Training Guide

Sheet Metal Basics

 TopSolid'Design - Sheet Metal Basics
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Version 7.12 Rev.01

Note: If you are experiencing problems using this training guide, please feel free to send your feedback and
comments at edition@topsolid.com.

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TopSolid'Design - Sheet Metal Basics

Contents
Exercise 1: Creating a Sheet Metal Part on Open Sketch .................................................................................... 1

Exercise 2: Creating a Sheet Metal Part on Close Sketch .................................................................................... 5

Exercise 3: Creating a Sheet Metal Part with Dragged Edges .............................................................................. 8

Exercise 4: Creating a Sheet Metal Part with Swept Flange .............................................................................. 17

Exercise 5: Creating a Sheet Metal Part with Flange ........................................................................................ 20

Exercise 6: Creating a Hood ............................................................................................................................ 24

Exercise 7: Creating a Box ............................................................................................................................... 33

Exercise 8: Creating a Counter ........................................................................................................................ 36

Exercise 9: Creating a Container...................................................................................................................... 43

Exercise 10: Creating a Support ...................................................................................................................... 51

Exercise 11: Creating a Sheet Metal from a Casing Step File ............................................................................. 61

Exercise 12: Creating an Assembly using Step Recovery ................................................................................... 63

Additional Exercise: Creating a Box with Manual Corner and Edge Reliefs ........................................................ 69

Additional Exercise: Forming Component Without Added Material ................................................................. 73

Additional Exercise: Forming Component with Added Material ....................................................................... 77

Additional Exercise: Creating a Sheet Metal Part with Forming Flange ............................................................. 82

Additional Exercise: Creating a Sheet Metal Part with Ball Corner ................................................................... 87

Annexes ......................................................................................................................................................... 91

Notes ............................................................................................................................................................. 95

Individual Course Evaluation Form ................................................................................................................. 98

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TopSolid'Design - Sheet Metal Basics Exercise 1: Creating a Sheet Metal Part on Open Sketch

Exercise 1: Creating a Sheet Metal Part on Open Sketch

Concepts addressed:
- Creating a sketch
- Creating a sheet metal part on sketch
- Creating an angle relief
- Producing an unfolding document

Creating a sheet metal part

 Create a new project using a blank template and rename it Your name - Sheet Metal Basics Training.
 From the Project tree, right-click on the project name and select Folder. Rename the folder Exercise 1 -
Sheet metal part on open sketch.
 Create a new Part document and rename it Keyboard support.
 Draw the following sketch and confirm it.

 From the Sheet Metal tab, select Sheet Metal on Sketch and complete the dialog box as follows.

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Exercise 1: Creating a Sheet Metal Part on Open Sketch TopSolid'Design - Sheet Metal Basics

Note: You can also right-click on the sketch to access the Sheet Metal on Sketch command.

 Create a rectangular sketch on the top face of the sheet, centered on the 280mm length, and then finish
setting the dimensions to produce the following result.

 Confirm the sketch.

 Select Pocket to create the following pocket on this sketch. In the Limit field, select Through all from the
drop-down list.

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TopSolid'Design - Sheet Metal Basics Exercise 1: Creating a Sheet Metal Part on Open Sketch

 Add the following four fillets using the Angle Relief command.

Note: Only the edges on the sheet's side faces can be selected.

 Save the document.

In the Entities tree, you can find the following system parameters in the Parameters > System Parameters
folders. If these parameters are not displayed, click the Show entities that are not available icon at the top of
the tree.

Note: Once the document has been saved, TopSolid automatically creates the Thickness parameter and the
Sheet Metal Boolean parameter. TopSolid no longer recognizes the part as a general mechanical part, but as a
sheet metal part that can be unfolded. Therefore, the Unfolding command is only available on sheet metal
parts.
You can use these elements to search for previously created sheet metal parts. For example, if you want to search
for a sheet metal part whose thickness is 2mm, proceed as follows:
 From the Project tree, create a new Search document (Advanced tab) in the Exercise 1 folder to
display the Search window.
 In the Type field, indicate that you are only searching for a part document and click Apply.
 Indicate that the search must be carried out in the current project.
 In the Property field, select Standard > Dimension > Thickness.
 In the Operator field, select Equals.
 In the Value field, enter 2mm.
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Exercise 1: Creating a Sheet Metal Part on Open Sketch TopSolid'Design - Sheet Metal Basics

 Click the Refresh icon to start the search.

Parts that match the defined criteria appear in the Search Results window.

 Save the search document.

 Right-click on the sheet metal part and select Others > Analyze Sheet Metal in the Shape 1
section.

Warning: You can only create sheet metals with the same thickness in a part document.

Creating the unfolding

 Right-click on the Keyboard support part document's upper tab and select Unfolding.
 Select Blank Template and click to confirm.
 Click to confirm the Unfolding dialog box.

Note: The part document must be saved for the Unfolding command to appear in the context menu.

You can hide the part by right-clicking on shape 1 and selecting Hide.

 Save the unfolding document.

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TopSolid'Design - Sheet Metal Basics Exercise 2: Creating a Sheet Metal Part on Close Sketch

Exercise 2: Creating a Sheet Metal Part on Close Sketch

Creating the assembly

 From the Project tree, create a new folder named Exercise 2 - Sheet metal part on close sketch.
 Create an Assembly document and rename it Keyboard support set.
 Drag the Keyboard support part document from exercise 1 into the Keyboard support set assembly
document.

