offset DTM1, yellow side from this surface of the box by 1.0 Mate these surfaces

Excluded surface Align offset the yellow side of DTM2 from this hidden surface of the box by 2.5

Figure 23: Form References

3. Pattern the form to match the dimensioning scheme shown in Figure 24.

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Figure 24: Patterning the Form

4. Use Mirror Geom to mirror the part. The part should appear as shown in Figure 25.

Figure 25: Mirroring the Part

5. Save the part and erase it from memory.


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MODULE SUMMARY
In this module, you have learned: You use a reference model to create a form feature. A form model can be a solid part or a sheetmetal part. You can represent rips or the shearing of the material by excluding surfaces from the form when you place it on the sheetmetal model. The Flatten Form option is used to flatten form geometry in the sheetmetal model.

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Module

Bend Features
In this module, you learn how to develop a sheetmetal model from the flat definition and then add bends and other geometry to reflect the true manufacturing process.

Objectives
After completing this module, you will be able to: Create Angle or Roll type bends on flat geometry Add bend line adjustment to obtain the desired location of the bend feature

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BEND FEATURES
A bend feature is used to add a bend to a flat section of the part. A bend cannot be added where it crosses another bend feature. There are two types of bend options.

Angle
An Angle type bend creates a bend with a specified radius and angle, as shown in Figure 1. An angle appears along the axis of the radius to show bend direction. The angle can be flipped to change the direction of bending.

Figure 1: Bend Feature Using the Angle Option

Roll
A Roll type bend creates a bend with a specified radius, but the resulting angle will be determined by the radius and the amount of material to bend, as shown in Figure 2.

Fixed Side Bend Side

Figure 2: Bend Feature Using the Roll Option

For each Angle or Roll bend there are three options to choose from: Regular , W/Transit , and Planar .

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Regular
A regular bend creates a bend with no transitional surfaces.

W/Transit (With Transition)


A bend with a transition deforms the surface between the bend and an area that is to remain flat, as shown in Figure 3.
Bend line Transition lines

Surfaces remain fixed

Figure 3: Bend with Transition

Planar Bends
A planar bend creates a bend feature around an axis that is perpendicular to the green surface and sketching plane, as shown in Figure 4. The neutral point for planar bends is placed according to the current y-factor and bend tables will not be applicable.

Axis normal to surface

Figure 4: Planar Bend

You can specify automatic bend reliefs to be created for a bend feature. If w/Relief is selected, then after the bend entity is sketched you will be prompted for each end in turn if you want it to be used for generating the bend relief.

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It is possible to create a bend or unbend feature over a form feature, as shown in Figure 5.

Figure 5: Bend over a Form Feature

BEND LINES
The bend line is used by the system as a reference point for developed length calculation when creating bend geometry. The location of the resulting wall depends on which side of the bend line you create the bend as shown in Figure 6, Figure 7, and Figure 8.

Bend Side and Fixed Portion

Figure 6: Bend Side Down

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Bend Side

Fixed Portion

Figure 7: Bend Side Up

Bend Side (Both)

Fixed Portion

Figure 8: Both Sides

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Bend Line Adjustment


It is possible to control the location or placement of a bend feature by adding bend line adjustment (BLA). The sketch of the bend line is dimensioned to a reference and this dimension is the BLA. The BLA dimension is modified to manipulate the placement of the bend. For the two surfaces in Figure 9 to be coplanar, the developed length of the bend (L) would have to be equal to the inside radius (R) plus the thickness (T). Since the system gives both the radius of the bend and developed length of the bend, a relation can be written to drive the BLA so that any change to the model will always be reflected in the bend line placement, as shown in Figure 10. For more information on relations, see Relations in PTC Help.

These surfaces are not coplanar

BS

FS

L = developed length of bend R = inside bend radius T = material thickness

Figure 9: BLA of 0

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BLA = L - (R + T)
These surfaces are coplanar

BS

FS

Figure 10: Relationship for BLA

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LABORATORY PRACTICAL
Goal
The goal of this lab is to create a model in Sheetmetal mode entirely with flat walls and bends.

Method
In this exercise, you create a part by creating flat walls and then bending the geometry into shape using a combination of Angle and Roll bends.

EXERCISE 1: Creating a Model in the Flat

Figure 11: Final Geometry

Task 1. Create a new sheetmetal part called CLIP with a flat wall as the base feature. 1. Create a new sheetmetal part called CLIP. 2. Create a flat wall as the first sheetmetal feature. In Sketcher, change the number of dimension decimal places to [3] (click Utilities > Sketcher Preferences > Parameters ). Sketch the

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section as shown in Figure 12, type a thickness of [0.01], and complete the feature.

Figure 12: Sectioning the First Base Feature

Task 2. Create a roll bend with transition areas where the clip attaches to the pencil. 1. Click Feature > Create > Sheet Metal > Bend > Roll > w/
Transition > Part Bend Tbl > Done/Return > Inside Rad > Done/Return .

2. Pick the green side of the part, click Okay for the viewing direction, and pick the lower edge of the T to face the bottom. 3. Sketch the single vertical bend line as shown in Figure 13.

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Figure 13: Sketching the Bend Line for the Roll

4. When the system prompts you to indicate the side on which to create the feature, click Both to center the roll bend on the sketched line, then click Okay to fix the area. 5. The system grays out the previous sketch, waiting for you to sketch the transition areas. The first line that you sketch for a transition area dictates the side that should remain bent. Sketch two horizontal lines as shown in Figure 14.

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Figure 14: Sketching Transitional Areas

6. When the system prompts you to define another transition area, type [no]. 7. Click Enter Value and type [0.16] as the bend radius to complete the feature. The part should appear as shown in Figure 15. Note that the bend starts its transition at the first sketched line and is completely flat at the second.

Pick this edge to remain fixed while unbending

Figure 15: Roll Bend with Transition

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Task 3. Create an Unbend All feature, add two additional walls without a radius, and bend back the geometry. 1. Create a regular unbend feature to unbend all geometry. Pick the edge indicated in Figure 15 to remain fixed. Note that the bend axis is now visible. 2. Create a flat wall attached to the lower edge (white or green). Sketch the wall shown in Figure 16 with a centerline aligned to the axis of the bend to make the sketch symmetric.

Figure 16: Sectioning the Additional Wall

3. Create another flat wall in the same fashion, as shown in Figure 17.

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Figure 17: Second Additional Wall Section

4. Create a bend back feature to bend back all of the geometry. Pick the same edge that you used earlier to remain fixed. The part should appear as shown in Figure 18.

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Figure 18: Clip after Creating the Two Additional Flat Walls

Task 4. Create a series of angular bends on the lower portion of the clip to fold up the various walls. 1. Click Feature > Create > Sheet Metal > Bend > Angle, Regular > Part Bend Tbl > Done/Return > Outside Rad > Done/Return . 2. Pick the green side of the wall that you just created as the sketching plane. 3. Accept the default viewing direction and pick the lowest horizontal line as the bottom reference. 4. Sketch the horizontal bend line as shown in Figure 19.

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Side to fix Sketch this line

Align to vertices

Side to create bend feature

Figure 19: Creating a 90-Degree Bend

5. Create the bend feature below the sketched line, and fix the larger portion of the clip. You do not need to add any relief for this bend feature. 6. Rotate the model to clearly view the bend angle of 90 degrees, and click Flip , if necessary. 7. Type [0.012] as the bend radius.

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Tip:
The most effective way to work with bend angles is to choose a direction, preview the bend, and then flip, if necessary.

8. Create a vertical bend using the Outside Rad option as before. Sketch the vertical bend line shown in Figure 20.

Sketch this line Bend side

Fixed side Align to edges, not to vertices

Figure 20: Creating Second and Third 90-Degree Bends

9. Create the bend on the left-hand side of the line toward the outside of the model. No relief is required. 10. Type [90] as the bend angle. 11. Type [0.012] as the bend radius.
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12. Create the second vertical bend on the other side of the clip. The part should appear as shown in Figure 21.

Top reference plane

Sketching plane (green side)

Figure 21: Specifying the Sketching Plane and Top Reference Plane

13. Create a 90 angular bend using the sketching and reference plane indicated in Figure 21. Sketch the section shown in Figure 22. Create the bend with no relief and a [0.012] bend radius.

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Bend side

Fixed side

Figure 22: Creating the Next 90-Degree Bend

14. Create the final bend using the approach that you used to create the two previous bends (Figure 23).

Bend side

Sketch this line

Fixed side

Figure 23: Creating the Last Bend


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Task 5.

Create solid rounds on the sharp corners.

1. Click Feature > Create > Solid > Round > Simple > Done . Pick the six edges indicated in Figure 24. Type [0.012] as the radius.

Pick these edges to create the round

Figure 24: Specifying the Edges for the Round

2. Save the file and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: An angle type bend creates a bend with a specified radius and angle. A roll type bend creates a bend with a specified radius, but the resulting angle will be determined by the radius and the amount of material to bend. A regular bend creates a bend with no translational surfaces. A bend with transition deforms the surface between the bend and an area that is to remain flat. Planar bends create a bend feature around an axis that is perpendicular to the green surface and sketching plane. You can specify automatic relief for a bend feature. You can control the location or placement of a bend feature by adding bend line adjustment.

Bend Featu r es

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Module

Unbending Sheetmetal Geometry


It is often necessary to unbend deformed surfaces, such as wall features consisting of complex curved surfaces. In order for the system to unbend deformed material, the unbend must be reduced to a simple unbend. The defining rule is that all surfaces to be unbent must either have an outside edge or be adjacent to a deformed area that has an outside edge.

Objectives
After completing this module, you will be able to: Unbend ruled geometry Unbend nonruled geometry Add tears to geometry Create deformation areas

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UNBENDING GEOMETRY AFTER DEFINING THE MODEL


Depending on the complexity of the sheetmetal or the design task, you can use various techniques to unbend the geometry: Create a regular unbend feature to unbend ruled geometry Use a cross section driven unbend feature to unbend nonruled geometry Create tears in geometry by ripping

Unbending Ruled Geometry: the Regular Unbend


You can unbend ruled bends in the sheetmetal model using the regular unbend feature. Although you can unbend both a wall and a bend, the material must be unbendable or developable. You cannot unbend nonruled surfaces using a regular unbend feature.

Unbending Nonruled Geometry: the Cross Section Driven Unbend


To unbend nonruled sheetmetal geometry, you can create the cross section driven unbend feature, as shown in Figure 1. The cross section term refers to the curve that you use to influence the shape of the unbent wall. To create a cross section driven unbend, you must do the following: 1. Select the cross section curve from existing geometry or sketch it (it must be in the same plane as the fixed geometry). 2. Specify the geometry that should remain fixed in the model during the unbend. The side that you fix must be planar. 3. Define the edges that should remain fixed since you cannot always use the same edges to drive the shape of the cross section.

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NOTES

Selected curve

Sketched section

Figure 1: Cross Section Driven Unbend Feature

Note:
The system does not determine a developed length for a cross sectional unbend.

Adding Tears to the Geometry: Ripping


Using the following methods, you can unbend sheetmetal geometry by tearing it: - Cut the geometry by creating a sketched section to use as the rip line, as shown in Figure 2.
Regular Rip

- Select existing edges to define references for a zero volume cut, as shown in Figure 3.
Edge Rip

- Select a surface patch on the geometry and exclude the entire surface from the model by creating a cut in the geometry, as shown in Figure 4.
Surface Rip

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Sketch

Rip created

Figure 2: Regular Rip

Figure 3: Edge Rip

Unbend ing Sh eetmet al Geom et ry

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Corner removed using a surface rip

Edge rip added along this edge

Figure 4: Surface Rip

DEFORMATION AREAS
When creating a regular unbend feature, Pro/ENGINEER highlights geometry that it is going to deform as a result of the operation. If the deformed surface does not extend to the edges of the model, you must specify a surface to deform so that it does extend to its boundaries, as shown in Figure 5.

Pick this surface

Figure 5: Selecting an Area to Deform

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If an appropriate surface does not exist on the model, you can break up a surface into multiple patches by creating a deformation area, then specify this area as the area to deform during the unbend operation. This gives you the advantage of creating geometry that closely reflects the developed part, as shown in Figure 6.

Developed length calculated Deformation only in these areas

Figure 6: Deformation Areas

The developed lengths of the unbent geometry reflect the proper values. Pro/ENGINEER approximates the geometry in the deformation area by attaching the vertices with a line segment. The geometry does not become thinner or thicker. Pro/ENGINEER also enables you to sketch the deformed geometry since the flat pattern is typically determined empirically. The part shown in Figure 7 has a deform area defined and the default flat pattern is shown on the right-hand side.

