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Fundamentals of
Sheetmetal Design
Release 2001
T780-320-01
Copyright
Fundamentals of Sheetmetal Design
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PRINTING HISTORY
Document No. Date Description
T780-320-0A 06/14/01 Initial Printing of Fundamentals of Sheetmetal Design for Release 2001
T780-320-01 06/21/01 Revisions
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Training Agenda
Fundamentals of Sheetmetal Design
Day 1
Introduction to Sheetmetal Design
Primary Walls
Secondary Walls
Unbend, Bend back and Cuts
Notches and Punches
Day 2
Duplicating Features
Sheetmetal Forms
Bend Features
Unbending Sheetmetal Geometry
Sheetmetal Design Environment
Day 3
Converting Solid Parts
Project Laboratory
Documenting Sheetmetal Design
Sheetmetal Design Information
Table of Contents
Fundamentals of Sheetmetal Design
Objectives
After completing this module, you will be able to:
Page 1-1
NOTES
DESIGNING IN PRO/SHEETMETAL
Using Pro/SHEETMETAL to generate sheetmetal components enables
you to do the following:
You can select the default template or choose one from a list of standard
or user customizable templates. When you use a template that contains
designated parameters, you can enter parameter values as you create the
model. Templates include default datum planes, coordinate system, saved
views, and layers.
Note:
Create features in an order that captures your design intent, not
in the order that you manufacture the geometry.
Developed Length
Pro/ENGINEER automatically compensates for stretching that occurs in
the area of a bend by calculating the developed length. The system takes
into account the thickness of the sheetmetal, the radius of the bend, the
bend angle, and other material properties. This capability enables you to
capture your design intent through the creation of the formed sheetmetal
model. It also enables you to create a flat form of the model for
manufacturers to use to develop the actual model.
Design
Information
Planning
Creating product structure
Sharing design-critical information
Capturing interactions between individual components
Top-down design can be conceived as an ongoing process of capturing,
communicating, and managing design information. It is the best
methodology to harness and control Pro/ENGINEERs associative design
tools when conceptualizing and building large assemblies.
Assemble
Components
Often, after creating the assemblies, a designer discovers that the models
do not meet the design criteria (for example, a critical interface on two
models does not match).
The skeleton model stores design intent at different levels of the product
structure. Various Pro/ENGINEER data-sharing features such as Copy
Geometry and Shrinkwrap can be used to communicate and propagate
the design intent from level to level and from model to model.
Many methods exist for populating the assembly structure with detailed
parts. Existing components can be assembled, or components can be
created in the context of the assembly. These individual parts can be
related to each other using other functionality such as assembly relations,
skeleton models, layouts, and merge features to further capture design
intentions.
Layouts
Layouts are central locations in which you can capture non-geometrical
top-level design criteria. A layout is useful when you do not have exact
information about the geometry. Dimensions, parameters, and relations
defined in a Layout can be parametrically linked to skeletons or part
models.
Skeletons
Skeletons are central locations where you can capture geometrical central
design information for a model. You can use skeleton models to represent
the design information in a layout in a 3-D representation. There are three
typical uses for skeletons:
Space claim (form / fit)
Reference Control
The EXTERNAL REFERENCE CONTROL dialog box allows you to define
the allowable scope for external references. This function is particularly
useful when designing in an assembly, or when creating Copy Geometry
features.
Figure 17: Reference Graph and Global Reference Viewer Dialog Boxes
7. Create a family table for each sheetmetal part that includes at least
two instances, flat state instance and the as designed instance.
MODULE SUMMARY
In this module, you have learned about:
Primary Walls
In this module you learn how to create primary walls. The first
sheetmetal feature must be a wall. You learn how to create
unattached walls and merge them with the final geometry.
Objectives
After completing this module, you will be able to:
Page 2-1
NOTES
WALL TYPES
Pro/SHEETMETAL gives you the ability to create two types of walls:
Primary Walls Do not need another wall in order to exist, and are
created as unattached walls.
Secondary Walls Must be attached to another wall because they
cannot exist independently, and are always a child of another wall.
Note:
You can also use advanced feature creation options like
variable section sweep, swept blend, and so on to create
primary walls.
Sketching Techniques
When creating an extruded wall, you insert bends to represent inside and
outside radii. Usually, you dimension all bends in sheetmetal parts to the
inside. You use the Thicken option to thicken the material and dimension
the offset edges, as shown in the following figure.
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 the following figure.
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to create the primary wall of a sheetmetal
part as an unattached extruded wall, then create additional unattached
walls and merge the final geometry.
Method
In the first exercise, you develop the lower housing of a cable box. You
thicken the extruded wall and apply an inside bend radius.
In the second exercise, you create two unattached offset walls and merge
them to complete the geometry of an assembly component using the top-
down design.
Tools
Icon Description
Primary Wall creation fly-out icons.
Unattached Flat Wall.
Revolved Wall
Blended Wall
Offset Wall.
Punch
Notch
Rip
Merge Walls
Done
Note:
Ask your instructor for assistance if you cannot find the
working directory or if it different for the classroom from what
is stated in the previous step.
5. Click OK .
1. Click File > New and select Assembly as the TYPE. Type
[connector] as the name of the assembly as shown in the
following figure.
2. Click OK .
Select these
two surfaces
7. Click Indiv Surfs from the SURF OPTIONS menu. Select the same
set of surfaces on the other side of the plastic shield as shown in
the following figure.
9. Click Misc Refs > Define from the COPY GEOMETRY dialog box.
10. Click Dtm Plane from the MISC REFS dialog box.
11. Click Sel by Menu . This will open up the SELECTION TOOLS
dialog box.
13. Click Sel All and Select from the SELECTION TOOLS dialog box,
as shown in the following figure.
14. Click Done Sel . The datum planes should appear in the MISC
REFS dialog box, as shown in the following figure.
Note:
The Copy Geometry feature becomes the first feature of the
connector shield part using the references from the assembly.
This Copy Geometry feature will become the parent of all the
features in the part and will automatically propagate any
changes made at the assembly level.