Creating the in-place side

 Right-click on the keyboard support's side face and
select In Place Part.

 Select Blank Template and click to confirm.

A new part document is then created. Since the part is

created "in place" in the assembly, the document is
included in the assembly document's node in the Project
tree, and not outside of this node like the Keyboard support
document.

 Draw the following sketch and confirm it.

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Exercise 2: Creating a Sheet Metal Part on Close Sketch TopSolid'Design - Sheet Metal Basics

 Right-click on the sketch, select Sheet Metal on Sketch, and then click to confirm.

 Rename the in-place part document Side.

 Modify the part color using the Attributes command.
 Confirm the in-place design by clicking on .

Creating the opposite side

 Duplicate the Side part by pressing Ctrl + left-click on the part.

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TopSolid'Design - Sheet Metal Basics Exercise 2: Creating a Sheet Metal Part on Close Sketch

 Constrain the duplicate part as shown below.

 Confirm the positioning by clicking on .

 Save the document.

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Exercise 3: Creating a Sheet Metal Part with Dragged Edges TopSolid'Design - Sheet Metal Basics

Exercise 3: Creating a Sheet Metal Part with Dragged Edges

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 3 - Sheet metal part with dragged edges.
 Create a new Part document and rename it Roof.
 Draw the following sketch.

 Right-click on the sketch, select Sheet Metal on Sketch and create a 2mm thick sheet metal on sketch
along Z+.

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TopSolid'Design - Sheet Metal Basics Exercise 3: Creating a Sheet Metal Part with Dragged Edges

 Right-click on one of the shape's upper edge and select Flange.

 Right-click on a flange face, select the following options and then

click OK.

Note: By activating the Close neighbour borders option, TopSolid drags the borders laterally to add the material.

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Exercise 3: Creating a Sheet Metal Part with Dragged Edges TopSolid'Design - Sheet Metal Basics

 Right-click on the top flange's upper edge and select Flange.

 Repeat this operation on the opposite edge. To achieve this, move the mouse
cursor to the flange operation, press Ctrl + left click, and then drag the duplicated
shape onto the opposite inner edge.

Note: Do not hesitate to zoom in when using this command.

If the flange is positioned in the opposite direction, click the Invert icon in the
dialog box.

 Save the document.

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TopSolid'Design - Sheet Metal Basics Exercise 3: Creating a Sheet Metal Part with Dragged Edges

 Add two new flanges to the edges of the previously created flanges.

 Create a flange on one of the side edges by selecting the flange face as the
limitation plane to be used. Enter a shift value of 0.1mm.
Note: The shift MUST be defined, otherwise TopSolid merges the metal sheets.

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Exercise 3: Creating a Sheet Metal Part with Dragged Edges TopSolid'Design - Sheet Metal Basics

 Repeat the procedure on the opposite side.

Warning: Here, it is not recommended to copy and paste the operation using Ctrl + left click method because
by default TopSolid will keep the previous limit face and you will have to edit the operation to reconnect the limit
face to the correct face.

 Right-click on the inner edge of one of the two top flanges and select
Hem Bend. Then select the inner edge of the other top flange.

Warning: The bending radii must be directed toward the inside of the sheet.

 Save the document.

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TopSolid'Design - Sheet Metal Basics Exercise 3: Creating a Sheet Metal Part with Dragged Edges

Creating an unfolding rule

 Right-click on the shape and select Others > Analyze Sheet Metal in the Shape 1 section.

The default unbending method is Neutral Fiber K Factor = 0.5.

 Right-click on the Roof part document's upper tab and select Unfolding.
The unfolding document is properly created. However, we want to use another unbending method than the
default one. So we will create an unfolding rule.
 Return to the Roof part document.
 From the Sheet Metal tab, select Unfolding Rules.
 Enable the Predefined Rules dialog box and select Steel Tables in the drop-down list.

 Return to the unfolding document.

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Exercise 3: Creating a Sheet Metal Part with Dragged Edges TopSolid'Design - Sheet Metal Basics

The Unfolding Building 1 - Unbending methods search failed error message appears in the graphics area, which is
normal because we have modified the bending method.
 Click OK.
 From the Unfolding tab, select Unbending Methods Check to identify the problematic bends.
The R1 and R5 bends display errors.
 Use the Search command to find the tables. To do this, create a new Search document (Advanced tab) in
the Exercise 3 folder.
 In the Type field, select Unfolding Rules from the Special tab and click Apply.
 Indicate that the search must be carried out in all projects and enable the icon.
 Click the Refresh icon to start the search.

 The search results are displayed in the corresponding window. In the list, right-click on Steel Tables and
select Show in project tree.

The TopSolid Mechanical library opens.

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TopSolid'Design - Sheet Metal Basics Exercise 3: Creating a Sheet Metal Part with Dragged Edges

 Save the search document.

 From this library, copy the Steel Tables document and paste it in the current project, and then
rename it My steel table.
 Open the My steel table document and enter the description and part number.
 In the table, create the missing line for T=2 R=1.

 Repeat the procedure for T=2 R=5.

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Exercise 3: Creating a Sheet Metal Part with Dragged Edges TopSolid'Design - Sheet Metal Basics

 Save the My steel table document.