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Figure 7: Flat State with Automatic Deform Control

By redefining the Deform Control element in the FEATURE dialog box, you can sketch the deform area's shape using the current sketcher constraints. In Figure 8, a tangent arc has been sketched to change the deformed geometry.

Figure 8: Flat State with Manual Deform Control

In addition to using the deform area feature to create a deformation area during unbending, you can also use it to define edges for edge rips or to split surfaces for bend line development.

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LABORATORY PRACTICAL
Goal
The goal of this lab is to teach you how to unbend both ruled and nonruled geometry.

Method
In the first exercise, the geometry contains some walls with curvature in two directions; you cannot automatically unbend it using the Regular Unbend option. You deform some surfaces to unbend this part and then extend the deformation to the outside of the model. In the second exercise the cross section driven unbend feature is used to unbend the part. In the third exercise, you create a deformation area feature to isolate all deformation.

EXERCISE 1: Creating a Regular Unbend Feature


Task 1. Open the TRANS sheetmetal part and create an Unbend All feature by selecting deformation areas. 1. Open TRANS.PRT. 2. Click Feature > Create > Unbend > Regular > Done . 3. Pick the surface indicated in Figure 9 to remain fixed during the unbend and click Unbend All > Done .
Surface to remain fixed (can be the white or green side)

Figure 9: Specifying Surface to Remain Fixed

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4. Pro/ENGINEER highlights two of the curved surfaces on the model and warns you that some deformation surfaces do not reach outside the part. Select the surfaces to deform as shown in Figure 10.

Pick the white or green surface

Figure 10: Specifying Additional Surfaces to Deform

5. Click Done Sel > Done Refs . 6. Click OK in the dialog box. The unbent part should appear as shown in Figure 11.

Figure 11: Finished Model

7. Save the file and erase it from memory.

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EXERCISE 2: Cross Sectional Unbend

Figure 12: Cross Sectional Unbend

Task 1.

Open XSEC.PRT and unbend the left-hand side of the part.

1. Open XSEC.PRT. 2. Click Feature > Create > Unbend > Xsec Driven > Done . 3. You are prompted to select the fixed edges. Click Surf Chain in the CHAIN menu and pick the surface shown in Figure 13. 4. Click From-To and pick the highlighted vertices shown in Figure 13. When the system prompts for a chain to use, make sure it is the three edges shown in Figure 13 by clicking Next or Accept .

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NOTES Surface for chain

Pick these two vertices

These edges make the desired chain

Figure 13: References for First Unbend

5. Click Done when the chain has been selected. 6. You are asked to specify a curve to control the cross sections. Click Select Curve > Done . 7. Select the same curves as you did in the previous steps. 8. Once the curves have been selected, click Done . 9. Keep the inside area fixed (right side of curve) and click OK in the dialog box. The part should appear as shown in Figure 14.

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Figure 14: First Unbend

Task 2. unbend.

Unbend the right-hand side of the part with a cross section

1. Create another Xsec Driven unbend feature. When prompted to select fixed edges, click One by One in the CHAIN TYPE menu. Pick the edge shown in Figure 15 and click Done .

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Pick this edge for the second unbend

Pick this surface as the sketching plane

Figure 15: References for Second Unbend

2. Click Sketch Curve and sketch the control curve as shown in Figure 16. Use the surface shown in Figure 15 as the sketching plane and DTM3 as the Bottom reference.

Sketch line referencing vertices

Fixed Side

Figure 16: Section for Cross Section Unbend

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3. Select the side shown in Figure 16 to keep fixed, then click OK to complete the unbend. The finished part should appear as shown in Figure 17.

Figure 17: Completed Part

4. Save the part and erase it from memory.

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EXERCISE 3: Creating a Deformation Area

Figure 18: Final Geometry

Task 1. Open DEFORM_AREA.PRT and create an Unbend All feature by selecting deformation areas. 1. Open DEFORM_AREA.PRT. 2. Create a Regular Unbend All feature. Pick the surface indicated in Figure 19 to remain fixed during the unbend.

Pick this surface to remain fixed

Figure 19: Specifying Surface to Remain Fixed

3. Pro/ENGINEER highlights the deformed surfaces inside the model. Pick the surfaces indicated in Figure 20 to deform when unbending.

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Pick these surfaces to deform

Figure 20: Specifying Surface to Deform

4. Click Done Sel > Done Refs . 5. Click OK in the dialog box. The unbent part should appear as shown in Figure 21. Note the undesirable distortion that occurs where the system forces the two rounded surfaces that you selected to fan out during the unbending process.

Distorted surfaces

Figure 21: Distorted Surfaces Resulting from Automatic Selection 6. Delete this undesirable unbend feature.
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NOTES

Task 2. Create deformation areas; then use one of the deformation areas to create an Unbend All feature. 1. Click Feature > Create > Deform Area . 2. Pick the side surface for a sketching plane and DTM1 to face the right side of the screen. 3. Sketch the deformation area shown in Figure 22. Create entities from existing geometry as indicated.

Entities from edges Sketching plane

Figure 22: Deformation Area Sketch

4. Complete the deform area feature. A second identical deform area feature has already been created on the opposite side of the model for you. 5. Create a Regular Unbend All feature. Specify the same surface to remain fixed as indicated in Figure 23. 6. Select the deformation areas as the additional surfaces to deform. After completing the unbend, note that the system isolated the large deformation in the deformation areas, which it was forced to stretch considerably, as shown in Figure 24.

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NOTES

Fixed surface

Deform area (same on other side)

Figure 23: Specifying the Deformation Area

Figure 24: Unbent Geometry with Deformation Areas

7. Save the part and erase it from memory.

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NOTES

MODULE SUMMARY
In this module, you have learned: A regular unbend feature can be used to unbend ruled geometry. A cross section driven bend can be used to unbend non-ruled geometry. Rip features can be created to enable sheetmetal geometry to be unbent. When creating a regular unbend feature, Pro/ENGINEER highlights geometry that it is going to deform as a result of the operation. If the deformed surface does not extend to the edges of the model, you must specify a surface or deformation area to deform so that it does extend to its boundaries

Unbend ing Sh eetmet al Geom et ry

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Module

Converting Solid Parts


After you have converted a solid box-type part to a sheetmetal one, you may need to convert sharp edges to bends and define rips so that the part can be flattened.

Objectives
After completing this module, you will be able to: Convert a solid part into a sheetmetal part Create a conversion feature to make the converted part developable

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NOTES

CREATING SHEETMETAL PARTS FROM SOLID PARTS


Solid Pro/ENGINEER parts that are retrieved in Sheetmetal mode can be converted to sheetmetal parts with two methods.
Driving Srf

The system prompts for a surface to use as the driving (green) surface. If the part has uniform thickness and can be offset by the material thickness, the part will be converted.

Figure 1: Using a Driving Surface


Shell

If the part does not have constant thickness, the Shell option can be used to shell the solid part and convert it at the same time.

Figure 2: Shelling a Model

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NOTES

Once converted to a sheetmetal part, all of the existing geometry is referenced to define the base wall feature. Thus this feature and any feature created in Sheetmetal mode would have to be deleted if you want to convert the part back to a solid part.

CREATING A DEVELOPABLE PART


Once the part is converted into a sheetmetal part, it may still be undevelopable. To convert the geometry so that it can be developed, a single feature can be added to the part. The Conversion feature enables multiple elements to be defined at once. These elements are as follows:
Point Reliefs

This element creates points along an edge to break the edge into multiple segments.

Figure 3: Splitting an Edge


Edge Rip

This element rips the geometry along an edge, similar to the Rip feature. The rip can then be converted from an open type edge to one in which the wall has overlap.
Rip Connect

This element rips the geometry between two points or vertices in the model.

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Edge rips added

Rip connect

Figure 4: Using Rip Connect


Bends

This element creates edge bends along non-tangent edges.

Figure 5: Edge Bend


Corner Relief

This element creates round or obround corner relief at eligible corners. As with the corner relief feature, the vertices selected or affected are highlighted with symbols that indicate the type of conversion feature or relief feature defined.
Table 1: Feature Symbols

Symbol
Ob Cir None No

Conversion Feature
Obround Circular Square corner is generated No relief is applied, the default V-notch is applied

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Corner relief created in combination with edge rip and bends

Figure 6: Circular Corner Relief

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LABORATORY PRACTICAL
Goal
The goal of this lab is to convert a solid part into a developable sheetmetal part.

Method
In the first exercise, you retrieve a solid part and use the shell method to convert it into a sheetmetal part. You also unbend the model by adding a rip feature. In the second exercise, you use the special sheetmetal conversion feature to convert a solid part into sheetmetal.

EXERCISE 1: Converting a Sheetmetal Part

Figure 7: Solid Part to Flattened Sheetmetal Part

Task 1. Open the CONVERSION sheetmetal part and convert it to sheetmetal geometry. 1. Open CONVERSION.PRT. 2. Note that this solid part contains only a protrusion and a round on three edges. Convert the part to sheetmetal by clicking Applications > Sheetmetal . 3. Click Shell and specify the removal of the three hidden surfaces indicated in Figure 8.

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Pick these three hidden surfaces to remove (two sides and bottom)

Figure 8: Specifying the Surfaces to Remove

4. Type [0.25] as the shell thickness. Notice that the system makes the part hollow and converts it to sheetmetal, with the outside of the model representing the green side of the sheetmetal. Task 2. Add an edge rip feature to one of the edges and then unbend the geometry. 1. Click Feature > Create > Rip > Edge Rip . 2. Pick two edges (white or green) as indicated in Figure 9. Complete the feature.

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Pick these edges for the rip

Figure 9: Specifying the Edges to Create the Edge Rip

3. Create a regular, unbend all feature. Specify the top surface to remain fixed. Note that some deformation of the convex triangular corner occurs as the system unbends it. Complete the feature. Note:
If your unbent wall contains a square rather than a small triangle in the corner, you selected only one edge for the rip feature. Repeat the previous step.

4. Save the part and erase it from memory.

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EXERCISE 2: Using the Sheetmetal Conversion Feature

Figure 10: Solid Part to Flattened Sheetmetal Part

Task 1.

Open the CONVERT part and convert it to sheetmetal.

1. Open CONVERT.PRT. This part was created as a solid part. It consists only of default datum planes and two rectangular protrusions. 2. Click Applications > Sheetmetal . 3. Click Shell on the SMT CONVERT menu. 4. Pick the three surfaces indicated in Figure 11 to remove with the shell and type [0.20] as a thickness.
Pick these three surfaces to remove: one on top and two hidden surfaces

Figure 11: Picking Surfaces to Remove

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Task 2. Convert the geometry to sheetmetal geometry using the conversion feature. 1. Click Feature > Create > Conversion . Note that all five elements in the dialog box are optional. 2. Click Point Reliefs > Define . 3. Click Create to create a datum point to locate the point relief. 4. Pick the edge indicated in Figure 12, click Offset , and pick the plane to locate the point.

Pick this edge

Pick this offset plane

Figure 12: Creating the Datum Point

5. Type [1.8] for the offset distance and click Done. Do not click OK . 6. Double-click Edge Rip from the dialog box, pick the three edges indicated in Figure 13, and click Done Sets . Do not click OK .

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NOTES

Pick these three edges

Figure 13: Specifying Edges on Which to Create the Edge Rip

7. Double-click Rip Connect in the dialog box and click Add . 8. For the first end, pick the end of the existing rip at the datum point. The system then highlights all of the possible corners and other rip features to which you could connect the rip. Pick the bottom of the other rip, as shown in Figure 14.

Pick this point for second end

Pick this point for first end

Figure 14: Creating the Rip Connect

9. Click OK > Done Sets .

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10. Double-click Corner Reliefs in the dialog box and click Add . One corner of the model has a note attached to it that reads, No. This note indicates that this corner is eligible for corner relief but currently has none. 11. Pick the note and click Redefine . 12. Click Corner # 1 > Done . 13. A dialog box appears. Double-click Corner Relief . 14. Click Circular > Enter Value and type [0.5] for the diameter. 15. Click OK > Done Sets > Preview . 16. Note that the conversion feature is about to add edge bends automatically to all remaining sharp corners, using the thickness of the material as an inside radius. Instead of selecting the Bends element to manually add or remove edges, allow the system to select them all automatically. Click OK to complete the conversion feature. The part should appear as shown in Figure 15. The corner relief does not appear until the part is unbent.

Figure 15: Final Geometry after Using the Conversion Feature

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Task 3.

With the conversion feature in place, unbend the part.