3. Select the surface on the right-hand side, as shown using the black
cursor in the following figure.
4. This will automatically select the quilt on the other side of the part,
since both the surfaces belong to the same copy geometry feature.
Type [0] as the offset value and press <ENTER>.
5. If necessary, flip the arrow outward (to the right), as shown in the
following figure. Click Okay .
Task 4. Create an unattached flat wall that spans the gap between the
two offset walls.
2. Select the FRONT datum plane as the sketching plane. Flip the
arrow outward, as shown in the following figure.
Note:
Keep in mind that the direction of viewing is also the direction
in which Pro/ENGINEER adds the material thickness.
3. Click Okay.
2. Select the small bend surface on the right hand offset wall and
click Done Sel > Done Refs .
3. Select the back green surface of the flat wall and click Done Sel >
Done Refs again, as shown in the following figure.
Figure 30: Merging the Flat Wall with the First Offset Wall
4. Click OK .
5. Create another merge feature for the other offset wall on the left
side. Repeat the above steps.
MODULE SUMMARY
In this module, you have learned:
Secondary Walls
In this module you learn how to create secondary walls
Objectives
After completing this module, you will be able to:
Page 3-1
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
the following figure.
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 the following
figure. The green or white surfaces of the attachment edge do not
necessarily have to be planar.
Se c o n d a ry Wal ls Pag e 3- 3
NOTES
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 the following figure. This bend deforms a portion of the existing
attachment wall.
You can also partially extrude a wall along an edge using a blind depth
and relief, as shown in the following figure.
Swept, Use Radius You can sketch the section for the wall, and
then specify the radius, as shown in the following figure. 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.
Resulting Geometry
The Use Radius option produces different results, depending on the
attachment edge that you select, as shown in the following figures.
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
Se c o n d a ry Wal ls Pag e 3- 5
NOTES
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.
Aligned to
inside edge
To generate the twisted geometry, you must specify the following values:
Se c o n d a ry Wal ls Pag e 3- 7
NOTES
Open Corner
Rip relief At the wall attachment points, rip the existing material
normal to the edge and back to the tangent line as shown in the
following figure.
Se c o n d a ry Wal ls Pag e 3- 9
NOTES
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to create secondary walls with relief.
Method
In the first exercise, you create secondary walls using different types of
automatic relief.
In the second exercise, you create secondary walls and create additional
extruded and extended walls to close gaps in the geometry.
Tools
Icon Description
Flat Wall fly-out icons
Extended Wall
Unbend
Bendback
Done
Se c o n d a ry Wal ls Pag e 3- 11
NOTES
Task 1. Create a FLAT, USE RADIUS wall with OBROUND relief on one
end of the cable box base.
3. Click Part Bend Tbl > Done/Return > Inside Rad >
Done/Return .
4. Select the lower green edge to attach the wall, as shown in the
following figure.
11. Click w/Relief > Done . A point on the attachment edge highlights
at the end of the new wall.
12. Click ObrndRelief > Done for the first end of the wall.
13. Click Enter Value , type [0.20] for the reliefs width and press
<ENTER>.
15. Define the same relief for the other end of the wall. Repeat the
above steps.
16. Click Enter Value , type [0.13] for the bend radius value and press
<ENTER>.
17. Click OK to complete the feature. The part should appear as shown
in the following figure.
Se c o n d a ry Wal ls Pag e 3- 13
NOTES
1. Create a similar flat wall on the opposite end of the cable box. Use
Obround relief on both ends of the wall. Repeat the above steps
that you used to create the previous wall. The part should appear as
shown in the following figure.
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.
3. Click Part Bend Tbl > Done/Return > Inside Rad >
Done/Return .
Se c o n d a ry Wal ls Pag e 3- 15
NOTES
12. Click Rip relief > Done twice for both ends of the wall.
13. Click Enter Value , type [.05] as the bending radius value and
press <ENTER>.
2. Click Part Bend Tbl > Done/Return > Inside Rad >
Done/Return .
4. Select the top white edge to attach the wall, as shown in the
following figure.
Se c o n d a ry Wal ls Pag e 3- 17
NOTES
6. Click Flip for the viewing direction. (Arrow should point away
from the model).
8. Sketch the section as shown in the following figure. Make sure that
the endpoint passes through the Sketcher point provided by the
system. Align the other end to the dimensional reference that you
selected in the previous step.
10. Finish the wall definition using Rip relief on both ends. Type
[.05] as the bending radius value and press <ENTER>. The part
should appear as shown in the following figure. The walls that you
created using two different methods look identical.
Task 3. Extend the flat wall to the outside of the side walls.
3. Click Query Sel to select the hidden inside surface of the side wall
to define the extension distance.
Se c o n d a ry Wal ls Pag e 3- 19
NOTES
5. Create another wall extension on the other end of the flat wall
using the references shown in the following figure.
Task 4. Use Extruded walls to create tabs on the back wall of the model
to close the gap.
Se c o n d a ry Wal ls Pag e 3- 21
NOTES
9. Click Sketch > Feature Tools > Thicken to set the thickness of
the wall. Click [Done] from the Sketcher.
11. Add another Extruded No Radius wall to the other side of the
wall to fully close up the cover. Repeat the above steps. The
completed part should appear as shown in the following figure.
Task 5. Determine if any of the walls that you created overlap in the
unbent state of the model.
1. Click [Unbend].
Se c o n d a ry Wal ls Pag e 3- 23
NOTES
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.
Automatic relief can be added to walls when necessary.
Se c o n d a ry Wal ls Pag e 3- 25
Module
Objectives
After completing this module, you will be able to:
Page 4-1
NOTES
Unbend All
You select a plane or edge to remain fixed while unbending the part with a
flat pattern feature. The flat pattern feature will automatically reorder itself
to be the last feature in the model tree even if walls and bend features are
added after the flat pattern was created.
The Flat Pattern is an unbend feature created to display the fully flat
condition of the design model. A Flat State instance should be created in
order to document both the fully formed Design State and the fully flat
state of a sheetmetal part.