 Drag the My steel table document in the Roof part document.
 Save the part document.

 In the part document, make sure that the new unfolding rule has been taken into account by right-clicking
on the sheet and then selecting Others > Analyze Sheet Metal.

 Return to the unfolding document.

No error message should be displayed.

 Save the unfolding document.

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TopSolid'Design - Sheet Metal Basics Exercise 4: Creating a Sheet Metal Part with Swept Flange

Exercise 4: Creating a Sheet Metal Part with Swept Flange

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 4 - Sheet metal part with swept flange.
 Create a new Part document and rename it Door with swept flange.
 Draw the following sketch.

 Right-click on the sketch, select Sheet Metal on Sketch and create a 2mm thick sheet metal on the
sketch along Z+.

 Draw the following sketch on one of the side face.

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Exercise 4: Creating a Sheet Metal Part with Swept Flange TopSolid'Design - Sheet Metal Basics

 Confirm the sketch by clicking on .

 From the Sheet Metal tab, select Swept Flange and create the following swept flange on the four border
edges.

 Save the part document.

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TopSolid'Design - Sheet Metal Basics Exercise 4: Creating a Sheet Metal Part with Swept Flange

Creating the unfolding

 Right-click on the Door with swept flange part document's upper tab and select Unfolding.
 Select Blank Template and click to confirm.
 Click to confirm the Unfolding dialog box.

 Save the unfolding document.

Creating the draft

 Import the package Sheet Metal A3H Drawing.pkg.

 Right-click on the unfolding document and select Drafting to create the drawing of the Door with
swept flange part. Select Sheet Metal A3H Drawing as the template to be used.

 Save the drafting document.

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Exercise 5: Creating a Sheet Metal Part with Flange TopSolid'Design - Sheet Metal Basics

Exercise 5: Creating a Sheet Metal Part with Flange

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 5 - Door with flange.
 Create a new Part document and rename it Door with flange.
 Draw the following sketch.

 Right-click on the sketch, select Sheet Metal on Sketch and create a 2mm thick sheet metal on the
sketch along Z+.

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TopSolid'Design - Sheet Metal Basics Exercise 5: Creating a Sheet Metal Part with Flange

 Right-click on one of the shape's upper edge and select Flange.

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Exercise 5: Creating a Sheet Metal Part with Flange TopSolid'Design - Sheet Metal Basics

 Right-click on the previously created flange's upper edge and select Flange. Then select the three other
border edges.

Note: When selecting several edges, if the flanges intersect, then a trim is automatically performed. The default
trimming gap value is 0.1mm, but it can be modified in the Advanced Options dialog box.

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TopSolid'Design - Sheet Metal Basics Exercise 5: Creating a Sheet Metal Part with Flange

 Right-click on the previously created flange's upper edge and select Flange. Then select the three
other border edges.

 Save the part document.

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Exercise 6: Creating a Hood TopSolid'Design - Sheet Metal Basics

Exercise 6: Creating a Hood

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 6 - Hood.
 Create a new Part document and rename it Hood.
 Draw the following sketch.

 Extrude the sketch to a length of 50mm.

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TopSolid'Design - Sheet Metal Basics Exercise 6: Creating a Hood

 From the Sheet Metal tab, select Sheet Metal by Thickening and complete the dialog box as seen below.

 Click to confirm the sheet metal by thickening operation.

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Exercise 6: Creating a Hood TopSolid'Design - Sheet Metal Basics

 Right-click on the upper edge on the left side of the shape and select Flange.

Note: By enabling the Create sketches option, TopSolid creates a rectangular sketch for each flange. You are then
able to modify the flange shape by editing the corresponding sketch.

 Click to confirm the flange operation.

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TopSolid'Design - Sheet Metal Basics Exercise 6: Creating a Hood

 Right-click on the resulting flange, select Edit Sketch and modify the sketch as shown below. Use the
Parallelism constraint.

Note: For the 100mm and 70mm dimensions, use the Constraint command. Click on both entities, right-

click in the graphics area and select Linear Dimension.

 Confirm the sketch by clicking on .

Note: You can modify the sketch as you want, or add material to the sides or the front of the part.

 Right-click on the back flange opposite to the one you created and draw the following sketch.

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Exercise 6: Creating a Hood TopSolid'Design - Sheet Metal Basics

 Right-click on the sketch you created and select Trim by Profile.

Note: Make sure that you check the Straighten lateral faces box in order to make the edges perpendicular to the
sheet metal faces.
The Lateral Faces Straightening command is also available directly from the Sheet Metal tab.

 Right-click on the lower face and draw the following sketch.

 Confirm the sketch by clicking on .

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TopSolid'Design - Sheet Metal Basics Exercise 6: Creating a Hood

 From the Sheet Metal tab, select Bend Along a Line.

Warning: The Trimming Profile option allows you to trim the face to bend by a profile (open). This profile must
have two intersections with the bend line.
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Exercise 6: Creating a Hood TopSolid'Design - Sheet Metal Basics

 Hide the sketch.

 From the Shape tab, select Repetition and repeat the bend along a line procedure using a linear
pattern. Select the Operations option and uncheck the Replay operations box.
 For the pattern, enter the following settings.