1. Create a regular, unbend all feature. Specify an appropriate surface to remain fixed. The finished part should appear as shown in Figure 16.

Figure 16: Final Geometry

2. Save the part and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: Solid Pro/ENGINEER parts that are retrieved in Sheetmetal mode can be converted to sheetmetal part. To convert the geometry so that it can be developed, a Conversion feature can be added to the part. The Conversion feature enables multiple elements to be defined at once, including Point Reliefs, Edge Rips, Rip Connects, Bends, and Corner Reliefs.

Conv erting So lid P a rt s

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Module

Sheetmetal Drawings with Flat States and Bend Order Tables


When documenting a sheetmetal part, you may want to show in one drawing the part as it appears when first cut out of the sheetmetal (flat pattern) and, in another drawing, as it appears when assembled (design condition).

Objectives
After completing this module, you will be able to: Create a production drawing of a sheetmetal component Document the bend order of a sheetmetal part

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FLAT STATES
In order to simplify and streamline the creation of Flat Pattern Representations for manufacturing, the FLAT STATE menu (called FLAT STAT) is provided. It is accessed through the SHEET METAL SETUP menu. It can be used to create instances directly, without having to edit the parts family table. The family table offers a very efficient method for quickly and easily developing variations of your sheetmetal design. You can generate variations of the original model by reusing the existing data. In a family table, the variations are referred to as instances and the original model is known as the generic model. Using this method, you can increase your productivity by accomplishing the following: Store multiple similar models within the same file Save different steps of the manufacturing of a model Save a developed flat instance inside a formed generic model

The instances created with the Flat State option are initially completely unbent. Features created in Flat State instances behave just like those created in regular family table members. For more information on family tables, see Family Tables in PTC Help. You can create the first flat state instance from a generic that is either fully formed or fully flat. If the generic is (fully) formed, the UNBEND FEATURE dialog box appears and prompts you for the unbends necessary to make it fully flat. After you click Done , the system creates the instance. The family table for the generic now contains a new column listing that new unbend. The unbend is suppressed for the generic and enabled for the instances. If the generic is already flattened (fully flat), the system prompts you to select the unbends that you created to make it that way. It creates the first flat state instance and bends back the generic (by suppressing the unbend). The Family Table for the generic now contains a new column listing that unbend. The unbend is suppressed for the generic and enabled for the instances.

Retrieving Instances
Once the family table resulting from the flat state is created, you can retrieve the flat state instance using one of the following three methods:
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Highlight the instance name in the FAMILY TABLE dialog box and click Open . Open the generic model to obtain a list of its instances. You can retrieve either the generic model or a specific instance. When retrieving an instance, you can select the instance by its name or by a specific parameter. Retrieve the instance directly if an instance index file is present.

CREATING MULTI-MODEL DRAWINGS


Once you have defined a flat state, you can use both instances of the model in a production drawing. By creating a multi-model drawing, you can add details, drawing annotations, and dimensions for both states, as well as independently scale views of the instances. For more information on multi-model drawings, see MultiModel Drawings in PTC Help.

Note:
When you add a model to a drawing, Pro/ENGINEER only associates that model. Once you have associated both instances of the sheetmetal model to the drawing, you can change the active model using the Set Model option in the DWG MODELS menu.

Tweaking the Flat Pattern


The flat pattern that the system generates when you create an unbend feature may not represent the exact outline of the model because deformation areas may exist in the model geometry. From your knowledge of sheet geometry, you can add material to the flat pattern by using the Deform Control element discussed earlier.

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Figure 1: Using Deform Control to Tweak the Flat Geometry

DOCUMENTING THE BEND ORDER


To document the bend order for manufacturing, you can use a bend order table, as shown in Figure 2. With the model completely unbent, you can select the bend or groups of bends in sequence; then save the bend order table to a file named PARTNAME.BOT. You can show it on a production drawing by creating a note and reading it in the .bot file. If you change the table in Sheetmetal mode, the note on the drawing automatically updates; however, you must add any new bends to the table manually.

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sequence 3, bend 1 sequence 2, bend 1

sequence 1, bend 1

sequence 1, bend 2

sequence 4, bend 1 sequence 2, bend 2

Figure 2: Creating a Bend Order Table

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LABORATORY PRACTICAL
Goal
The goal of this lab is to document the manufacturing process of a sheetmetal model.

Method
In this exercise, you add a solid protrusion to a sheetmetal part and document the manufacturing process by creating a production drawing.

EXERCISE 1: Documenting the Model


Task 1. Retrieve the DOC_CONVERSION sheetmetal part and create a flat state. 1. Open DOC_CONVERSION.PRT. Select the Generic and click Open in the SELECT INSTANCE dialog box. This part contains an edge rip feature that enables it to be flattened.

Pick this surface to remain fixed

The edge rip feature is located along this edge

Figure 3: Specifying the Surface to Remain Fixed

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2. Click Set Up > Sheet Metal > Flat State > Create . 3. Accept the default name for the flat pattern instance and click Fully Formed . 4. Pick the top surface, as shown in Figure 3, to remain fixed. It highlights the corner surface in red and indicates that it will be deformed. 5. Click OK . The system automatically creates a third version of the model in the family table, which now includes the following: a fully formed version (the generic) a fully flat version (the flat state named DOC_CONVERSION_FLAT1) using edge rips a special version for the bend order table with the corner removed by a surface rip Open the flat state instance.

Task 2.

1. Close the active window. 2. Open DOC_CONVERSION.PRT. Select DOC_CONVERSION_FLAT1 and click Open in the SELECT INSTANCE dialog box. Task 3. Redefine the unbend feature to define Deform Control to better represent the flat state geometry. 1. Redefine the unbend feature. 2. Select the Deform Control element and click Define . 3. Click Auto Area # 1 . The Unbend dialog box appears. 4. Select the Deform Type element and click Define . 5. Click Manual. The system automatically places you in Sketcher so that the deform area can be sketched. 6. Sketch a single arc, as shown in Figure 4, to define the deformed area.

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Have the endpoints and centerpoint of the arc snap to these vertices

Figure 4: Sketching Protrusion to Add to the Instance

7. Exit from Sketcher and click OK > Done > OK . The unbent part should appear as shown in Figure 5.

Figure 5: Unbent with Deform Control

8. Close the active window. Task 4. Create an additional wall on the generic and check the Model Tree for the suppressed unbend feature. 1. Open the generic part and create a flat, use radius wall. Specify the part bend table and an inside radius. Pick the edge indicated in Figure 6, accept the default bend angle of 90 degrees, and click Okay to accept the default viewing direction.

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Pick this edge (green side)

Figure 6: Specifying the Edge for the Wall Feature

2. Sketch the section, as shown in Figure 7. After finishing the sketch, click No Relief > Enter Value and type [0.25] as the bend radius to complete the feature.

Figure 7: Sketching Section of the Additional Wall

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3. Close the GENERIC window and activate the fully flat state (i.e., DOC_CONVERSION_FLAT1). Notice the new wall in the flat instance. Regenerate if necessary. 4. Close the window. Task 5. Create a bend order table for the DOC_BND_ORD_TBL instance. 1. Open DOC_CONVERSION.PRT. Select DOC_BND_ORD_TBL and click Open in the SELECT INSTANCE dialog box. Since the bend order table cannot unbend any geometry that has to be deformed, this instance contains a surface rip that removes the convex corner from the model.

Specify this surface to remain fixed

Figure 8: Specifying the Top Surface to Remain Flat

2. Click Set Up > Sheet Metal > Bend Order > Show/Edit and pick the top flat surface of the part. The part should now appear fully unbent, as shown in Figure 9.

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3. Pick the first two bends as indicated in Figure 9. These will be included in the first bend sequence.

Pick these two bends

Figure 9: Specifying Bends for Bend Order Table

4. Click Done Sel > Next and specify the top surface that you picked previously to remain fixed. The system bends back the two selected bends and displays the model, as shown in Figure 10. 5. Pick the bend indicated in Figure 10 for the second sequence, click Done Sel > Next , and specify the same top surface to remain fixed.

Pick this bend

Figure 10: Specifying Bend for Second Sequence

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6. The model should now have the bend in the second bend sequence bent back, as shown in Figure 11. Pick the last bend, click Done Sel > Done , and specify the same surface to remain fixed. The system should now inform you that the bending sequence is successful.

Pick this bend

Figure 11: Specifying Bend for Third Sequence

7. Click Info to view the bend order table; then close the INFORMATION window. Note:
The out and in references in the bend order table refer to the GREEN side of the sheetmetal. Since it is a text file, you can modify text in the .bot file at any time.

8. To create a drawing with the bend order table that includes the notes to the appropriate bend, create a regular unbend all feature in the DOC_BND_ORD_TBL instance. Pick the same top surface to remain fixed. 9. Close the window.

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Task 6. Create a two-sheet multi-model drawing to document the flat state and bend order table that you just created. 1. Before proceeding, close all working windows. 2. Create a new drawing called DOC_CONV. Remove the check mark from the Use default template option at the bottom of the NEW dialog box. 3. Click Browse to select DOC_CONVERSION.PRT as the default model. Accept all other defaults and click OK . 4. Select the Generic and click Open in the SELECT INSTANCE dialog box. 5. Create a general view of the generic model by clicking Views > Add View > General > Full View > No Xsec > Scale > Done . 6. Pick a point in the right upper corner of the drawing to place the view. 7. Type [0.3] as the scale and leave the view in the default orientation by clicking OK . 8. Add the flat state instance to the drawing by clicking Dwg Models
> Add Model > DOC_CONVERSION.PRT > Open > DOC_CONVERSION_FLAT1.PRT > Open .

9. Click Add View > General > Full View > No Xsec > Scale > Done . 10. Pick a point in the lower left-hand corner. 11. Type [0.3] as the scale. 12. Orient the view by specifying the green surface as the Front reference and the top edge of the model as the Top reference. Click OK . Move the view if necessary to locate it as shown in Figure 12. 13. Click Done/Return > Show/Erase . 14. Click Show > . Click Show All in the Show By section. Click Yes to confirm the Show All. Click Accept All in the Preview tab. 15. Close the dialog box.

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16. Click Create > Dimension . Create the dimensions shown in Figure 12.

Figure 12: First Sheet of Drawing

17. Create a second sheet to display the bend order table by clicking Done/Return > Sheets > Add > Done/Return . 18. Click Views > Dwg Models > Add Model . 19. Click DOC_CONVERSION.PRT > Open> DOC_BND_ORD_TBL > Open . 20. Click Add View > General> Full View> No Xsec > Scale > Done . 21. Pick a point in the middle of the screen. 22. Type [0.3] as the scale. 23. Pick the green side as the Front reference and the top edge as the Top reference and click OK . If necessary, move the view to locate it as shown in Figure 13.

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24. Click Done/Return > Show/Erase > Show > > > Show All > Yes >Accept All > Close to show the bend order table on the drawing. 25. Close the dialog box. The second sheet should appear as shown in Figure 13.

Figure 13: Second Sheet of Drawing

26. Save the drawing and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: You can create a flat state instance of a sheetmetal part for use in documenting the design for manufacturing. You can create the flat state instance from a generic sheetmetal part that is either fully formed or fully flat. Once you have defined a flat state, you can use both instances of the model in a production drawing. From your knowledge of sheet geometry, you can tweak the flat pattern by creating a flat wall or solid protrusion in the model. To document the bend order for manufacturing, you can use a bend order table.

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Module

Additional Features
When creating a part in Sheetmetal mode, there are a number of additional features and techniques that can be used to aid in the design.

Objectives
After completing this module, you will be able to: Use a flat pattern to get started on drawings and manufacturing Use projected datum curves as a guide for creating sheetmetal cuts

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FLAT PATTERN
A Flat Pattern is equivalent to an Unbend All feature, but is always positioned last in the regeneration cycle. You can create a Flat Pattern feature early in the design to get started on drawings and manufacturing. If new features are later added to the part, they are automatically reordered before the Flat Pattern feature. After the Flat Pattern is created, the part is always displayed in the flattened state; however, once you start creating a new feature, the Flat Pattern is temporarily suppressed, and then automatically resumed and reordered when the new feature is completed. If you do not want the part to be constantly flipping back and forth, you can suppress the Flat Pattern feature and resume it only when you want to see or use the flat pattern of the part.

SOLID FEATURES
Some solid features are available for use in sheetmetal parts. They can be added in Sheetmetal mode, as well as in Part and Assembly modes. Holes, rounds, chamfers, cuts, and protrusions are available. All features can be placed on white surfaces and edges as well as green surfaces and edges.