Note:
When a sheetmetal wall overlaps and intersects in the unbent
position, the system highlights it and issues a warning.
Solid cut
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 easier to design sheetmetal
parts in the completely bent condition. When you create an unbend
feature, it is important to select sketcher references carefully. See the
example in the following figure.
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to create sheetmetal cuts across bent
geometry that result in flat contours.
Method
In this exercise, you create a wall with two bends. You create an unbend
feature followed by a sheetmetal cut. A bend back feature is then created,
but with a contour remaining flat.
Tools
Icon Description
Primary Wall fly-out icons.
Done
Unbend
Bend back
4. Select the FRONT datum plane as the sketching plane. Accept the
default direction. Select the TOP datum plane as the Top reference
plane.
7. Click [Done].
8. The arrow should point outward. Click Okay . Type [.5] as the
thickness and press <ENTER>.
1. Click [Unbend].
Select this
surface to
remain fixed
4. Click Unbend All > Done and click OK to complete the feature.
1. Click Insert> Create > Sheet Metal Cut > Thin from the pull-
down menu.
2. Select the large top surface as shown in the following figure as the
sketching plane.
5. Sketch three line segments for the cut, and dimension the cut as
shown in the following figure.
7. Type [0.25] for the width of the cut feature and press <ENTER>.
8. Click Thru Next > Done for the depth of the cut. Click OK to
complete the feature. The completed feature should appear as
shown in the following figure.
2. Select the same surface that you used for the unbend feature to
remain fixed, as shown in the following figure.
Select this
surface to remain
fixed
6. Type [yes] at the prompt for the contour to remain flat and press
<ENTER>.
MODULE SUMMARY
In this module, you have learned:
Objectives
After completing this module, you will be able to:
Page 5-1
NOTES
In Pro/ENGINEER notches and punches 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.
The following figure shows examples of notches and a punch that can be
defined with user-defined features (UDF).
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:
2. Create a cut feature. Sketch the desired section for the punch or
notch. Be sure to include the coordinate system. When you align
and dimension, 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.
Note:
If you set up relations for the feature, it reduces the number of
variable dimensions you have to type when placing the punch
or notch.
4. Click Create , then type the name of the UDF. The UDF OPTIONS
menu displays.
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.
10. The SYMMETRY menu displays to define the symmetry of the tool
relative to the feature coordinate system. Click one of the options.
12. Click OK in the dialog box. The system creates and stores the UDF.
Notes:
All punch and notch UDF feature attributes, including Tool
Name and Symmetry Flags, can be redefined after the UDF
has been placed on the base part.
4. The SCALE menu appears. Click one of the first two options, then
click Done .
5. The DISP OPTION menu displays. Click one of the first three
options, then click Done .
LABORATORY PRACTICAL
Goal
The goal of this laboratory 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 this exercise, you create a cut that is used to define a UDF. The UDF is
then used to define notch features in the flat state of another part.
Tools
Icon Description
Unbend and Bend back fly-out icons
Unbend
Bend back
SMT cut
Sketcher coordinate system and point fly-out icons
Sketcher coordinate system
Done
Relief fly-out icons
Notch
1. Open SQUARE_NOTCH_REF.PRT.
Surface to
remain fixed
Figure 3: SQUARE_NOTCH_REF.PRT
2. Click [Unbend].
3. Click Regular > Done . Select the top surface to remain fixed as
shown in the above figure.
Sketching plane
Bottom reference
plane
Select vertical
tangent bend edge
as a reference
Select horizontal
axis A_2 as a
reference
11. Click Okay to remove the material from the inside of the section
4. Select the square sheetmetal cut that you just created in the
previous task.
6. Type [Y] to confirm that you are defining a UDF for a notch and
press <ENTER>.
Note:
The section of the cut and the axes will be highlighted in blue
along with the reference that you are entering the prompt for.
Vertical bend
axis (A_1)
Placement plane
(vertical bend
surface)
End surface
(small horizontal
bend surface)
Vertical bend
tangent edge
Horizontal bend
axis (A_2)
10. Click Var Elements > Define from the FEATURE dialog box, as
shown in the following figure.
12. Check the MaterialSide option from the SEL ELEMENT dialog
box.
Task 4. Place the UDF on the tuner cover model to create notch relief at
the corners.
2. Click [Notch].
4. Type [yes] to retrieve the reference part and press <ENTER>. You
can use the reference part to help place the UDF.
5. 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.
Vertical bend
axis
End surface
Horizontal bend
axis
10. Add the notch relief to the other three corners on the part repeating
the above steps. Make sure that the Material Side is towards the
inside of the cut section when you place the notches.
Add the
other
three
notches
MODULE SUMMARY
In this module, you have learned that:
Duplicating Features
In this module, you learn the different options available for
duplicating features in sheetmetal models.
Objectives
After completing this module, you will be able to:
Page 6-1
NOTES
Creating Patterns
Pattern instances can affect the dimensioning scheme of your model and
the order in which you create features. Therefore, before using patterns in
a model, you should perform some work in advance.
Dimension Patterns
The default method for creating a dimension pattern is to increment the
driving dimensions of the lead feature as shown in the following figure.
After you select the dimensions to increment, you must specify an
incremental value for each, as well as the number of instances that the
system should pattern in each direction.
The Pattern
dimension
Notes:
When incrementing dimensions to create a dimension pattern,
the system creates parameters for the number of instances in
each direction as well as the incremental spacing.
Reference Patterns
When you reference an existing pattern in a model, the reference must be
the leader of the pattern as shown in the following figure.
To create this type of pattern, you choose the Ref Pattern option as the
pattern type, and the system creates a pattern of the feature by following
the existing pattern.
Note:
Contrary to the dimension pattern, the system does not provide
parameters for the number of instances or increment values in
a reference pattern. It obtains this information from the pattern
that it references. A reference pattern updates automatically
when the pattern that it references changes.
Secondary wall
built on lead
features edge
Cut location
driven by a table
The CORNER
CUT group
Note:
You can only group features that are in consecutive order in
the regeneration cycle.