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TopSolid'Design - Sheet Metal Basics Exercise 6: Creating a Hood

 Right-click on the lower face and draw the following sketch.

 Confirm the sketch by clicking on .

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Exercise 6: Creating a Hood TopSolid'Design - Sheet Metal Basics

 From the Sheet Metal tab, select Bend Along a Line.

 Save the document.

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TopSolid'Design - Sheet Metal Basics Exercise 7: Creating a Box

Exercise 7: Creating a Box

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 7 - Box.
 Create a new Part document and rename it Box.
 Draw the following sketch.

 Extrude the sketch to a length of 50mm.

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Exercise 7: Creating a Box TopSolid'Design - Sheet Metal Basics

 From the Sheet Metal tab, select Sheet Metal by Thickening and create the following sheet metal.

 Save the part document.

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TopSolid'Design - Sheet Metal Basics

Creating the unfolding

 Right-click on the Box part document's upper tab and select Unfolding.
 Select Blank Template and click to confirm.
 Click to confirm the Unfolding dialog box.

 Save the unfolding document.

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Exercise 8: Creating a Counter TopSolid'Design - Sheet Metal Basics

Exercise 8: Creating a Counter

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 8 - Counter.
 Create a new Part document and rename it Counter.
 Draw the following sketch.

 Extrude the sketch to a length of 600mm.

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TopSolid'Design - Sheet Metal Basics Exercise 8: Creating a Counter

 Select Sheet Metal by Thickening to create the following sheet metal.

 Generate the edge reliefs and bends using Relief Assistant.

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Exercise 8: Creating a Counter TopSolid'Design - Sheet Metal Basics

 Right-click the lower edge on the left side of the shape and select Flange. Then select the lower edge
on the right side of the shape as shown below. In the Bending Angle field, select Direction from the drop-
down list, and then select the lower edge as shown below.

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TopSolid'Design - Sheet Metal Basics Exercise 8: Creating a Counter

 Right-click on the lower edge as shown below and select Flange. Then click on the edge on the
opposite side.

 Select Covering and proceed as follows.

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Exercise 8: Creating a Counter TopSolid'Design - Sheet Metal Basics

 Continue using the Covering command to create another covering operation on the opposite side.

 Draw the following sketch on the shape's front face.

 Position the sketch as shown below.

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TopSolid'Design - Sheet Metal Basics Exercise 8: Creating a Counter

 Right-click on the sketch and select Pocket.

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Exercise 8: Creating a Counter TopSolid'Design - Sheet Metal Basics

 Right-click on the pocket operation and select Others > Repetition.

 Save the document.

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TopSolid'Design - Sheet Metal Basics Exercise 9: Creating a Container

Exercise 9: Creating a Container

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 9 - Container.
 Create a new Part document and rename it Container.
 From the Shape tab, select Block and create the following shape.

 Draw the following sketch on the side face.

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Exercise 9: Creating a Container TopSolid'Design - Sheet Metal Basics

 Right-click on the sketch and select Trim by Profile.

 Draw the following sketch on the top face.

 Draw the following new sketch on the oblique front face.

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TopSolid'Design - Sheet Metal Basics Exercise 9: Creating a Container

 From the Surface tab, select Imprint.

 From the Sheet Metal tab, create the following sheet metal using the Sheet Metal by Thickening
command.

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Exercise 9: Creating a Container TopSolid'Design - Sheet Metal Basics

 Select Slot and create the first slot as seen below.

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TopSolid'Design - Sheet Metal Basics Exercise 9: Creating a Container

 Create the second slot as shown below.

Note: The extra thicknesses correspond to the tool extrusions on the top and bottom faces. The extensions
correspond to the extension lengths of the subtraction tool at the edge of the sheet.

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Exercise 9: Creating a Container TopSolid'Design - Sheet Metal Basics

 Select Corner Relief to create the following corner reliefs.

 Select Edge Relief to create the following edge reliefs.

 Select Bend on Edge to create the following bends.

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TopSolid'Design - Sheet Metal Basics Exercise 9: Creating a Container

Note: By default, the bend is calculated up to the neighboring faces. The Delimit bends option allows you to
create a bend only on the length of the selected edge.

 Select Corner Filler and then click on the side faces of the corners, or check the All corners box.

Note: The Maximum of material method fills the hole to its maximum while the Minimum of material
method fills the hole to its minimum.

 From the Shape tab, select Pattern Union and then select a symmetrical pattern.

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Exercise 9: Creating a Container TopSolid'Design - Sheet Metal Basics

The result should look like the following image.

 Save the part document.

Creating the unfolding

 Right-click on the Container part document's upper tab and select Unfolding. Select Blank Template.
 Click to confirm the Unfolding dialog box.

 Save the unfolding document.

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TopSolid'Design - Sheet Metal Basics Exercise 10: Creating a Support

Exercise 10: Creating a Support

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 10 - Support.
 Create a new Part document and rename it Support.
 Select Block to create the following shape.

 Select Sheet Metal by Thickening to create the following sheet.

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Exercise 10: Creating a Support TopSolid'Design - Sheet Metal Basics

 Draw the following sketch on the front face using the Dynamic Symmetry mode.

 Select Slot to create the following slots.

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TopSolid'Design - Sheet Metal Basics Exercise 10: Creating a Support

 Select Bend on Edge to create the following bends.

 Right-click on the front upper edge and select Flange.