EDGE TREATMENTS
You can create solid features, such as round and chamfers, to denote multiple types of sheetmetal geometry (for example, a radius in the corner of a cut). You can also use them to show edge treatments in order to make the sheetmetal a nonconstant wall thickness, as shown in Figure 1.

Figure 1: Edge Treatments

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Determining the Developed Length


If you apply an edge treatment to the edge of a sheetmetal model using a forming operation such as rolling, you must adjust the developed length of that model. Using the optional Edge Treatment element of the Flatten Form option, you can adjust the length based on the volume of material that you remove.
Chamfer

Model shortened to keep same volume

Figure 2: Determining the Developed Length

Using Projected Datum Curves


When you develop geometry in the formed state of the model, you can use the projected datum curve to communicate information from the formed state to the flat state. The system projects a datum curve onto the surface of a sheetmetal part from a defined sketch or a selected curve. You can place the curve by following a surface when the model is bent or unbent, or by following a surface during a bend back operation if the curve is projected in the unbent state.
Follow Surface

Using the Follow Surf option, you can specify that the curve follows the surfaces of the sheetmetal model when you bend or unbend the model (Figure 3). This enables you to create the curve in the bent state, then unbend the model to use the curve as a reference for another feature such as a sheetmetal cut.

Figure 3: Placing a Curve Using the Follow Surface option

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Using the Regular option, you can have the curve follow a surface during a bend back operation if the curve is projected in the unbent state (Figure 4). This can be helpful if you need to communicate information, such as a curve length, between the bent and unbent state of the model. However, the curve does not unbend if you project it in the bent state.
Regular

Figure 4: Placing a Curve Using the Regular Option

For more information on projected datum curves, see Working with Datum Curves in PTC Help.

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LABORATORY PRACTICAL
Goal
The goal of this lab is to create a single cut in the flat state that results in the desired formed geometry.

Method
In this exercise, you use a projected datum curve as a guide as you create a cut in the flat.

EXERCISE 1: Using a Projected Datum Curve to Create a Cut

Figure 5: Cut Created Using a Projected Datum Curve

Task 1.

Open PROJ_CURVE.PRT and create a projected datum curve.

1. Open PROJ_CURVE.PRT. 2. Click to create a datum curve.

3. Click Projected > Done > Follow Surf > Sketch > Done . 4. Pick the surface indicated in Figure 6 as the sketching plane. Click Okay for the direction of viewing the sketching plane and Flip > Okay for the direction of feature creation. 5. Pick the FRONT datum plane to face bottom.

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Sketching plane

Figure 6: Sketching Plane for Projected Datum Curve

6. Sketch the section shown in Figure 7.

Figure 7: Sketch for Projected Datum Curve

7. When finished in Sketcher, reorient to the default view and pick the surfaces indicated in Figure 8 on which to project the datum curve.

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NOTES Pick these five surfaces

Figure 8: Surfaces on which to Project Datum Curve

8. Click Done Sel > Done . 9. Click Norm to Sket > Done . Click OK . The datum curve should appear as shown in Figure 9.
Projected datum curve

Figure 9: Projected Datum Curve

Task 2. Unbend the entire part and create a sheetmetal cut using the projected datum curve as a guide. 1. Create an unbend feature to flatten the entire part. Pick the top surface of the part to remain fixed. The unbent part should appear as shown in Figure 10.

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NOTES This surface should remain fixed

Figure 10: Unbent Part

2. Create a sheetmetal cut using the surface you picked to remain fixed as the sketching plane. Pick the FRONT datum plane to face bottom. Sketch the section shown in Figure 11. Create entities from the projected datum curve.

Figure 11: Sketch for Sheetmetal Cut

3. Create the cut Thru All . The completed cut is shown in Figure 12.

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Figure 12: Sheetmetal Cut

4. Create a dependent, mirrored copy of the cut about the RIGHT datum plane. The part should appear as shown in Figure 13.

Figure 13: Mirrored Cut

5. Create a bend back feature to return to the fully formed part. The final part should appear as shown in Figure 14.

Figure 14: Fully Formed Part with Cut

6. Save the part and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: A Flat Pattern is equivalent to an Unbend All feature, but is always positioned last in the regeneration cycle. You can create solid features to denote multiple types of sheetmetal geometry. If you apply an edge treatment to the edge of a sheetmetal model using a forming operation such as rolling, you can adjust the length based on the volume of material that you remove using the optional Edge Treatment element of the Flatten Form option. When you develop geometry in the formed state of the model, you can use the projected datum curve to communicate information from the formed state to the flat state.

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Module

Setting Up for Design


In this module, you learn how to set up your Pro/ENGINEER session in preparation for sheetmetal modeling to ensure that you effectively capture your design intent.

Objectives
After completing this module, you will be able to: Calculate the developed length of a sheetmetal model Specify a default radius for bends Specify default fixed geometry

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CALCULATING DEVELOPED LENGTH


When you unbend a sheetmetal model, the developed length that Pro/ENGINEER calculates may not be appropriate for your particular manufacturing process. You can override the bend calculation by simply modifying the bend. If you change the dimension of the developed length manually to override the system calculation, you can reset it at any time in the design cycle. Many factors determine if Pro/ENGINEER calculates the proper developed length for a sheetmetal model. You should make it a practice to determine in advance how the system calculates the developed length and the adjustments that you can make, if necessary.

Using the Default Formula


Pro/ENGINEER uses a standard bend formula to calculate the developed length of a sheetmetal model. If you currently use this formula to calculate the developed length of bends, you should not need to make any further adjustments: L = (/2 x R + yfactor x T) /90 where: L = developed length R = inside radius T = material thickness = bend angle

The y-factor
The developed length calculation includes a parameter called the y-factor, which is a ratio based on the neutral bend line with respect to the thickness of the material, as illustrated in Figure 1. The y-factors default value is .50, but you can change it in each part by modifying the sheetmetal setup. You can also specify a new default value by setting the configuration file option INITIAL_BEND_Y_FACTOR; however, the setting only affects new parts.

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A. Before the Bend B. After the Bend 1. Neutral bend line

y factor = ( / 2) * K factor K factor = / T

Figure 1: The y-factor

Using Bend Tables


Instead of using the default formula to calculate the developed length of a sheetmetal model, you can use a bend table. Bend tables consist of tabulated data, as shown in Figure 2, with the radii in columns across the top and varying thicknesses in rows. The body of the table documents the various developed lengths. If the radius and thickness exactly match the values in the table, the system uses the exact value. If a value falls between two table values, it is interpolated. If a value is outside the table, it uses the tables formula, if it has one. If it does not have a table formula, it uses the default formula and the y-factor.

Figure 2: Radius and Thickness Entries

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Tip:
To be sure that the bend table uses the same material type that you have specified in the SETUP menu, you can assign materials within the bend table to check the material properties of the sheetmetal model.

Predefined Bend Tables


The three bend tables listed below are available with Pro/ENGINEER. You can use them without changing them, or use them as a starting point to develop your own company standard table.
TABLE1 Used for Soft Brass and Copper, as shown in Figure 3 TABLE2 Hard Brass, Copper, Soft Steel, and Aluminum TABLE3 Hard Copper, Bronze, Cold Rolled Steel, and Spring Steel

Figure 3: Standard Bend Table

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Figure 4 shows an example of a customized bend table.

Figure 4: Customized Table

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SETTING UP A DEFAULT RADIUS


To reduce the number of selections that you must make and also develop standards for your sheetmetal models, you can use the parameter SMT_DEF_BEND_RAD to define a default radius. When you add this parameter to your model, the system makes the Default option available. If you choose this option when adding bends or using radius walls, the system automatically adds a relation to drive the dimension.

Notes:
If you sketch a bend in Sketcher, you cannot make the dimension equal to the default radius parameter. You must manually write a relationship to drive the bend with the default parameter. If the value of the default radius is changed, all of the radii that you set using the Default option and any relations that you wrote using the parameter automatically update.

SETTING DEFAULT FIXED GEOMETRY


When unbending and bending back sheetmetal geometry, it is always good practice to specify the same surface or edge to remain fixed. You can use the SETUP menu option Fixed Geom to automatically specify the same reference when creating unbend and bend back features.

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LABORATORY PRACTICAL
Goal
The goal of this exercise is to use set up options to control the default bend radius, default fixed geometry, and developed length.

Method
In the first exercise, you see how the developed length of a sheetmetal part is affected by thickness. In the second exercise, you experiment with various sheetmetal options such as Default Radius , Fixed Geometry , Flat State , and Bend Table .

EXERCISE 1: Calculating the Length of a Sheetmetal Part


Task 1. Open the sheetmetal model and create an unbend feature.

1. Open MEASURE.PRT. 2. Create an unbend feature using the surface indicated in Figure 5 as the fixed surface.

Pick this surface to remain fixed

Figure 5: Specifying the Fixed Surface

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Task 2.

Measure the length of the fixed part.

1. Click Analysis > Measure . 2. Click Distance on the Type drop-down list in the MEASURE dialog box. 3. Specify the from and to surfaces as shown in Figure 6. The system calculates the value as 3.91040 and displays it in the RESULTS box.

Pick the hidden surface as the from reference Pick this surface as the to reference

Figure 6: Measuring the Distance Between the Two End Surfaces

Task 3.

Save this analysis for future use.

1. Click Saved Analyses to expand the area in the MEASURE dialog box. 2. Type [distance] in the Name text box and press <ENTER>. 3. Close the dialog box. Task 4. length. Change the thickness of the first wall to update the developed

1. Click Done to access the highest level menu in the menu manager. 2. Click Modify and select FIRST WALL from the Model Tree. Pick the .25 dimension, as shown in Figure 7, and type [.1].

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Modify the thickness

Figure 7: Changing the Thickness

3. Regenerate the part. 4. Check the analysis that you saved earlier by clicking Analysis > Measure . Click Distance from the Saved Analysis area of the dialog box. Notice that the distance value is now 3.83540 5. Close the dialog box. Task 5. Manually change the developed length so that an internal equation does not drive it. 1. Click Modify and select FIRST WALL from the Model Tree again. 2. Pick the .84 developed dimension. Click Enter Value and type [1.00] as the length. 3. Regenerate the part. 4. Retrieve the saved measure analysis distance again. Notice that the distance is listed as 4.00000. 5. Save the model and erase it from memory.

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EXERCISE 2: Setting Up for Sheetmetal


Task 1. Open the U_SHAPE sheetmetal part and set the default radius using the SETUP menu. 1. Open U_SHAPE.PRT. 2. Click Set Up > Sheet Metal > Default Rad > Enter Value . 3. Type [0.25].

Attach wall to this white edge

Figure 8: Specifying the Attachment Edge

Task 2.

Create a flat wall that uses the default radius.

1. Create a flat wall with a radius and that uses the part bend table and an inside radius. Pick the white edge indicated in Figure 8 to attach the wall. Specify an angle of 90. Sketch the wall as shown in Figure 9.
Reference

Sketch to points

Figure 9: Sketching the First Wall

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2. Finish the sketch and then click W/Relief > Rip relief for both ends of the wall. 3. Click Default from the SEL RADIUS menu and click OK to complete the wall. The completed wall should appear as shown in Figure 10. The inside radius was automatically set to 0.25.

Specify this edge to extend

Extend to this outside surface

Figure 10: Creating Extend Wall Feature

Task 3.

Extend the flat wall to close the gap.

1. Create an extended wall as shown in Figure 11.

Wall extended to outside

Figure 11: Extended Wall Feature Geometry

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Task 4. Define a default surface to remain fixed and create Unbend All and Bendback All features. 1. Click Set Up > Sheet Metal > Fixed Geom > Select . 2. Pick the surface indicated in Figure 12.

Pick this surface to remain fixed

Figure 12: Specifying a Surface to Remain Fixed

3. Unbend the entire part. Note that you did not have to specify a fixed surface. 4. Create a bend back feature. Again, note that you did not have to specify a fixed surface. 5. Since you do not need the two features that you just created, delete them. Task 5. Create an additional flat wall and check the relations that the system created as a result of using the Default radius option. 1. Create a flat wall with a radius and that uses the part bend table and an inside radius. Pick the white edge indicated in Figure 13 to attach the wall. Specify an angle of 90. Sketch the wall as shown in Figure 14.

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Attach to this inside edge

Figure 13: Specifying Attachment Edge for the Wall

Reference sketch to outside wall

Reference endpoints to attachment edges

Figure 14: Sketching the Additional Wall

2. After you have finished the sketch, click W/Relief > Strtch Relief . Type [0.25] as the width value of the stretch and [45] as the angle. Do the same for the other end.