Modified
location after
unpatterning
Figure 7: Unpatterning
Figure 8: Ungrouping
Breaking
Dimensional
Dependency of this
instance
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to use patterns and local groups to
duplicate features.
Method
In the first exercise, you modify a pattern of mounting forms by using a
pattern table to dimension from the original reference.
In the second exercise, you create local groups, then pattern and unpattern
them to break the dimensional dependency of the instances.
Tools
Icon Description
Flatten Form
Task 1. Redefine the pattern of mounting forms and drive the pattern
using a table.
1. Open PATTERN_CABLEBOX.PRT.
1. Move one instance in the pattern. Click Modify and select the
instance as shown in the following figure. Change the 2.25
dimension to 5.00. Click Regenerate.
Modify this
instance
Modify 2.25
dimension
2. Modify the pattern table. Click Modify > Pattern Table . Select
and edit the MOUNTS table using the edit option, as shown in the
following figure.
Note:
Pro/TABLE displays the table instances (denoted by the
column idx). The * indicates that the value is set by the
leader of the pattern.
3. Change the entry in the 2nd column for IDX 1 from * to 1.5.
4. Delete the row for entry IDX 4. Highlight the row. Click Edit >
Delete > Rows , and OK .
1. Create a flatten form feature from the leader of the pattern. Click
[Flatten Form].
2. Select the Form element from the model dialog box and click
Define .
Flatten this
form.
Task 4. Define a reference pattern for flattening the other form features
of the original pattern.
Figure 17: Creating a Reference Pattern for the Flatten Form Feature
1. Open ADV_PATTERNS_COVER.PRT.
2. Try to pattern the form in the top of the cover. Click Feature >
Pattern . Select the form feature.
Warning:
The system warns you that you cannot pattern this feature
because the form was placed on the part using the Copy
option. When Pro/ENGINEER copies forms, it copies all of
the features into the part independently.
1. Create a local group of the form features. Click Group > Local
Group , then type [TOP_FORMS] as the name and press <ENTER>.
2. Specify the features of the form to use in the group. Select the
features from the model tree, as shown in the following figure.
1. Pattern the group. Click Pattern from the GROUP menu. Select
TOP_FORMS from the model tree.
Increment these
dimensions in the
second direction.
Increment these
dimensions in the
first direction.
2. For the first direction, select the 1.00 dimension (locating the form
from the front wall). Type [1] as the dimension increment and
press <ENTER>.
5. For the second direction, select the .70 dimension (locating the
form from the right side wall). Type [1] as the dimension
increment and press <ENTER>.
5. Click the 2.00 dimension. Type [2.5] and press <ENTER>. Click
Regenerate .
MODULE SUMMARY
In this module, you have learned how to:
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:
Page 7-1
NOTES
Figure 1: Forms
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.
Convex radius
greater than
thickness
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.
Concave radius
greater than
thickness
Sh e etmet al Fo rm s Pag e 7- 3
NOTES
H ollo w ab ove
base p lane
Figure 4: Hollows
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.
Excluded surface
Sh e etmet al Fo rm s Pag e 7- 5
NOTES
Seed surface
Base plane
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.
Sh e etmet al Fo rm s Pag e 7- 7
NOTES
Note:
You should use the as a tool to create the flatten form
feature, not to reduce regeneration time.
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 the following
figure.
Chamfer
Model
shortened to
keep same
volume
Sh e etmet al Fo rm s Pag e 7- 9
NOTES
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to reference the geometry in another model
to create form features in a sheetmetal part.
Method
In the first exercise, you use two different form models to create geometry
in a sheetmetal part.
In the second exercise, you place a die form that represents louvers on a
part for ventilation.
Tools
Icon Description
Form fly-out icons
Form
Flatten Form
SMT cut
Unbend
Task 1. Create the formed feature for the recess on the cover part.
1. Open SHEET_FORM_CABLEBOX.PRT.
4. Click Mate from the PLACE menu. Select the top surface of the
form and the underside surface on the cable box part, as shown in
the following figure.
5. Click Align Offset from the PLACE menu. Select FRONT on the
form part, Yellow from the DTM ORIENT menu and the front wall
of the cable box, as shown in the following figure. Type [2] as the
offset value and press <ENTER>.
6. Click Align Offset from the PLACE menu. Select SIDE on the
form part, Yellow from the DTM ORIENT menu and the inside
surface of the left wall in the cable box, as shown in the following
figure. Type [.75] as the offset value and press <ENTER>.
Sh e etmet al Fo rm s Pag e 7- 11
NOTES
Note:
If you have selected the wrong constraint or entered the wrong
value, use the COMPONENT PLACEMENT window to
redefine it.
Select these
surfaces to
exclude
9. Click Exclude Surf > Define from the model dialog box. Select
the three surfaces to exclude, as shown in the above figure. Click
Done Sel > Done Refs .
Sh e etmet al Fo rm s Pag e 7- 13
NOTES
1. Click Feature > Pattern . Select the form that you just placed.
3. Select the 0.75 dimension and increment the value by 1.5. Click
Done . Type [2] as the total number of instances for the second
direction and press <ENTER>.
Task 3. Create the knockouts on the side of the box as a pattern of form
features.
1. Click [Form].
4. Place the form on the cable box using the assembly constraints, as
shown in the following figures.
Align offset
FRONT (Yellow
side) datum with
inside surface of
the back wall.
Enter [3] as
value.
Mate offset
hidden surface on
form with right
Align offset TOP
wall surface on
datum (Yellow
the cable box.
side) with top
Enter [.04] as
surface of the
value.
box. Enter [-
1.25] as value.
5. Click Show Placement > Done . Flip the arrow towards the model
and click Okay.
Sh e etmet al Fo rm s Pag e 7- 15
NOTES
6. Select the optional Exclude Surf element in the FORM dialog box
and click Define .
1. Click Feature > Pattern . Select the knock out form feature that
you just created.
Increment by 1 to
create two
instances
5. Click Done when asked for the second direction. The completed
part should appear as shown in the following figure.