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Exercise 10: Creating a Support TopSolid'Design - Sheet Metal Basics

 Right-click on the left upper edge and select Flange.

 Right-click on the right upper edge and select Flange.

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TopSolid'Design - Sheet Metal Basics Exercise 10: Creating a Support

 Right-click on the sheet metal edge of the left upper bend and select Covering.

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Exercise 10: Creating a Support TopSolid'Design - Sheet Metal Basics

 Right-click on the sheet metal edge of the right upper bend and select Covering.

 From the Sheet Metal tab, select Unbending of Bend.

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TopSolid'Design - Sheet Metal Basics Exercise 10: Creating a Support

 Draw the following sketch on the inner face. Center the circle in the middle of the bend using the

Centering constraint.

 Right-click on the sketch and select Pocket. In the Limit field, select Through all in the drop-down list.

 From the Sheet Metal tab, select Rebending of Bend.

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Exercise 10: Creating a Support TopSolid'Design - Sheet Metal Basics

 From the Sheet Metal tab, select Unbending of Bend.

 Draw the following sketch on the inner face.

 Right-click on the sketch and select Trim by Profile.

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TopSolid'Design - Sheet Metal Basics Exercise 10: Creating a Support

 From the Sheet Metal tab, select Rebending of Bend. Check the All flat bends box.

The result should look like the following image.

 Save the part document.

Creating the unfolding

 Right-click on the Support part document's upper tab and select Unfolding. Select Blank Template.
 Click to confirm the Unfolding dialog box.

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 TopSolid'Design - Sheet Metal Basics

 From the Unfolding tab, select Unfolding Dimensioning.

 Save the unfolding document.

Creating the drafting document

 Create a Drafting document from the Support part document. Select Part A3 ISO Landscape as the
template to be used.
 Drag the unfolding document to the drafting document.

 Save the drafting document.

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TopSolid'Design - Sheet Metal Basics Exercise 11: Creating a Sheet Metal from a Casing Step File

Exercise 11: Creating a Sheet Metal from a Casing Step File

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 11 - Sheet metal from casing step file.
 Right-click on the folder and select Import/Export > Import File with Conversion. Open the file labeled
Casing.stp, and then enter the following import settings.

 From the Simplification and sewing tab, enable Simplify geometry and Sew sheet bodies options.

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Exercise 11: Creating a Sheet Metal from a Casing Step File TopSolid'Design - Sheet Metal Basics

 From the Sheet Metal tab, select Sheet Metal Recognition.

 Save the part document.

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TopSolid'Design - Sheet Metal Basics Exercise 12: Creating an Assembly using Step Recovery

Exercise 12: Creating an Assembly using Step Recovery

Concepts addressed:
- Recovering a 3D file
- Editing a 3D file
- Creating partial parts

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 12 – Assembly using Step recovery.
 Right-click on the folder and select Import/Export > Import File with Conversion. Open the file
mk2 aircraft.stp.

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Exercise 12: Creating an Assembly using Step Recovery TopSolid'Design - Sheet Metal Basics

 From the Simplification and sewing tab, enable the Simplify geometry and Sew sheet bodies options.

 Analyze the file to know how to unfold and divide it.

We are going to divide the wings into two pieces:

- left side mk2
- right side mk2
 Open the part file left side mk2.

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TopSolid'Design - Sheet Metal Basics Exercise 12: Creating an Assembly using Step Recovery

 Create a trim by profile.

 From the Tools tab's pull-down menu, select Derivations > Partial Parts.
This operation has created all the part documents in the Project tree.

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Exercise 12: Creating an Assembly using Step Recovery TopSolid'Design - Sheet Metal Basics

 Repeat the procedure for the right side mk2 file.

 From the Project tree, select all the documents in the mk2 aircraft folder.

 Right-click and select Sheet Metal, and then select Sheet Metals Recognition.

 Click to confirm the window.

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TopSolid'Design - Sheet Metal Basics Exercise 12: Creating an Assembly using Step Recovery

 From the Project tree, select all the documents in the mk2 aircraft folder.

 Right-click on the selected documents and select Sheet Metal > Unfoldings.

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Exercise 12: Creating an Assembly using Step Recovery TopSolid'Design - Sheet Metal Basics

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Creating a Box with Manual Corner and Edge Reliefs

Additional Exercise: Creating a Box with Manual Corner and Edge

Reliefs

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 13 - Box with manual corner and edge reliefs.
 Create a new Part document and rename it Box with manual corner and edge reliefs.
 Draw the following sketch.

 Extrude the sketch to a length of 50mm.

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Additional Exercise: Creating a Box with Manual Corner and Edge Reliefs TopSolid'Design - Sheet Metal Basics

 From the Sheet Metal tab, select Sheet Metal by Thickening to create the following sheet metal.

 Select Corner Relief and create the following corner reliefs.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Creating a Box with Manual Corner and Edge Reliefs

 Select Edge Relief and create the following edge reliefs.

 Select Bend on Edge to create the following bends.

 Save the part document.

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Additional Exercise: Creating a Box with Manual Corner and Edge Reliefs TopSolid'Design - Sheet Metal Basics

Creating the unfolding

 Right-click on the part document's upper tab and select Unfolding. Select Blank Template.

 Click to confirm the Unfolding dialog box.