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3. Click Default for the radius of the bend and OK to complete the feature. The part appears as shown in Figure 15.

Figure 15: Geometry after Creating the Wall

4. Click Part > Relation > Show Rel . These relations set the bend radius of the wall features equal to the parameter for the default radius that you set in a previous step. Close the window. 5. Click Modify and pick the wall you just created. Note that the developed length of the bend is 0.52. Task 6. part. Modify an existing bend table and assign it to the sheetmetal

1. Click Set Up > Sheet Metal > Bend Allow > Bend Table > Define > From Part . Type [U_SHAPE] as the name. 2. Edit the table as shown in Figure 16.

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Click Edit > Insert to add a row between START MATERIALS and END MATERIALS. Type [BRASS].

Edit these cells by highlighting the text and clicking Edit > Cut to delete the text.

Figure 16: Editing the Bend Table

3. When finished editing, exit the Pro/TABLE editor. 4. Define a material file called Brass by clicking SetUp > Material > Define . Type [brass] as the name. 5. In the text editor, scroll down to BEND_TABLE. At the end of this line (next to '='), type [u_shape], which was the bend table that you created in the previous step. Save the file and exit the editor. 6. Click Set Up > Material > Assign > BRASS > Accept to assign the material to the part. 7. Click Set Up > Sheet Metal > Bend Allow > Bend Table > Set > Confirm > From Part > U_SHAPE to assign the bend table to the part. The system regenerates the model. If you made an error, the system displays a warning. 8. Click Modify and pick the last wall feature. The developed length is now 0.53. Show the bend table and confirm this value is correct for a thickness of 0.25 and radius of 0.25. 9. Save the part and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: Pro/ENGINEER uses a standard bend formula to calculate the developed length of a sheetmetal model. Instead of using the default formula to calculate the developed length of a sheetmetal model, you can use a bend table. You can use the SETUP menu option Default Rad to set a default value for bend radius so that the system automatically adds a relation to drive the dimension if you choose this option when adding bends or use-radius walls. You can use the SETUP menu option Fixed Geom to automatically specify the same reference when creating unbend and bend back features.

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Module

Interrogating the Sheetmetal Model


In this module, you learn how to extract information from the sheetmetal model that you can use to develop your part and satisfy the design intent. You also become familiar with standard sheetmetal design rules.

Objectives
After completing this module, you will be able to: Make measurements on a sheetmetal model Use Gaussian Curvature analysis to identify surfaces that cannot be unbent without deformation. Generate sheetmetal bend reports Generate sheetmetal radii reports Set up design rules

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SHEETMETAL INFORMATION
Pro/ENGINEER provides you with unique tools that you can use to interrogate the sheetmetal part. By using them to extract information, you can isolate problem areas and correct them.

Measurement
Using the Analysis and Measure options, you can determine the curve length, angle, surface area, and distance. For example, you can compare the length of an edge on a bend in its bent state versus its unbent state or check complex angles between walls. For more information on doing measurements, see Measurement Operations in PTC Help.

Surface Analysis
One of the most common problems encountered when modeling sheetmetal components is an inability to unbend the geometry. Using tools such as the Gaussian curvature tool, you can evaluate your ability to unbend. Surfaces that curve in two directions must deform drastically to form that shape in a sheetmetal model. Pro/ENGINEER cannot capture this deformation through empirical formulation. Using the Gaussian curvature tool, you can calculate a summation of the maximum and minimum curvature vectors at any point on a surface, as shown in Figure 1. Pro/ENGINEER highlights the model with a fringe plot, distinguishing any surface that curves in two directions from those with zero curvature. Planar surfaces and ruled surfaces (cylinders and cones) have a Gaussian curvature value of zero, since there is no curvature in at least one direction on the surface. For more information on surface analysis, see Surface Analysis Operations in PTC Help.

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NOTES Solid color surface is planar or curved in one direction

Fringe plot surface is curved in two directions

Figure 1: Using the Gaussian Curvature Tool

Sheetmetal Bend Reports


By generating a bend report, as shown in Figure 2, you can interrogate bends on a model to obtain information on the overall calculation parameters used in the component. The report can also provide you with information concerning bends that are not 90 degrees so that you can interrogate them further. This can be very helpful when you use bend tables or a bend formula that does not consider the bend angle in its calculation.

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Figure 2: Typical Bend Report

Sheetmetal Radii Reports


Using a sheetmetal radii report, as shown in Figure 3, you can investigate the bend radii that have been created in the model, including the feature ID, dimension parameter name, and the radius value. You can also use this tool to quickly determine if the radii values adhere to the company standard.

Figure 3: Typical Radii Report

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DESIGN RULES
Design rules vary according to the materials and manufacturing process that you use to develop your model. To set up design rules for a model, you can use the Design Rules option in the SHEETMETAL SETUP menu.

Establishing a Design Rule Table


To set up design rules, you must establish a design rule table, as shown in Figure 4, and assign it to the model. You can develop as many tables as you would like, based on the different manufacturing practices and materials that you use. Using the tables, you can establish rules for such values as minimal slot widths and depths, minimal cut distances from boundaries, and minimal wall heights.

Figure 4: Default Settings

After you set up the rules for your model, you can check for design violations in the model. An Information window displays the rule name and formula, along with the dimensional values, enabling you to determine why it did not meet the rule criteria, as shown in Figure 5.

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Figure 5: Violated Rules

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LABORATORY PRACTICAL
Goal
The goal of this lab is to learn how to obtain information and verify that your design rules have not been violated before sending the sheetmetal part to manufacturing.

Method
In this exercise, you use sheetmetal information tools to obtain certain information about the sheetmetal part.

EXERCISE 1: Using Sheetmetal Information Tools


Task 1. Open the DOC_CABLEBOX sheetmetal part and review the geometry. 1. Open DOC_CABLEBOX.PRT.

Figure 6: DOC_CABLEBOX.PRT

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2. Use the Model Tree and the Feature option in the Info pull-down menu to review the last three features. Task 2. Create a bend report.

1. Click Info > Sheetmetal > Bend Report . 2. Clear the File check box to write output only to the screen. Click OK . 3. Click View > Line Numbers in the Information window. Note that the part information is displayed on lines 2 through 8, including the part name, material, thickness, and y-factor. 4. Note that the two bend IDs use a feature bend table (lines 10 through 15). In the Model Tree, identify the two bends with the IDs shown in the Information window. Pick the two bends and notice that the system highlights them on the model. You may need to click View > Model Tree Setup > Highlight Model in the Main window. 5. Note that the same two bend IDs are listed on lines 17 through 22 as being non-90-degree bends. After reviewing the information, close the Information window. Task 3. Create a sheetmetal radii report.

1. Create a radii report that outputs to the screen only. Click View > Line Numbers in the Information window. 2. Note that the part information is displayed on lines 2 through 8, including the part name, material, thickness, and y-factor. 3. Four bends were created (on lines 10 through 17) with nonsuggested radii. Use the Model Tree to determine the location of these bends on the model, then close the window. Task 4. Create a design rule, assign it to the part, and check the design.

1. Click Set Up > Sheet Metal > Design Rules > Define . Type [rule_set1] as the name. Pro/TABLE appears. 2. Investigate the seven default design rules. Notice that the left column contains parameter names for each design rule, and the right column contains the design rule in the form of a value or

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equation involving R and T. The design rule value or equation is always the minimum allowable value. 3. Change the MIN_CUT_TO_BEND to 4*T+R, change MIN_LASER_DIM to 1.25*T, change MIN_WALL_HEIGHT 0.5*T+R, and change MIN_CUT_TO_BOUND to 5*T. Save and exit Pro/TABLE. 4. Assign the rule set to the part by clicking Assign > From Part > RULE_SET1 . Note the message that appears in the message area. 5. Click Info > Sheetmetal > Design Check to check the design rules. Clear the File check box. Click OK . 6. Display line numbers in the Information window. 7. Review the Information window. Notice that line 3 displays the design rule set that you assigned to this model. 8. Read line 1. Choose line 9 and observe the model as it highlights the violating dimension. The current value column corresponds to the highlighted dimension. Using the DESIGN RULES VIOLATIONS DIAGNOSTIC window, investigate the model further, and then click Cancel . Task 5. Modify the model to avoid the two MIN_CUT_TO_BEND violations. 1. Click Modify > Query Sel and pick the rectangular form, as shown in Figure 7.

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Use Query Sel to pick this rectangle. Pick the Form feature.

Figure 7: Modifying the Dimension

2. The system does not show the actual violated dimension of 0.38 because the form was placed with the offset dimension of 0.75. Change the dimension to [0.85] and regenerate the model. Use the same procedure as before to verify that the modification eliminates the violation. 3. Save the part and erase it from memory.

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MODULE SUMMARY
In this module, you have learned that: Using tools such as the Gaussian curvature tool, you can evaluate your ability to unbend. By generating a bend report you can interrogate bends on a model to obtain information on the overall calculation parameters used in the component. Using a sheetmetal radii report you can investigate the bend radii that have been created in the model. Design rules can be used to verify that sheetmetal designs meet with a set of predefined criteria.

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Module

Additional Exercises
This appendix provides you with additional practice of some of the concepts covered in this training course. The exercises can be completed during class if time permits, or they can be done on your own time as they require no pre-existing files.

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EXERCISE 1: Creating a Blended Primary Wall


In this exercise, you create a blended wall as the sheetmetal primary wall.

Figure 1: Blended Primary Wall Task 1. Create a new sheetmetal part with a blended wall.

1. Create a new sheetmetal part called BLEND.PRT using the default template. 2. Click Feature > Create > Sheet Metal > Wall > Blend . Accept the defaults Parallel > Regular Sec > Sketch Sec > Straight . 3. Pick datum plane FRONT as the sketching plane and Flip the arrow for the direction of feature creation. 4. Pick datum plane TOP as the Top reference and sketch the first section as shown in Figure 2.

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Figure 2: First Blend Section

5. Click Sketch > Feature Tools > Toggle Section (or click Toggle Section from the pop-up menu) to toggle to sketch the second section. 6. Sketch the second section within the first as shown in Figure 3.

Figure 3: Second Blend Section

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Tip:
If you need to change the start point of one of the blend sections, pick the desired vertex on the section and click Start Point from the pop-up menu.

7. After exiting from Sketcher, flip the arrow to the inside. Type [0.1] as the thickness and [7.0] as the depth for the second section. The part should appear as shown in Figure 4.

Figure 4: Completed Part

8. Save the file and erase it from memory.

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EXERCISE 2: Creating a Flat Primary Wall


In this exercise, you create a new sheetmetal part with a flat wall as the sheetmetal primary wall.

Figure 5: Flat Primary Wall

Task 1.

Create a new sheetmetal part with a flat wall.

1. Create a new sheetmetal part called SWEEP.PRT using the default template. 2. Click Feature > Create > Sheet Metal > Wall > Flat . 3. Pick datum plane FRONT as the sketching plane and datum plane TOP as the Top reference. 4. Sketch the section as shown in Figure 6.

Figure 6: Section Dimensions


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5. Type [0.1] as the thickness. The completed part should appear as shown in Figure 7.

Figure 7: Completed Part

6. Save the file and erase it from memory.

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EXERCISE 3: Creating a Swept Secondary Wall


In this exercise, you create a swept secondary wall along a tangent edge using the Sweep, No Radius wall options.

Figure 8: Swept Secondary Wall

Task 2.

Retrieve the sweep sheetmetal part and create a swept wall.

1. Open SWEEP.PRT. 2. Click Feature > Create > Wall > Swept > No Radius . 3. Click Tangnt Chain and pick the green edges indicated in Figure 9. Note the location of the start point, and click Start Point to change its location if necessary.
Start point here

Pick this green edge for the tangent chain

Figure 9: Defining the Trajectory Path

4. Accept the default upward direction, and create the cross-section of the swept hem. Sketch the section as shown in Figure 10. Use a 270-degree 3-point arc, a tangent arc, and a line.

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Figure 10: Section for the Swept Blend

5. When you have finished sketching, click No Relief > Done > OK . The part appears as shown in Figure 11.

Figure 11: Completed Part

6. Save the file and erase it from memory.

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EXERCISE 4: Creating a Twisted Secondary Wall


In this exercise, you create a twist wall along an edge, and then unbend the geometry to observe the changes that occur in the developed length.

Figure 12: Twisted Secondary Wall

Task 1.

Create a flat primary wall.

1. Create a new part called TWIST.PRT using the default template. 2. Create a flat primary wall as shown in Figure 13.

Figure 13: Flat Primary Wall

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Task 2.

Create a twisted wall along the bottom of the part.