Sh e etmet al Fo rm s Pag e 7- 17
NOTES
Task 1. Add the form model as a reference die form, pattern the form,
and mirror the part.
1. Open FORM_BOX.PRT.
Sh e etmet al Fo rm s Pag e 7- 19
NOTES
Boundary
Seed plane
(Round)
surface
Excluded
surface
Align offset
DTM1, yellow Align offset the yellow
side from this side of DTM2 from this
top surface of hidden surface of the
the box by 1.0 box by 2.5
Mate these
surfaces
4. Click Feature > Mirror Geom to mirror the part. The part should
appear as shown in the following figure.
Sh e etmet al Fo rm s Pag e 7- 21
NOTES
MODULE SUMMARY
In this module, you have learned:
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:
Page 8-1
NOTES
Angle Bend
An Angle type bend creates a bend with a specified radius and angle, as
shown in the following figure. An angle appears along the axis of the
radius to show bend direction. The angle can be flipped to change the
direction of bending.
Roll Bend
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 the following figure.
Fixed Side
Bend Side
For each Angle or Roll bend there are three options to choose from
Regular , W/Transit , and Planar .
Bend line
Transition lines
Surfaces remain
fixed
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 the following figure.
The neutral point for planar bends is placed according to the current y-
factor, and bend tables are not applicable.
Axis normal to
surface
You can specify automatic bend relief for bend features using the w/Relief
option. The system highlights each end of the bend entity for specifying
bend relief.
You can also create a bend or unbend feature over a form feature, as
shown in the following figure.
Bend Side
Fixed Side
Bend Side
(Both)
Fixed Side
You can control the location of a bend feature by adding a bend line
adjustment (BLA). BLA is the dimension that locates the sketched bend
line from a reference. It can be modified to manipulate the placement of
the bend. For two surfaces to be coplanar, the developed length of the
bend (L) would have to be equal to the sum of the inside radius (R) and
the thickness (T), as shown in the following figure.
These surfaces
are not coplanar
BS FS
Since the system calculates both the radius of the bend and developed
length of the bend, a relation can be written to drive the BLA. Any change
to the model will be reflected in the bend line placement, as shown in the
following figure.
BLA = L - (R + T)
These surfaces
are coplanar
BS FS
CREATING HEMS
A hem is a finishing feature used to bend sharp edges of a sheetmetal part.
There are five types of hem options.
Open Hem The open hem option bends and flattens a section of
sheetmetal wall 180 about a selected edge. You can define the radius of
the bend and the width of the wall to be bent, as shown in the following
figure.
Flushed Hem The flushed hem option sets the radius of the bend to be
equal to the thickness of the wall. You have to define the width of the wall
to be bent as shown in the following figure.
Duck Hem The duck hem option interlocks and flattens two pieces of
sheetmetal to make them coplanar. This is sometimes more useful than
using a single large piece of sheetmetal. You define the bend radii, the
bend angle, the overall width, and the offset for a duck hem, as shown in
the following figure.
C Hem The C hem option is similar to the open hem option, but you
define an offset from the plane of the sheetmetal wall containing the select
edge for bending, thus creating a C-shaped hem.
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to create a model in Sheetmetal mode
entirely with flat walls and bends.
Method
In this exercise, you create a part with flat walls and then bend the
geometry into shape using a combination of Angle and Roll bends. Then
you add rounds and hems to finish the part.
Tools
Icon Description
Bend fly-out icons
Bend
Hem
Bend back
Done
Apply changes and close; Commit and Exit
Task 1. Create a new sheetmetal part with a flat wall as the base feature.
3. Select the FRONT datum plane as the sketching plane. Click Okay.
Select the TOP datum plane as the Top reference plane.
6. Click the Parameters tab and change the Num Digits value to [3].
Click [Apply changes and close].
Hint:
Sketch a centerline aligned to the Right datum plane and make
the Tsection symmetric about the centerline using the
[Constraints] option.
Task 2. Create a roll bend with transition areas where the clip attaches
to the pencil.
1. Click [Bend].
3. Click Part Bend Tbl > Done/Return > Inside Rad >
Done/Return .
4. Select the green side of the part as the sketching plane. Click Okay
for the viewing direction, and select the lower edge of the T as
the Bottom reference plane.
6. Sketch the single vertical bend line, then dimension it, as shown in
the following figure.
Note:
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.
10. Click Enter Value . Type [0.16] as the bend radius and press
<ENTER>. Click OK to complete the feature. The part should
appear as shown in the following figure. Note that the bend starts
its transition at the first sketched line and is completely flat at the
second.
Task 3. Create an Unbend All feature, add two additional walls without
a radius, and bend back the geometry.
2. Click Unbend All > Done . Click OK . Note that the bend axis is
now visible.
3. Create a flat wall attached to the lower edge. Click [Flat Wall
No Radius].
4. Click Part Bend Tbl > Done/Return . Select the lower green edge
of T as the attachment edge.
5. Click Okay to accept the viewing direction. Click Close from the
REFERENCES dialog box.
Note:
Do not sketch a line over the attachment edge between the two
sketch points. There should be only three line entities and a
centerline aligned to the bend axis.
8. Create another flat wall repeating the above steps, as shown in the
following figure.
9. Create a bend back feature to bend back all of the geometry. Click
[Bend Back].
10. Select the same front green edge on the left-hand side of the T wall
that you used for the Unbend feature to remain fixed.
11. Click BendBack All > Done . Click OK to complete the feature.
The part should display as shown in the following figure.
Figure 23: 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 [Bend].
3. Click Part Bend Tbl > Done/Return > Outside Rad >
Done/Return .
4. Select the green side of the wall that you just created in the
previous task as the sketching plane.
Side to remain
fixed
Sketch this
line
Select these
vertices as
dimensional
references and
align the
Side to create sketched line to
bend feature them
9. Click [Done].
10. Create the bend feature below the sketched line. Click Flip from
the BEND SIDE menu, so that the arrow points down below the
sketched line. Click Okay.