 Return to the part document and edit the corner relief operations. In the Advanced Options dialog box,
check the Extract on unfolding option.
 Save the part document.
 Return to the unfolding document to view the result.

TopSolid has automatically updated the unfolding by extracting the corner reliefs.

 Save the unfolding document.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Forming Component Without Added Material

Additional Exercise: Forming Component Without Added Material

Concepts addressed:
- Creating a subtraction shape
- Creating parameters
- Providing a function
- Creating a family

 From the Project tree, create a new folder named Exercise 14 - Forming component without added
material.
 Create a new Part document and rename it Keyhole.
 Draw the sketch shown below and create the following parameters:
- D1 = Large diameter
- D2 = Small diameter
- A = Center distance

 Extrude the sketch to a length TH = 2mm.

Note: The height of the extruded shape must be equal to the thickness parameter of the sheet metal.

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Additional Exercise: Forming Component Without Added Material TopSolid'Design - Sheet Metal Basics

Providing the sheet metal function

 From the Tools tab's pull-down menu, select Functions > Provide Function.
Note: Here, we only need to perform a subtraction operation.
 Select Standard Forming Subtraction from the drop-down menu and check the Create parameter option.

Now we will associate the parameters and the shape with the function.

Note: In our case, the parameter, the thickness, the positioning frame and the shape are enough.

 Define the document as a virtual document via File > Virtual Document.

 Save the document.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Forming Component Without Added Material

 From the Project tree, right-click on the Keyhole part document and create a Family document.
 In the Entities tree, from the Generics folder move the D1, D2, A and TH parameters to the Drivers folder
of the family.

Note: This is done to create dimensional drivers when inserting the family in the part file.

 Save the document and check the document into the vault.

 Create a new Part document and rename it Front.

 Draw the following sketch.

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Additional Exercise: Forming Component Without Added Material TopSolid'Design - Sheet Metal Basics

 Create the following sheet metal on sketch.

 Select Standard Forming.

 Save the document.

76 Missler Software
TopSolid'Design - Sheet Metal Basics Additional Exercise: Forming Component with Added Material

Additional Exercise: Forming Component with Added Material

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 15 - Forming component with added material.
 Create a new Part document and rename it Hook.
 Create the following extruded shape corresponding to the addition of 2mm thick material.

Warning: The sketch MUST be created on the XZ plane.

 Create the tool shape corresponding to the hook housing.

Note: The height of the extruded shape must be equal to the thickness parameter of the sheet metal.

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Additional Exercise: Forming Component with Added Material TopSolid'Design - Sheet Metal Basics

Providing the sheet metal function

 From the Tools tab's pull-down menu, select Functions > Provide Function.
 Select Standard Forming Subtraction and Union and check Create parameter.

 After validation, hide the two shapes.

 Change the value of the sheet metal thickness = Function thickness.
 Change the value of the extruded shape = Function thickness.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Forming Component with Added Material

Now we will associate the parameters and the shape with the function.
 From the Entities tree, open the Functions folder and double-click on the Standard Forming Subtraction and
Union function

 Save the document.

Creating a symbol
 Draw a sketch corresponding to the cutting symbol.

Warning: The sketch MUST be created on the XZ plane.

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Additional Exercise: Forming Component with Added Material TopSolid'Design - Sheet Metal Basics

Providing the sheet metal function

 From the Tools tab's pull-down menu, select Functions > Provide Function.
 Select Standard Forming Unfolding Section.

 Click on the previously created sketch.

Using the component

 Create a new Part document and rename it Front.
 Draw the following sketch.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Forming Component with Added Material

 Create the following sheet metal on sketch.

 Select Standard Forming.

Note: If this component is only used on 2mm sheets, it is not necessary to create a family of parts to manage the
thickness.

 Save the document.

 Create the unfolding document.

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Additional Exercise: Creating a Sheet Metal Part with Forming Flange TopSolid'Design - Sheet Metal Basics

Additional Exercise: Creating a Sheet Metal Part with Forming

Flange
Concepts addressed:
- Creating a forming flange
- Creating a derived part
- Straightening a forming flange

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 16 - Sheet metal part with forming flange.
 Create a new Part document and rename it Sheet metal part with forming flange.
 Draw the following sketch.

 Right-click on the sketch and select Sheet Metal on Sketch. Create the following sheet metal.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Creating a Sheet Metal Part with Forming Flange

 Right-click on the back upper border edge and select Flange.

 Draw the following sketch.

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Additional Exercise: Creating a Sheet Metal Part with Forming Flange TopSolid'Design - Sheet Metal Basics

 Right-click on the sketch and select Drilling Group.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Creating a Sheet Metal Part with Forming Flange

 From the Sheet Metal tab, select Swept Flange and create a flange on the following border edges.

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Additional Exercise: Creating a Sheet Metal Part with Forming Flange TopSolid'Design - Sheet Metal Basics

 Open the Sheet metal part with forming flange (Derived) part document, and then from the Sheet Metal tab
select Forming Flange Straightening and perform the straightening operation on the four edges shown
below.

 Save the part document.