1. Click Feature > Create Wall > Twist > Done. 2. Pick the green or white lower edge of the wall, as indicated in Figure 14.

Pick this edge to attach the twist

Figure 14: Attachment Edge

3. Click Use Middle to create a datum point at the midpoint of the selected edge to locate the twist axis. 4. Type [2.0] as the start width. The default value is the length of the selected edge. 5. Type [2.5] as the end width. 6. Type [2.5] as the twist length (length after twisting). 7. Type [90] as the twist angle. 8. Type [4.0] as the developed length. This represents the length of the wall if you unbend it. 9. Click OK . The completed part appears as shown in Figure 15.

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Figure 15: Completed Part

10. Save the part and erase it from memory.

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EXERCISE 5: Bend Line Adjustment


In this exercise, you control bend line placement with relations.

Task 1.

Create a new sheetmetal part called BLA.PRT.

1. Create a sheetmetal part called BLA.PRT using the default template. 2. Create a flat wall, sketched on datum plane FRONT, as shown in Figure 16.

Figure 16: Section for Flat Wall

Task 2.

Create two angular bend features.

1. Create an regular angular bend using the part bend table and an inside radius. Sketch the section shown in Figure 17 on the large front face of the part.

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BS = bend side FS = fixed side


Sketched bend line Use RecRelief here

BS

FS

Figure 17: Flat Wall Section

2. Specify the bend and fixed sides as shown in Figure 17. 3. Use RecRelief on the right side (inside) and no relief on the other side. For the rectangular relief, specify a width of [0.5] and Up To Bend depth. 4. The bend angle should be 90 degrees and the radius is [1.0]. If the wall bends the wrong direction, Flip the direction. The part should appear as shown in Figure 18.

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Figure 18: First Bend Feature

5. Create the same bend on the other side of the part as shown in Figure 19.

Figure 19: Second Bend feature

Task 3.

Determine if bend line is in the desired location.

1. Click Analysis > Measure . Click Distance from the Type pulldown menu. 2. Pick the two surfaces shown in Figure 20. The distance reported should be 0.054. The two surfaces are not coplanar because the bend line adjustment is incorrect. You used a value of 0.5. The formula for the BLA is BLA= L - (R+T), where L is the developed length, R is the inside radius, and T is the thickness.
Measure between these surfaces

Figure 20: Distance Measurement

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Task 4.

Add a relation to control the BLA.

1. Click Modify and pick the left bend. The dimensions should appear as shown in Figure 21. The developed length (L) is 1.70.

Figure 21: Bend Dimensions

2. Click Modify and pick the original flat wall feature. 3. With the dimensions shown, click Relations . 4. You now need to identify the symbolic form for the appropriate dimensions. Find the developed length (d14 in Figure 22), the inside radius (d13 in Figure 22), the thickness (d8 in Figure 22), and the BLA (d9 in Figure 22). Your dimension symbols may be different.

Figure 22: Dimensions Required for Relation

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5. Click Add . The relation you need is the equation for the BLA. For this example in Figure 22, the relation is: d9 = d14 - (d13 + d8). Enter your relation. Be sure to use your dimension symbols. Press <ENTER> twice. 6. Regenerate the part. 7. Measure the distance again to ensure that the surfaces are coplanar. 8. Create a relation for the right-side bend. 9. To test the relations, modify both of the bend radii to [2.00]. 10. Regenerate the part twice. 11. Measure again to ensure that the surfaces remain coplanar. 12. Save the part and erase it from memory.

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EXERCISE 6: Creating an Edge Bend and a Rip


In this exercise, you create a part with a constant thickness in Part mode, convert the part into a sheetmetal part, and unbend it using the edge bend and rip features.

Figure 23: Part with Edge Bend and Rip

Task 1.

Create a new solid part called RIP.PRT.

1. Create a new solid part called RIP.PRT using the default template. 2. Create an extruded thin protrusion with a rectangular section as shown in Figure 24. 3. Create the feature on both sides of the section. 4. Type [0.1] as the width (thickness) of thin feature, and [4.0] as the blind depth.

Figure 24: Sketch for Thin, Solid Protrusion

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Task 2.

Convert the solid part into a sheetmetal part.

1. Click Applications > Sheetmetal . 2. Click Driving Surface for the conversion method. 3. Specify the outer surface, as indicated in Figure 25, as the driving surface (the driving surface is the green side of a sheetmetal part). 4. Accept the default value of [0.1000] for the thickness. The system automatically converts the part into a sheetmetal part.
Pick this surface as the green surface

Add Edge Bend to these edges

Figure 25: Specifying Driving Surface and Adding Edge Bends

Task 3.

Create edge bends on the four corner edges.

1. Click Feature > Create > Edge Bend . 2. Pick all four edges shown above in Figure 25 (you can pick inside or outside). Complete the feature. The system creates the edge bends using the thickness of the material as the inside radius of the bend.

3. Modify the radii of each bend to [2.0]. The model should appear as shown in Figure 26.

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Sketch the rip on this surface

Figure 26: Sketching Plane for the Rip Feature

Task 4.

Create a regular rip.

1. Click Feature > Create > Rip > Regular Rip > Done . 2. Pick a surface, as indicated in Figure 26, as the sketching plane. Use the Default reference plane. 3. Sketch a spline similar to the one shown in Figure 27. Reference and dimension the ends of the spline and complete the rip feature.

Figure 27: Section Sketch for the Rip Feature

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Task 5.

Create a flat pattern of the model.

1. Click Feature > Create > Flat Pattern . 2. Specify a surface to remain fixed, as indicated in Figure 28.

Pick this surface to remain fixed for flat pattern

Figure 28: Specifying Top Flat Surface to Remain Fixed

3. The completed flat pattern should appear as shown in Figure 29.

Figure 29: Final Geometry

4. Save the part and erase it from memory.

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Module

Sketcher Basics
You have learned that Pick and Place features allow for very fast creation of features such as holes and rounds whose geometry is easily understood as part of standard engineering operations. For any geometry that involves the definition of more complex, individual shapes, you will actually sketch them. To enable this, Pro/ENGINEER provides a Sketcher mode and includes a built-in Intent Manager to help you capture design intent. This module starts with the basics of the Sketcher mode.

Objectives
After completing this module, you will be able to: Describe the functions and tools in the Sketcher mode. Explain how the Sketcher dimensioning scheme allows you to capture design intent. Create geometry including lines, centerlines, arcs, circles, rectangles, and sketched points. Apply geometrical constraints to sketched entities, such as the equal lengths constraint and the perpendicular constraint. Employ Sketcher Tools to change section sketches.

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THE SKETCHER ENVIRONMENT


The Sketcher Interface
The Sketcher interface consists of: A menu bar with the usual Pro/ENGINEER pull-down menus and two additional Sketcher-specific menusEDIT and SKETCH. A standard Pro/ENGINEER toolbar. An additional Sketcher toolbar with specific Sketcher functionality such as Undo , Dimensions On/Off , and Grid On/Off . A message area below the toolbars. An Intent Manager with fly-out icons on the right to perform frequently used actions. An additional Sketcher-specific message area at the bottom left of the window describing Intent Managers fly-out icons.

Figure 1: Sketcher Interface

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The color red is used to highlight and select entities. This provides accurate and easily identifiable entities selections. Using the mouse, you can select individual or multiple-specific sketched entities, or all entities that fall within a swept box.

Intent Manager
The Intent Manager with fly-out icons appears automatically on the right side of the screen when you enter the Sketcher mode. These icons are logically grouped together, based on capability.
Default cursor to pick entities

Icons to create different kinds of geometry

To create dimensions To modify dimensions To impose constraints To trim Entities

Figure 2: Intent Managers Fly-Out Icons

With fly-out icons, you can access the most frequently used sketching tools with a single click without having to go to pull-down menus.

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Pop-Up Menus
Additional pop-up menus can be accessed by holding the right-mouse button in the Sketcher mode display area. These pop-up menus aid ease-of-use. They offer short-cut methods for sketching, modifying, dimensioning, deleting, and undoing steps.

Figure 3: A Typical Sketcher Pop-Up Menu

SKETCHER MODE FUNCTIONALITY


Sketcher Menus

EDIT and SKETCH are two top-level menus specific to the Sketcher

mode. They contain all the commands needed in the sketching environment. They are shown in Figure 4.

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Figure 4: Edit and Sketch Menus

In addition, all Intent Manager commands are available through these menus. You can insert Text into the Sketching area using the Text option in the SKETCH menu. With the new EDIT menu, you can manipulate your sketched geometry with the Modify, Move , Trim , Toggle Construction , and Toggle Lock commands.

Specifying References
One of the first things you will be prompted for after beginning a sketch in the Sketcher mode will be to specify references of the section you are about to sketch. You will need to provide references when you: Create a new feature. Redefine a feature with missing or insufficient references. Provide insufficient references to place a section.

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It is good practice to reference before sketching. This provides the sketched entities a location to automatically align to and dimension from.

Note:
The references that you select for a section create Parent/Child relationships.

Creating Geometry
Sketcher mode enables the creation of a variety of geometrical shapes and entities. The basic oneslines, arcs, and circlesare discussed below.

Lines

Figure 5: Lines Fly-Out Icons

Using the Line fly-out icons in the Intent Manager, you can create two types of sketched linesstraight lines from point to point or centerlines for referencing or constraining entities.

Arcs

Figure 6: Arcs Fly-Out Icons

Using the Arcs fly-out icons in the Intent Manager, you can create four types of arcs. You can create: An arc by 3 points or tangent to an entity at its endpoint. A concentric arc. An arc by picking its center and endpoints. A conic arc.

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Circles

Figure 7: Circle Fly-Out Icons

Using the Circle fly-out icons in the Intent Manager, you can create three types of circles. You can create: A circle by picking the center and a point on the circle. A concentric circle. A full ellipse.

Sketched circle

Concentric to this edge

Figure 8: Sketching a Concentric Circle to an Edge

Dimensioning
After completing a sketch, you must dimension it. To place dimensions in Sketcher, pick the entity with the left mouse button and place the dimension with the middle-mouse button. The following figure illustrates the simple dimensioning of a rectangle.

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Figure 9: Creating Dimensions for a Rectangle

You can grab a dimension and place it at a more convenient position in the Sketcher at any point during or after sketching. An orderly arrangement of dimensions helps visual clarity, particularly when the sketch gets complex.

Figure 10: Grabbing and Moving Dimensions

Modifying Dimensions
Sketcher makes it easy to modify dimensions of geometric entities at any time. With the MODIFY DIMENSIONS dialog box, shown below, you can change the dimension values of multiple entities with just a click of the mouse.

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Figure 11: Modify Dimensions Dialog Box

In addition, you can now double-click on an individual dimension to change its value. The SENSITIVITY scrollbar at the bottom right of the dialog box allows you to adjust the sensitivity of the control wheels for changing dimensions dynamically. You also have the options to dynamically Regenerate and Lock Scale the sketch.

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Constraining
Sketcher assumes certain constraints for the geometrical entities you create. You are free to impose your own constraints overriding the systems default constraints to capture your design intent. This can be done easily by accessing the CONSTRAINTS dialog box shown below.

Figure 12: Sketcher Constraints Dialog Box

You can use constraint options to: 1. 2. 3. 4. 5. 6. 7. 8. 9. Make a line or two vertices vertical. Make two entities tangent. Make two points or vertices symmetrical about a centerline. Make a line or two vertices horizontal. Place a point on the middle of the line. Create equal lengths, equal radii or same curvature constraint. Make two entities perpendicular. Creates same points or points on entities. Make two lines parallel.

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Additional Sketcher Tools


EDGE
The Edge tool has two instances represented by its two fly-out icons in the Intent Manager, as shown below:

Figure 13: Edge Fly-Out Icons

Uses an existing model edge to create sketched entities. Automatically selects that edge as a specified reference.
Use Edge

Figure 14: Using Existing Model Edge to Create Sketched Entities

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Uses existing model edge to create sketched entities at an offset distance.


Offset Edge

Figure 15: Creating Sketched Entities at an Offset Distance

Note:
The Use Edge and Offset Edge options create parent/child relationships with the referenced feature.

Copy
Copies 2-D draft/imported entities from a drawing. You can dynamically move and scale a section, making legacy data easier to manipulate. This functionality can be accessed by clicking Edit > Copy from the pull-down menus.

Mirror
This tool mirrors sketched entities from one side of a centerline to the other. This can be accessed by Edit > Mirror.

Move
Repositions sketched entities. The MOVE ENTITY menu displays the following options:
Drag Item

Moves an entity or its vertex to a new location. Translates picked entities within a sketch.