11. Click Okay from the DIRECTION menu to accept the area above
the sketched line as the side to remain fixed.
13. Rotate the model to view the bend angle of 90 degrees. Click Flip ,
if necessary. Click Done .
Tip:
The most effective way to work with bend angles is to choose
a direction, preview the bend, and then flip, if necessary.
14. Type [0.012] as the bend radius and press <ENTER>. Click
Preview . Make sure the bend is in the correct direction. Click OK
to complete the feature.
17. Click Part Bend Tbl > Done/Return > Outside Rad >
Done/Return .
18. Select the green side of the wall that you just created in the
previous task as the sketching plane.
19. Click Okay to accept the default viewing direction. Select the
bottom green surface of the bent wall as the Bottom reference
plane.
20. Delete the existing reference from the REFERENCES dialog box.
Select the bottom edge and the left edge as dimensional references,
as shown in the following figure.
Bend side
Fixed side
Align to
edges, not to
vertices
21. Sketch the vertical bend line and dimension it, as shown in the
previous figure.
22. Create the bend on the left-hand side of the line toward the outside
of the model. Click Flip > Okay .
23. Click Okay to set the right-hand side as the side to be fixed. Click
No relief > Done . Accept the 90 -degree angle.
24. Click Flip if necessary to create the bend on the correct side. Click
Done .
25. Type [0.012] as the bend radius and press <ENTER>. Click
Preview . Make sure the bend is in the correct direction. Click OK
to complete the feature.
26. Create the another vertical bend on the other side of the clip using
the same sketching and reference planes as the previous bend that
you just created. Repeat the above steps that you used for the
previous vertical bend. The part should appear as shown in the
following figure.
Hint:
You can use the Use Prev option when prompted to select the
sketching and reference plane. This will use the sketching and
reference plane that you selected for the previous bend.
Top reference
plane
Sketching plane
(green side)
Figure 26: Specifying the Sketching Plane and Top Reference Plane
29. Click Part Bend Tbl > Done/Return > Outside Rad >
Done/Return .
30. Select the green side of the bottom wall as the sketching plane.
Click Okay to accept the viewing direction. Select the white side
of the larger flat wall as the TOP reference plane, as shown in the
previous figure.
Bend side
Fixed side
Select the small
horizontal edge
as dimensional
reference
32. Sketch a bend line and dimension it, as shown in the above figure.
Click [Done].
33. Make sure the bend side is the above the sketched line, as shown in
the above figure. Click Okay .
34. Click Flip if necessary to fix the side below the sketched line.
Click Okay.
36. Click Flip if necessary to create the bend on the correct side. Click
Done .
37. Type [0.012] as the bend radius and press <ENTER>. Click
Preview . Make sure the bend is in the correct direction. Click OK
to complete the feature.
38. Create the final 90 bend using the approach that you used to
create the previous bend. Use the information shown in the
following figure to complete the bend feature.
Fixed side
Task 5. Create solid rounds on the sharp corners of the bottom portion
of the clip.
1. Click Insert> Round > Simple > Done . Click Constant > Edge
Chain > Done.
2. Click Tangent Chain and select the four edges, as shown in the
following figure.
1. Click [Hem].
2. Select the outer edge of the left wall as the edge reference. Click
Done . Click Done again to accept the direction of the hem.
6. Create another hem using the outer edge of the right hand side
bend as reference. Repeat the above steps. The part should appear
as shown in the following figure.
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.
You can create finishing features like solid rounds and chamfers and
hems to remove sharp corners and edges of a sheetmetal part.
Objectives
After completing this module, you will be able to:
Page 9-1
NOTES
Selected curve
Sketched section
Note:
The system does not determine a developed length for cross
sectional driven unbends.
Sketch
Rip created
Surface Rip Select a surface patch on the geometry and exclude the
entire surface from the model by creating a cut in the geometry.
Corner
removed using
a surface rip
Select this
surface
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 the following figure.
Developed
length
Deformation calculated
only in these
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.
In addition to using the Deform Area feature during unbending, you can
also use it to define edges for edge rips, or to split surfaces for bend line
development.
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to unbend both ruled and non-ruled
geometry.
Method
In the first exercise, the geometry contains some walls with curvature in
two directions. You cannot automatically unbend the walls using the
Regular Unbend option. You deform some surfaces to unbend the part
and then extend the deformation to the outside of the model.
In the second exercise, you use the cross section driven unbend feature to
unbend the part.
In the third exercise, you create a deformation area feature to unbend the
part.
Tools
Icon Description
Unbend and Bend back fly-out icons
Unbend
Deform Area
Use Edge
Done
2. Open TRANS.PRT.
Task 2. Open XSEC.PRT and unbend the left-hand side of the part.
1. Open XSEC.PRT.
3. You are prompted to select the fixed edges. Click Surf Chain in
the CHAIN menu. Select the surface shown in the following figure.
These edges
make the desired
chain
7. Select the same three edges for the curve. Click Done .
8. Keep the inside area fixed (right side of curve). Click OK . The part
should display, as shown in the following figure.
Task 3. Unbend the right-hand side of the part with a cross section
unbend.
Select this
surface as the
sketching plane
for the control
curve
2. Click Sketch Curve > Done . Select the surface shown in the
above figure as the sketching plane and DTM3 as the Bottom
reference plane.
Sketch line
referencing these
vertices
Fixed Side
4. Click [Done].
5. Select the side shown in the previous figure to keep fixed, then
click OK to complete the unbend. (Click Flip if necessary). The
finished part should display as shown in the following figure.
1. Open DEFORM_AREA.PRT.
Select this
surface to
remain fixed
Select these
surfaces to
deform
Distorted
surfaces
Task 2. Create deformation areas; then use one of the deformation areas
to create a Regular Unbend feature.
2. Select the front surface for a sketching plane and DTM1 to face the
Right side of the screen, as shown in the following figure.
Sketching Plane
3. Click Close from the REFERENCES dialog box. Click Yes from
the MISSING REFERENCES dialog box.