Creating the unfolding

 Right-click on the Sheet metal part with forming flange (Derived) part document's upper tab and select
Unfolding. Select Blank Template.
 Click to confirm the Unfolding dialog box.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Creating a Sheet Metal Part with Ball Corner

Additional Exercise: Creating a Sheet Metal Part with Ball Corner

Concept addressed:
- Opening a ball corner

Creating a sheet metal part

 From the Project tree, create a new folder named Exercise 17 - Sheet metal part with ball corner.
 Create a new Part document and rename it Tub.
 Create the following shape.

 Select Sheet Metal by Thickening to create the following sheet.

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Additional Exercise: Creating a Sheet Metal Part with Ball Corner TopSolid'Design - Sheet Metal Basics

 From the Tools tab's pull-down menu, select Derivations > Derived Part.
 In the current window, select the target project and click to confirm.

 Keep the default entities selected and click to confirm.

The derived part previously created appears in the Project tree.

 Open the Tub (Derived) part document, and then from the Sheet Metal tab select Edge Relief and create
the following edge reliefs.

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TopSolid'Design - Sheet Metal Basics Additional Exercise: Creating a Sheet Metal Part with Ball Corner

 Select Forming Flange Straightening.

 Repeat the procedure on every ball corner.

The result should look like the following image.

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Additional Exercise: Creating a Sheet Metal Part with Ball Corner TopSolid'Design - Sheet Metal Basics

 Select Slot to create the following slot.

 Save the part document.

Creating the unfolding

 Right-click on the Tub (Derived) part document's upper tab and select Unfolding. Select Blank
Template.
 Click to confirm the Unfolding dialog box.

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TopSolid'Design - Sheet Metal Basics Annexes

Annexes
Unfolding and unbending processes

General considerations
The unfolding process provides the part geometry as obtained after the first shaping by cutting operations:
punching, shearing, fluid cutting. The machines used can also produce additional machining operations: local
deformations, tapped holes, etc.

Generally, unbendable sheet metals and sheet metals which cannot be unbended may be distinguished.
For unbendable sheet metals, the methods of calculating the lengths on the unfolding are described below.

Methods for calculating the unrolled length of a bend

When performing a bend, the material is compressed inside the bend and stretched outside the bend. Between
these two zones, there is a part named "neutral fiber" which is neither stretched nor compressed.
A bend is considered to be modeled by two cylindrical surfaces; one for the internal face and the other for the
external face. These two faces are equidistant from the thickness value.
This neutral fiber is modeled as being located at a constant distance from the internal face of the bend. Its
position is therefore determined on the basis of a thickness coefficient.
In practice, there is no guarantee that the neutral fiber is divided that easily between the two bend faces, or that
these two bend faces are cylindrical and equidistant. However, this model is accurate enough for our purpose.

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Annexes TopSolid'Design - Sheet Metal Basics

In contrast, when unrolling a bend, we need to know the flat length to be obtained. This length is a function of:
- The material
- The thickness
- The bending angle
- The inner bending radius
- The bending process (even if it is highly correlated with the bending angle)

The calculation of this flat length is usually obtained through the use of standard calculation methods. These
calculation methods consist of two parts:
- First the calculation of a basic length obtained by applying analytical formulas that model the
bending/unbending process in a more or less accurate way.
- Then the application of a correction to this basic calculation, whose values generally result from
measurements made on actual cases.
These calculation methods are extended by analogy to all the unrolling methods supported by the unfolding
calculation (unrolling of a cone, unrolling of an extruded face, etc.).

Methods for calculating the basic length

- L: Unrolled length
- T: Thickness
- R: Inner bend radius
- A: Bending angle (measured angle)
- K: Neutral fiber coefficient

Calculations by neutral fiber

These calculations provide the length of a neutral fiber located at a given position.
- User neutral fiber: L = (R + K . T) . (Pi – A).
With K between 0 and 1, given by the user.
- DIN6935 neutral fiber: L = (R + K . T) . (Pi – A).
With K = (0.65 + 0.5 . log(R / T) ) / 2.
- Theoretical neutral fiber: L = (R + K . T) . (Pi – A).
With for K:
Ratio = R / T
K0 = 0
Ratio1 = 1
K1 = 0.27
Ratio2 = 4
K2 = 0.5

If Ratio < Ratio1, then K = K0 + Ratio. (K1 - K0) / (Ratio1 - 0).

If Ratio > Ratio1 and Ratio < Ratio2, then K = K1 + Ratio. (K2 - K1) / (Ratio2 - Ratio1).
If Ratio > Ratio2, then K = K2.

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TopSolid'Design - Sheet Metal Basics Annexes

Loss calculations on draft

The reported lengths correspond to the internal or external lengths obtained by deleting the bending radius.
- Internal dimension + shift coefficient.
L = 2 . (R + K . T) . Tan((Pi – A) / 2).
- External dimension + shift coefficient.
L = 2 . ((R + T) - K . T) . Tan((Pi – A) / 2).
- External tangent dimension + shift coefficient.
L = 2 . ((R + T) - K . T) . Tan((Pi – Max(A, Pi / 2)) / 2).

These lengths are calculated for the different types of basic calculations. Green is for the neutral fiber, blue for
the internal dimension, orange for the external dimension and purple for the tangent dimension (shown in orange
in the first two diagrams above).

Corrections
They result from measurements that are usually made by bending machine manufacturers or users.

Equivalent K factor
Regardless of the calculation mode of the flat length, particularly when applying a correction value to the chosen
analytical calculation, it is always possible to derive an equivalent K factor. This concept is important because it
shows that there are several different ways to calculate the right dimensions of an unfolding.