Drag Many

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Rotates sketched entities about a specified point by multiples of 90 degrees. Repositions a dimension within a sketch.

Dimension

Trim
This can be accessed by clicking Edit > Trim . Trim shortens (or extends) an entity in three different ways corresponding to the three fly-out icons shown below:

Figure 16: Trim Fly-Out Icons

The first dynamically trims section entities The second cuts or extends entities to other entities or geometry. The third divides an entity at the point of selection, replacing the original with two new entities.

Replace
Replaces a sketched entity from the original section with a newly sketched entity.

Section Analysis
To obtain information about a particular section within Sketcher, click Analysis > Section Analysis . This option provides you with information about intersection and tangency points angles and distances dimensioning references entity curvature display

Sketcher Points
They force coincidence among sketched entities. Allow slanted dimensions between sketched entity end-points.

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Figure 17: Midpoint Definition Using Sketcher Point

Figure 18: Defining Theoretical Sharps Using Sketcher Points

SETTING SKETCHER PREFERENCES


You can now modify the Sketcher environment in the new SKETCHER PREFERENCES dialog box in the UTILITIES menu.

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Figure 19: Sketcher Preferences Dialog Box

Use the SKETCHER PREFERENCES dialog box to: Modify the display options of various sketcher entities. Set constraints preferences by enabling or disabling constraints assumed by Sketcher. Set grid, grid spacing, and accuracy parameters. Click the Default button to reset the preferences.

Sketching in 3-D
When you select the Use2D Sketcher option from the ENVIRONMENT dialog box. Sketcher starts in 2-D orientation (that is, with the sketching plane parallel to the computer screen).

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Figure 20: The Environment Dialog Box

When you do not select this option, Sketcher starts in 3-D orientation. You may change the view orientation at any time and sketch in 3-D. Using View > Sketch View , you can re-orient a Sketcher section into the 2-D view while in Sketcher mode.

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SKETCHER PHILOSOPHY
Rules of Thumb
Certain rules of thumb must be rigorously adhered to gain maximum advantage from the power of the Sketcher modes diverse capabilities, 1. Keep sketches simple. This makes the final model flexible and helps regeneration. 2. Use the Undo option The Undo option restores a sketched section to its prior state. This is extremely useful when sketching features incrementally. 3. Do not sketch to scale. Firstly, concentrate on getting your geometry straight by sketching large. Secondly, resolve the sketch by modifying dimensions. This rule is particularly helpful when the sketched entities are small. 4. Use the grid as an aid. Create lines equal, parallel, or perpendicular. Align sketched entities. Align centers horizontally and vertically. 5. Do not extend the sketch outside of the part. There is no need to sketch sections that extend outside the part, as is required with some solid modeling packages. 6. Make effective use of Sketcher accuracy. The range for the accuracy is 1.0 e-9 through 1.0 (default). To prevent Sketcher from making constraints, you can increase Sketcher accuracy by changing it from 1.0 to a lower number. 7. Use open and closed sections appropriately. When sketching an open section, you cannot have more than one open section per feature.

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If you use an open section, you must explicitly align its open ends to the part. When in doubt over whether you should use an open or closed section, you should use a closed one since it is easier to regenerate, and is less prone to failure.
Protrusion B Protrusion A

Cut

Figure 21: Open and Closed Sections

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LABORATORY PRACTICAL
Goal
By the end of this lab, you will be conversant with basic sketching skills such as entering sketcher mode, creating straight lines, creating arcs, applying constraints, dimensioning, and generating solid models.

Method
In Exercise 1, you learn sketching basics. In Exercise 2, you create a snap ring by sketching in steps. In Exercise 3, you create a hex section using construction entities.

EXERCISE 1: Sketching Basics

Figure 22: Completed Sketch after Exercise 1

Task 1.

Create a new sketch named ROUND_RECTANGLE.

1. Click File > New . 2. In the NEW dialog box, select Sketch . 3. Type [ROUND_RECTANGLE]. 4. Sketcher mode activates.

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Task 2.

Sketch four lines as shown, the bottom line being horizontal.

Figure 23: Sketching a Quadrilateral

Task 3.

Apply the constraint to make the lines perpendicular.


>

1. Click

, then pick two lines to make them perpendicular.

2. Similarly, once again pick the other two lines to make them perpendicular.

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Figure 24: Applying the Perpendicular Constraint

3. Close the CONSTRAINTS dialog box. Task 4. Delete the two vertical lines.

1. With the pointer icon pick the left vertical line. 2. Hold shift and pick the right vertical line. 3. Right-click and select Delete from the pop-up menu. Task 5. Sketch a tangent end arc on the left side of the section. .

1. Click

2. Pick the top left vertex and drag the mouse out of the left quadrant of the circle to get a tangent end arc. 3. Pick the end point to be the bottom left end point, as shown below.

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Figure 25: Sketching a Tangent End Arc

Task 6.

Repeat the process on the right side of the section.

Figure 26: Sketching Tangent End Arcs on Both Sides

Task 7.

Add the proper dimensions. .

1. Click

2. Pick each arc with the left mouse button, then place the dimension where you would like it to appear with the middle button. 3. Select Tangent and Horizontal for type and orientation.

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Figure 27: Dimensioning the Arcs

Task 8.

Create a diameter dimension on the left arc. .

1. Click

2. Pick the left arc twice with the left mouse button and place it with the middle.

Figure 28: Dimensioning the Left Arc

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Task 9.

Modify both dimensions.

1. Pick both the horizontal dimension and the diameter dimension using the <SHIFT> key and click icon.

Figure 29: Modify Dimensions Dialog Box

2. Modify the diameter to [2] and the linear dim to [4]. 3. Save and close the MODIFY DIMENSIONS dialog box.

Figure 30: Sketch with Modified Dimensions

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EXERCISE 2: Sketching in Steps

Figure 31: Completed Snap Ring after Exercise 2

Task 1.

Create a new sketch called SNAP_RING.

1. Click File > New . 2. Select Sketch . 3. Type [SNAP_RING] as the name of the sketch. Task 2. Create two offset circles aligned horizontally. and draw two circles as shown in the next figure.

1. Click

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Figure 32: Two Offset Circles Aligned Horizontally

Task 3. Create a rectangle that snaps to the inside circle on both upper vertices.

Stop cursor here

Delete

Start dynamic trim here

Figure 33: Sketching a Rectangle Inside Circles

1. For the rectangle, click again to end sketching.

. Just click once to start and then click

2. Then use the dynamic trim to create intersections. Click , Put your cursor below the bottom horizontal line and drag it to above the top horizontal line.

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NOTES

3. Make sure that each item becomes highlighted. If all the crossed items are not highlighted continue to hold the mouse button and drag over the lines until they do highlight. 4. The result is shown in the figure below.

Figure 34: Using Dynamic Trim

Task 4.

Sketch another rectangle.

1. This time snapping to the outside circle and the bottom of the two vertical lines as shown below. 2. Make sure not to snap through any of the arc's vertices.

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Figure 35: Sketching a Second Rectangle

Task 5.

Use the dynamic trim to remove the final lines and arc. to trim the unwanted entities.

1. Click 2.

The result is shown below.

Figure 36: Capturing Intent with Dynamic Trim

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Task 6.

Dimension the entities. to create the dimensions.

1. Click

2. Pick each entity with the left mouse button and place the dimension with the middle mouse button. 3. Click to modify the six dimension values.

Figure 37: Modifying Dimensions

4. Save and close.

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EXERCISE 3: Sketching a Hexagon


Task 1. Create a new sketch called HEX.

1. Click File > New . Select Sketch and type [HEX] as the name. Task 2. Create a sketcher point

1. Click the

point button.

2. Place a point in the center of the screen. Task 3. Add vertical centerlines passing through the Sketcher Point.

1. Click on the centerline button in the line fly-out icons.

2. Create a vertical centerline that passes through the point. 3. Create two additional centerlines that pass through the point at an angle. Task 4. Modify the angles to 60.

1. Modify the angle between centerlines to 60 as shown below.

Figure 38: Modifying Angles between Centerlines

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Task 5.

Create a circle centered on the point.

1. Left-click on the circle to highlight it in red. 2. Right-click and hold on the circle for a pop-up menu. 3. Click Toggle Construction to convert it to a construction circle

Figure 39: Creating a Construction Circle

Task 6. Create a hexagon by sketching 6 lines from the intersection points of the circle and the centerlines.

Figure 40: Creating a Hexagonal Sketch

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1. Add a diameter dimension to the construction circle and modify it's value to [1.0] 2. Save and close.

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MODULE SUMMARY
In this module, you have learned that: The Sketcher interface consists of the main sketcher area, pull-down menus, toolbars, message areas, the INTENT MANAGER with fly-out icons, and pop-up menus. All geometry has to be sketched, dimensioned, and constrained. You can create lines, arcs, circles, rectangles, splines, and many other geometrical entities using the Intent Manager. The EDIT and SKETCH menus contain most of the tools that are unique to Sketcher mode such as Copy , Mirror , Move , and Trim . System dimensions can be over-ridden and dimensions can always be modified at any stage of model generation. It is possible to over-constrain a model. The system notifies you when there is a clash of constraints though. Sketcher preferences can be set using the SKETCHER PREFERENCES dialog box.

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Appendix

Using PTC.Help
PTC is continuing its commitment to provide integral internet/intranet enhancements through the i-series of software products, including the innovative changes in this release of PTC Help.

Objectives
After completing this module, you will be able to: Start the PTC.Help system. Obtain help while performing a task

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PTC HELP OVERVIEW


PTC Help is integrated with fully functional, highly flexible CAD/CAM and Data Management software available from PTC. It is easy to locate a desired topic. PTC Help can be installed on a Web server, allowing Web clients to access PTC Help without having direct mounts to file server machines, thus reducing network traffic and enabling a LAN/WAN configuration.

PTC HELP FEATURES


PTC Help offers: A new help system with integrated table of contents, index, and search capability Full certification of Internet Explorer 4.0 and Netscape 4.06 Web server installation capabilities Full context-sensitive help, allowing access to PTC Help with a click of the mouse Expanded context-sensitive help in dialog boxes

Database ,

Also, please visit the PTC Technical Support Online Knowledge which features thousands of Suggested Techniques. For more information, see the Technical Support Appendix.

USING THE PRO/ENGINEER HELP SYSTEM


The Pro/ENGINEER Help System (also called PTC Help) provides you with help topics that give you the information you need while you work.

Getting Help While Performing a Task


You can get Help on your current task when you are working in a dialog box or with a menu by using one of these three procedures.

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To Get Help on Tasks in a Dialog Box


1. Click on the right end of the main Pro/ENGINEER toolbar.

2. Click anywhere inside the dialog box. A navigational topic opens in a Help window. The navigational topic contains a list of links to Help topics about tasks that you perform in the dialog box. 3. Click the topic you want to read. 4. Click Back on the browser toolbar to return to the navigational topic and choose another topic.

To Get Help on Commands on the Pro/ENGINEER Menu Bar


1. Click on the right end of the main Pro/ENGINEER toolbar.

2. Click a menu command. A navigational topic opens in a Help window. The navigational topic contains a list of links to Help topics about that command. 3. Click the topic you want to read.

To Get Help on Commands on Vertical Menus


1. Click a menu command with the right mouse button and hold the button down until the GetHelp window appears. 2. Point to GetHelp and then release the mouse button. A navigational topic opens in a Help window. The navigational topic contains a list of links to Help topics about the command.