Select these
curves for
Use Edge
Fixed
surface
8. Click OK to complete the feature. Note that the system isolated the
large deformation in the deformation areas, which it was forced to
stretch considerably, as shown in the above figure.
MODULE SUMMARY
In this module, you have learned:
Objectives
After completing this module, you will be able to:
Page 10-1
NOTES
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 the following figure. The y-factors default
value is 0.50, but you can modify it using the following methods:
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.
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.
TABLE1 Used for Soft Brass and Copper, as shown in the following
figure.
TABLE2 Hard Brass, Copper, Soft Steel, and Aluminum
TABLE3 Hard Copper, Bronze, Cold Rolled Steel, and Spring Steel
You can customize the standard bend tables to suit your company
standards. You can setup the materials and conversion factors when
You can customize the standard bend tables to suit your company
standards. You can setup the materials and conversion factors when
customizing a bend table. An example of a customized bend table is
shown in the following figure.
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 By Param option and any relations that you
wrote using the parameter automatically updates.
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to use set up options to control the default
bend radius, default fixed geometry, and developed length.
Method
In the first exercise, you calculate and modify the developed length of a
sheetmetal part.
In the second exercise, you setup the default bend radius, fixed geometry
and a bend table to configure the sheetmetal design environment.
Tools
Icon Description
Unbend and Bend back fly-out icons
Unbend
Bend back
Extended Wall
Done
1. Open MEASURE.PRT.
Select this
surface to
remain fixed
Select this
hidden surface
as the From
reference
Select
this
surface as
the To
reference
2. Type [distance] in the NAME text box and press <ENTER>. The
analysis is stored, as shown in the following figure.
Task 4. Change the thickness of the first wall to update the developed
length.
1. Click Modify from the PART menu and select FIRST WALL from
the Model Tree. Select the .25 THICK dimension, as shown in the
following figure. Type [.1] and press <ENTER>.
Modify the
thickness
3. Check the analysis that you saved earlier. Click Analysis >
Measure . Click Distance from the SAVED ANALYSES area of the
dialog box.
4. Click Retrieve and notice that the distance value is now 3.83540
1. Click Modify. Select FIRST WALL from the Model Tree again.
2. Select the .84 DEV .L dimension. Click Enter Value . Type [1.00]
as the length and press <ENTER>.
1. Open U_SHAPE.PRT.
Note:
You will be informed by the system status that you have not
used the thickness or 2 * thickness default settings. You have
specified a numeric value as the default bend radius for all
bend features.
4. Click OK .
1. Click [Flat Wall Use Radius]. Create a flat wall with a radius
and that uses the part bend table and an inside radius. Select the
white edge as shown in the following figure to attach the wall.
Specify an angle of 90.
Attach wall to
this white edge
Sketch to points
3. Finish the sketch and then click W/Relief > Rip relief for both
ends of the wall.
Extend to this
outside surface
Wall extended to
outside
Task 4. Define a default surface to remain fixed and create unbend and
bend back features.
1. Click Set Up > Sheet Metal > Fixed Geom > Select .
4. Click [Unbend]. Unbend the entire part. Note that you did not
have to specify a fixed surface.
5. Click [Bend Back]. Bend back the entire part. Again, note that
you did not have to specify a fixed surface.
6. 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 By Param radius option.
1. Create a flat wall with a radius and that uses the part bend table
and an inside radius. Select the white edge shown in the following
figure to attach the wall. Specify an angle of 90.
Attach to this
inside edge
Reference
sketch to
outside wall
Reference
endpoints to
attachment edge
4. Click By Param for the radius of the bend and OK to complete the
feature. The part appears as shown in the following figure.
5. Click Relations from the PART menu. Click Part Rel> 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.
6. Click Done from the MODEL REL menu. Click Modify and select
the flat wall you just created in the previous step. Note that the
developed length of the bend is 0.52. Click Done .
1. Click Set Up > Sheet Metal > Bend Allow > Bend Table >
Define > From Part . Type [U_SHAPE] as the name and press
<ENTER>.
2. Select the END MATERIALS row. Click Edit > Insert . Select
Before current selections . Click OK , as shown in the following
figure.
4. When finished editing, save and exit the Pro/TABLE editor. Click
Done/Return until you reach the PART SETUP Menu.
7. Click Assign from the MATL MGT menu. Click From Part
>BRASS > Accept to assign the material to the part.
8. 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. Click Done/Return until you close all
the sub menus.
9. Click Modify from the PART Menu. Select the last wall feature.
The developed length is now 0.53. Click Done .
10. Click Setup > Sheetmetal > Bend Allow > Bend Table > Show
> From Part > U_SHAPE. Confirm that the developed length of
0.53 is correct for a thickness of 0.25 and radius of 0.25.
MODULE SUMMARY
In this module, you have learned that:
Objectives
After completing this module, you will be able to:
Page 11-1
NOTES
Driving Srf You can use this option to convert a solid part that has a
uniform thickness and can be offset by the material thickness. The system
prompts for a surface to use as the driving (green) surface.
Shell If the part does not have uniform thickness, the Shell option can
be used to shell the solid part and convert it at the same time.
Point Reliefs This element creates points along an edge to break the
edge into multiple segments.
Co n v e r t i n g So l i d P a rt s Pag e 1 1- 3
NOTES
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.
Corner relief
created in
combination with
edge rip and
bends
Co n v e r t i n g So l i d P a rt s Pag e 1 1- 5
NOTES
LABORATORY PRACTICAL
Goal
The goal of this laboratory 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 then, 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.
Tools
Icon Description
Unbend fly-out icons
Unbend
Rip
Conversion
Co n v e r t i n g So l i d P a rt s Pag e 1 1- 7
NOTES
1. Open CONVERSION.PRT.
3. Click Shell and specify the removal of the three hidden surfaces as
shown in the following figure.
Select these
three hidden
surfaces to
remove (two
sides and
bottom)
4. Click Done Sel > Done Refs . Type [0.25] as the shell thickness
and press <ENTER>.
Task 2. Add an edge rip feature to one of the edges and then unbend the
geometry.