Usual behavior of standard steels

In general, the unfolding lengths on standard steels are reasonably well approximated by a neutral fiber
calculation with K factor values between 0.3 and 0.5.
More specifically, when R is close to T, we can set the K value close to 0.3. The more important the bending
radius, the more the neutral fiber comes closer to the internal face of the bend (K approaches 0). When R gets
large compared to T, K takes values close to 0.5. This can be assimilated to rolling processes.
The "theoretical" basic calculation method gives a good overview of this behavior.

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Annexes TopSolid'Design - Sheet Metal Basics

Management of unfolding/unbending methods

Strictly speaking, the bending die/punch combination totally determines the calculation mode to be applied.
In this combination, the bending die is predominant since it imposes the radius of the bending punch, the V-width
and thus the length of the shortest edge that can be bent. It also imposes the kind of bending (air bending or
coining – bottoming).
The shape and the punch length depend on the bend to be performed. However, they determine the effort to be
made to perform the bend.
A bending die can be used to bend parts of different thicknesses, on different materials, but comparable in terms
of mechanical behavior.
To calculate the unfolding lengths of a given part, you will have to specify:
- The basic calculation type, as well as associated parameters
- The neutral fiber coefficient (K factor)
- The correction value to be applied
- Other user parameters

Each of these data may vary depending on:

- The part material
- The part thickness
- The die ( bending radius)
- The bending angle
- The tool used

In the following table, only the bending radius is indicated without being associated with a bending tool.
T = 1mm
R 1.0mm 1.3mm 1.6mm 2.0mm
A T K C T K C T K C T K C
0° CCT 0 0.2 CCT 0 0.6 CCT 0 1 CCT 0 1.6

15° CCT 0 -0.2 CCT 0 0.2 CCT 0 0.5 CCT 0 0.9

30° CCT 0 -0.5 CCT 0 -0.3 CCT 0 0 CCT 0 0.3

45° CCT 0 -0.9 CCT 0 -0.7 CCT 0 -0.5 CCT 0 -0.3

60° CCT 0 -1.2 CCT 0 -1.1 CCT 0 -1.1 CCT 0 -1

75° CCT 0 -1.6 CCT 0 -1.6 CCT 0 -1.6 CCT 0 -1.6

90° CCT 0 -1.9 CCT 0 -2.0 CCT 0 -2.1 CCT 0 -2.2

105° CCT 0 -1.3 CCT 0 -1.4 CCT 0 -1.4 CCT 0 -1.5

120° CCT 0 -0.9 CCT 0 -0.9 CCT 0 -0.9 CCT 0 -1

135° CCT 0 -0.6 CCT 0 -0.6 CCT 0 -0.6 CCT 0 -0.6

150° CCT 0 -0.4 CCT 0 -0.4 CCT 0 -0.4 CCT 0 -0.4

165° CCT 0 -0.2 CCT 0 -0.2 CCT 0 -0.2 CCT 0 -0.2

(180°) CCT 0 - CCT 0 - CCT 0 - CCT 0 -

Amada sources.

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TopSolid'Design - Sheet Metal Basics Notes

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Notes TopSolid'Design - Sheet Metal Basics

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TopSolid'Design - Sheet Metal Basics Notes

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 ...............................................................................................................................................................................................................................................................
Individual Course Evaluation Form TopSolid'Design - Sheet Metal Basics

Individual Course Evaluation Form

(To be completed and returned to the training instructor at the end of the course)

TopSolid’Design 7 – Sheet Metal Basics

Name : .........................................................................................................................................................
Company : .........................................................................................................................................................
Date(s) from ................................................................ to ............................................................................
By completing this individual evaluation form, you are helping to improve the quality and usefulness of the training provided in the future. Please complete it
carefully.

Number of people during the course: Onsite at your company? YES □ NO □

GENERAL ASSESSMENT Poor Average Good Excellent

Overall, this course has been: □ □ □ □

What grade would you assign? 0 1 2 3 4 5 6 7 8 9 10

LOGISTIC Poor Average Good Excellent

Orientation (quality, organization, user-friendliness, etc.) □ □ □ □
Physical setup (room, materials, etc.) □ □ □ □

TRAINING Poor Average Good Excellent

Instructor's teaching method □ □ □ □
Group relationship (participation, sharing of experiences) □ □ □ □
Quality and clarity of educational materials (documentation) □ □ □ □
Balance between Theory and Practice □ □ □ □
Consistent presentations with what has been announced □ □ □ □
Training Content □ □ □ □

DURATION No Somewhat no Somewhat yes Yes

Does the overall duration of the course seem appropriate? □ □ □ □
If no, was it? Too short □ Too long □

PACE No Somewhat no Somewhat yes Yes

Does the overall pace of the course seem appropriate? □ □ □ □
If no, was it? Too slow □ Too fast □

USE OF ACQUIRED KNOWLEDGE IN THIS TRAINING No Somewhat no Somewhat yes Yes

Have you found this training to be useful in your work? □ □ □ □
Do you think you can put the acquired knowledge into use quickly? □ □ □ □
Do you believe that you have achieved your objectives
upon completion of this course? □ □ □ □

Comments and suggestions: ............................................................................................................................................

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