GETTING HELP THROUGH THE PTC HELP SIDEBAR


With the PTC Help Sidebar, you can browse the Contents or Index of the PTC Help System and get help anytime you are using Pro/ENGINEER. 1. On the Pro/ENGINEER menu bar, click Help > Pro/E Help System to display the Help home page as shown below

Append ix B

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Figure 1: Starting PTC Help

2. Click Contents to browse Help topics by functional area, Index to view Help keywords for a specific domain, or Search to find topics in both the Contents and the Index that match a word or phrase

PTC HELP MODULE LIST


There are four main branches in the PTC Help table of contents: Welcome, Pro/ENGINEER Foundation, Using Foundation Modules, and Using Additional Modules. Consult the following list to find a particular module in the table of contents. Associative Topology Bus-CADDS 5 Using Foundation Modules Associative Topology Bus-ICEM Using Foundation Modules Basic Assembly Using Foundation Modules Behavioral Modeler Using Additional Modules, Behavioral Modeling Extension Configuration File Options Pro/ENGINEER Foundation Core Pro/ENGINEER Foundation Design Animation Using Additional Modules, Behavioral Modeling Extension Expert Machinist Using Additional Modules, Machining Import Data Doctor Using Foundation Modules Mechanism Design Using Additional Modules, Behavioral Modeling Extension Part Modeling Pro/ENGINEER Foundation

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Pro/ASSEMBLY Using Additional Modules, Advanced Pro/ASSEMBLY Extension Pro/CABLING Using Additional Modules, Routed Options Pro/CASTING Using Additional Modules, Tooling Pro/CMM Using Additional Modules, Computer Aided Verification Pro/COMPOSITE Using Additional Modules, Advanced Surface Extension Pro/DETAIL Using Foundation Modules Pro/DIAGRAM Using Additional Modules, Routed Options Pro/DIEFACE Using Additional Modules, Tooling Pro/ECAD Using Foundation Modules Pro/HARNESS-MFG Using Additional Modules, Routed Options Pro/INTERFACE Using Foundation Modules Pro/LEGACY Using Foundation Modules Pro/MOLDESIGN Using Additional Modules, Tooling Pro/NC Using Additional Modules, Machining Pro/NC-SHEETMETAL Using Additional Modules, Machining Pro/PHOTORENDER Using Foundation Modules Pro/PIPING Using Additional Modules, Routed Options Pro/PROCESS for ASSEMBLIES Using Additional Modules, Advanced Pro/ASSEMBLY Extension Pro/PROCESS for MFG Using Additional Modules, Machining Pro/PROGRAM Using Foundation Modules Pro/REPORT Using Foundation Modules Pro/REVIEW Using Foundation Modules Pro/SCAN-TOOLS Using Additional Modules, Advanced Surface Extension Pro/SHEETMETAL Design Using Foundation Modules Pro/SURFACE Using Additional Modules, Advanced Surface Extension Pro/VERIFY Using Additional Modules, Computer Aided Verification Pro/WELDING Using Foundation Modules Sketcher Pro/ENGINEER Foundation

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Appendix

PTC Global Services: Technical Support


PTC Global Services is committed to making the best possible resources available for customers. In addition to our telephonebased Technical Support, we also have Internet-based offerings that are designed to fit a customer's individual needs, leveraging the Internet to provide availability on a 24 x 7 basis. PTC Global Services is committed to continually improving service to our customers. Through continuous improvement and our Quality Monitoring program, we have demonstrated our commitment to service by achieving Global ISO 9000 Certification for our Technical Support offerings. We strongly believe that our commitment to support is unmatched in the industry..

Objectives
After completing this module, you will be able to: Technical Support Call Register for on-line Technical Support Navigate the Knowledge Base Locate contact numbers for support and services

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FINDING THE TECHNICAL SUPPORT PAGE


Choose Support from the PTC Home Page http://www.ptc.com or go directly to http://www.ptc.com/support/support.htm.

OPENING A TECHNICAL SUPPORT CALL


Opening a call via email:
PTC Customers Send email to cs_ptc@ptc.com with copen as the subject of the email. Please use the following format: (or download the template from http://www.ptc.com/cs/doc/copen.htm) FNAME: LNAME: FirstName LastName U.S., Germany, France, U.K., Singapore, or

CALLCENTER: Tokyo PHONE: CONFIG_ID: PRODUCT: MODULE: PRIORITY: DESC_BEGIN: description starts

NNN NNN-NNNN x-NNNN NNNNNN X XX X

description continues description ends DESC_END Rand Customers To open calls by email with RAND, send your questions to tech.support@rand.com.

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Opening a Call via Telephone:


PTC Customers Call us directly by phone (refer to Contact Information page for your Local Technical Support Center). The Technical Support Engineer will ask you for the following information to log a call: PTC Software Configuration ID Your name, telephone number PTC Product (module) name Priority of the issue

Opening calls on the PTC Web Site:


You can use the PTC Web site www.ptc.com/support to open Technical Support calls 24 hours a day, 7 days a week, by using the Pro/CALL LOGGER This application provides easy to follow instructions and returns a call number immediately upon submission of all information. To open calls through the Web with RAND, visit the Rand Customer Service Web site at www.rand.com/cust_serv.

Sending Data To Technical Support


If you want to sent data to the Technical Support please follow the instructions on the external PTC Web site http://www.ptc.com/support/cs_guide/additional.htm. When the call is resolved your data will be deleted by the Technical Support Engineer and will not divulged to any third party vendors under any circumstances. For secure data you can request from the Technical Support Engineer a Non-Disclosure agreement template.

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CALL / SPR FLOW CHART AND PRIORITIES


Call
Customer question

Telephone Call

Web Call

Tech SupportEngineer creates a call in the database

Call is automatically created in the database

Investigation

Call Back and Investigation

Support Engineer solves issue or reports it to Development (SPR)

SPR
Software Performance Report SPR fixed from Development

Software Performance Report (SPR) SPR Verification through Tech. Support Engineer

Update CD to customer

Figure 1: Call / SPR Flow Chart

Call Priorities:

Extremely Critical Critical Urgent

- Work stopped

- Work severely impacted - Work impacted

Not Critical General Information

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Software Performance Report Priorities



Top Priority -

Highly critical software issue that is causing a work

stoppage. Critical software issue that affects immediate work and a practical alternative technique is not available.
High -

Software issue that does not affect immediate work or a practical alternative technique is available.
Medium -

REGISTERING FOR ON-LINE SUPPORT


Go to www.ptc.com/support and click Sign-up Online , to open the registration form and enter your Configuration ID. To find the Configuration ID, in Pro/ENGINEER, click Help > About for example. Complete the information needed to identify yourself as a user with your personal details.

Pro/ENGINEER ,

Figure 2: On Line Support Registration

Please write down your username and password for future reference.

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ONLINE SERVICES
After you have registered you will have full access to all Online Tools.

Figure 3: On line service options

You can search our Knowledge Base using a Search-Engine. Our Online Support Applications allow to control the status of Calls (Call Tracker) and SPRs (SPR Tracker) and to add comments to these. If you add an comment the Technical Support Engineer assigned to your call will be notified automatically. Additionally contact information such as the customer feedback line and electronic order of software and manuals are available. The Software Update Tool allows you to request to newest software updates for any PTC product.

FINDING SOLUTIONS IN THE KNOWLEDGE BASE


The Technical Support Knowledge Base contains over 18.000 documents, which are updated from our engineers. Technical Application Notes TAN, Technical Point of Interest TPI, Frequently Asked Questions FAQs and Suggested Techniques offer up-to-date information about all relevant software areas. Limit the search by entering the PTC product/module and the search string. All FAQs and Suggested Techniques are translated in French and German.
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Figure 4: Searching The Knowledge Database

Definitions:
TAN -

Technical Application Note - A technical document that provides information about SPRs that may affect more than just the customer originally reporting an issue. TANs also may provide alternative Techniques to allow a user to continue working.

Technical Point of Interest - A document that provides additional technical information about a software product. TPIs are created by Technical Support to document the resolution of common issues reported in actual customer calls. TPIs are similar to TANs, but donot reference an SPR.
TPI -

Provides step-by-step instructions including screen snapshots, on how to use PTC software to complete common tasks.
Suggested Techniques: FAQ

- Frequently Asked Questions Provides answers to many of the most commonly asked questions compiled from the PTC Technical Support database.

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GETTING UP-TO-DATE INFORMATION


To subscribe to our email service, the Knowledge Base Monitor, go to www.ptc.com/support. 1. Click Technical Support > Online Support Applications > Knowledge Base Monitor . 2. Select the PTC product/module for which you want to get information. 3. You will receive a daily email with update information, this can help you by upgrading to a new PTC Product or to a new Release.

Figure 5: Knowledge Base Monitor sign-up

CONTACT INFORMATION
Internet
Rand Customers
Rand Worldwide customers can visit the following Web site for phone numbers: http://rock.rand.com/webtracker/CustomerServicesWorldwide.htm

PTC Customers
PTC Technical Support Worldwide Electronic Services
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These services are available seven days a week, 24 hours a day.


URL:


E-mail

http://www.ptc.com/support/index.htm (Support) http://www.ptc.com/company/contacts/edserv.htm (Education)


FTP:

cs_ptc@ptc.com (for opening calls and sending data) cs-webmaster@ptc.com (for comments/suggestions on CS Web site)

ftp.ptc.com

Technical Support Customer Feedback Line


The Customer Feedback Line is intended for general Customer Service concerns that are not technical product issues.
E-mail

cs-feedback@ptc.com are listed at:

Phone: Numbers

http://www.ptc.com/cs/doc/feedback_nums.htm

Telephone
For assistance with technical issues contact should be directed through the Electronic Services noted in the previous section, or through the Technical Support line as listed in the Phone and Fax Information sections below. PTC has nine integrated Technical Support Call Centers, in North America, Europe, and Asia. Our worldwide coverage ensures telephone access to Technical Support for customers in all time zones and in local languages.

North America Phone Information


Customer Services (including Technical Support, License Management, and Documentation Requests)

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NOTES Within the U.S.:

800-477-6435

Outside the U.S.:

781-894-5332 781-894-5513

Maintenance

888-782-3774

Education

888-782-3773

EUROPE Phone Information


Technical Support Phone Numbers Austria Belgium Denmark Finland France Germany Germany) Ireland Israel Italy Luxembourg Netherlands Norway Portugal South Africa 1-800-409-1622 1-800-945-42-95 (All languages including Hebrew) 177-150-21-34 (English only) 800-79-05-33 0800-23-50 0800022-4519 8001-1872 05-05-33-73-69 0800-991068 0800 29 7542 0800-15-241 (French support) 0800-72567 (Dutch support) 8001-5593 0800-117092 0800-14-19-52 0180-2245132 49-89-32106-111 (for Pro/MECHANICA outside of

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Spain Sweden Switzerland

900-95-33-39 020-791484 0800-55-38-33 (French support) 0800-83-75-58 (Italian support) 0800-552428 (German support)

United Kingdom

0800-318677

License Management Phone Numbers Belgium Denmark Finland France Germany Ireland Italy Netherlands Norway Portugal Spain Sweden Switzerland United Kingdom 0800-75376 8001-5593 0800-117-092 0800-14-19-52 49 (0) 89-32106-0 1800-409-1622 39 (0) 39-65651 0800-022-0543 8001-1872 05-05-33-73-69 900-95-33-39 020-791484 41 (0) 1-8-24-34-44 0800-31-8677

Russia/Eastern Europe 44 1252 817 078

Education Services Phone Numbers Benelux France Germany Italy Spain/Portugal Sweden Switzerland 31-73-644-2705 33-1-69-33-65-50 49 (0) 89-32106-325 39-039-65-65-652 34-91-452-01-00 46-8-590-956-00 (Malmo) 46-8-590-956-46 (Upplands Vasby) 41 (0) 1-820-00-80 39-039-6565-1

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United Kingdom

44-0800-212-565 (toll free within UK) 44-1252-817-140

Asia and Pacific Rim Phone Information


Technical Support Phone Numbers Australia China* Hong Kong India* Indonesia Japan Malaysia New Zealand Philippines Singapore South Korea Taiwan Thailand 1800-553-565 10800-650-8185 (international toll free) 108-657 (manual toll free) 800-933309 000-6517 001-803-65-7250 97-2-48-55-00-35 0120-20-9023 1-800-80-1026 0800-44-4376 1800-1-651-0176 65-830-9899 00798-65-1-7078 (international toll free) 080-3469-001 (domestic toll free) 0080-65-1256 (international toll free) 080-013069 (domestic toll free) 001-800-65-6213 *Note: Callers dialing from India or China must provide the operator with the respective string: China India MTF8309729 MTF8309752

The operator will then connect you to the Singapore Technical Support Center. License Management Phone Numbers Japan Hong Kong 81 (0) 3-3346-8280 (852) 2802-8982

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Education Services Phone Numbers Australia China 61 2 9955 2833 (Sydney) 61 3 9561 4111 (Melbourne) 86-20-87554426 (GuangZhou) 86-21-62785080 (Shanghai) 86-10-65908699 (Beijing) Hong Kong India 852-28028982 91-80-2267272 Ext.#306 (Bangalore) 91-11-6474701 (New Delhi) 91-226513152 (Mumbai) Japan Malaysia Singapore South Korea Taiwan 81-3-3346-8268 03-754 8198 65-8309866 82-2-3469-1080 886-2-758-8600 (Taipei) 886-4-3103311 (Taichung) 886-7-3323211 (Kaohsiung)

ELECTRONIC SERVICES
Up-to-Date + Information Worldwide ISO 9000 Certification Quality Control System

= Maximum Productivity with PTC Products

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