3. Click Done Sel > Done Refs . Click OK to complete the rip.
5. Click Regular > Done . Specify the top surface to remain fixed as
shown in the above figure.
6. Click Unbend All > Done . Note that some deformation of the
convex triangular corner occurs as the system unbends it. Click OK
to 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 to select the other edge also.
Co n v e r t i n g So l i d P a rt s Pag e 1 1- 9
NOTES
Select these
three surfaces
to remove (one
on top and two
hidden back
and side
surfaces
4. Select the edge indicated in the following figure, click Offset , and
select the right hand surface as the offset plane to locate the point.
Select this
green edge
Select this
side
surface as
offset
plane
5. Type [1.8] for the offset distance and press <ENTER>. Click
Done.
Note:
Do not click OK . You still have to define the other elements
for the conversion feature.
6. Double-click Edge Rip from the dialog box. Select the three edges
shown in the following figure. Click Done Sel > Done Sets .
Co n v e r t i n g So l i d P a rt s Pag e 1 1- 1 1
NOTES
8. For the first end, select the datum point you created for the point
relief. The system then highlights all of the possible corners and
other rip features to connect the rip. Select the bottom vertex of the
other rip, as shown in the following figure.
Select the
datum point
for first end
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.
15. Type [0.5] for the dimension value and press <ENTER>.
Note:
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, you allow the system to select them all automatically.
Co n v e r t i n g So l i d P a rt s Pag e 1 1- 1 3
NOTES
MODULE SUMMARY
In this module, you have learned that:
Co n v e r t i n g So l i d P a rt s Pag e 1 1- 1 5
Module
Project Laboratory
In this project module, you practice how to create sheetmetal models
using the top-down design approach. You will also use
Pro/ENGINEERs sheetmetal design tools to unbend complex
geometry.
Objectives
After completing this module, you will be able to:
Page 12-1
NOTES
LABORATORY PRACTICAL
Goal
The goal of this laboratory is to create a sheetmetal component in an
assembly using the top-down design approach. You also unbend a
sheetmetal part using deformation areas.
Method
In the first exercise, you complete the battery bracket part located in the
routed system sub-assembly of a car that was created using the top-down
design approach. The necessary assembly information has been copied
into the battery bracket part. The changes made to the top-level assembly
will automatically be reflected in the battery bracket part.
In the second exercise, you unbend a connector part where the ends were
created first and completed by blending the wall in between them.
Pro/ENGINEER will indicate that some of the geometry needs to be
deformed to create the flat pattern.
Finished Battery
Bracket
1. Click File > Set Working Directory and change your working
directory to <user home directory>\Sheetmetal_320\Project.
4. Switch to the 1_WALL view from the saved view list. Adjust your
model orientation by panning and zooming in for better viewing.
P ro j e c t L ab o rat o r y Pag e 1 2- 3
NOTES
6. Use the Default sketching plane and accept the default viewing
direction of the sketching plane.
8. Sketch four line segments and three fillets of equal radii, and
dimension the section, as shown in the following figure.
9. Complete the wall with No Relief and set the Bend Radius to be
equal to the thickness of the part.
2. Click Edit > Set Attribute to Auto > Yes in the SHEETMETAL
PARAMETERS dialog box.
P ro j e c t L ab o rat o r y Pag e 1 2- 5
NOTES
Task 3. Create another extruded wall on the other side of the bracket
2. Sketch the wall and dimension it, as shown in the following figure.
3. Complete creating the wall. Notice that the system did not prompt
you for some of the attributes, since you set default values using
the SHEETMETAL PARAMETERS dialog box.
P ro j e c t L ab o rat o r y Pag e 1 2- 7
NOTES
2. Sketch the wall and dimension it, as shown in the following figure.
3. Complete the wall. Notice that the system added a rip relief
automatically.
1. Create an Extend wall on the right-hand side end of the flat wall by
selecting the edge and up to the surface, as shown in the following
figure.
2. Create another extend wall on the left-hand side using the edge and
surface, as shown in the following figure.
P ro j e c t L ab o rat o r y Pag e 1 2- 9
NOTES
Select outside
edge and outside
surface to extend
upto
4. Save the assembly and erase all the models from memory.
P ro j e c t L ab o rat o r y Pag e 1 2- 11
NOTES
Sketch a spline
for the deform
area
MODULE SUMMARY
You have learned to:
P ro j e c t L ab o rat o r y Pag e 1 2- 13
Module
Objectives
After completing this module, you will be able to:
Page 13-1
NOTES
You can create the first flat state instance from a generic model that is
either fully formed or fully flat.
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:
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.
If an instance index file is present, retrieve the instance directly.
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.
Sequence 1,
Sequence 3, Bend 1
Bend 1
Sequence 1,
Bend 2
Sequence 2,
Bend 1
Sequence 2,
Bend 2
Sequence 4,
Bend 1
LABORATORY PRACTICAL
Goal
The goal of this laboratory 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.
Tools
Icon Description
Flat Wall fly-out icons
Unbend
Done
Show/Erase Axes
Select this
surface to
remain
fixed The edge rip
feature is
located along
this edge
2. Click Set Up > Sheet Metal > Flat State > Create .
1. Select the Unbend feature from the model tree and right-click
Redefine as shown in the following figure.
7. Click [Done]. Click OK > Done > OK . Set the unbent part to
its default orientation, as shown in the following figure.
2. Create a flat use radius wall. Click [Flat Use Radius]. Click
Part Bend Tbl > Done/Return . Click Inside Rad > Done/Return .
3. Select the green edge as shown in the following figure. Accept the
default bend angle of 90 degrees, and click Done . Click Okay to
accept the default viewing direction.
4. Click Close from the REFERENCES dialog box. Sketch three lines
and dimension them, as shown in the following figure.
5. Click [Done].
6. Click No Relief > Done. Click Enter Value and type [0.25] as
the bend radius and press <ENTER>.
Note:
Any changes made to the fully formed generic will be
propagated to the flat state instance automatically.
Note:
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
2. Click Set Up > Sheet Metal > Bend Order > Show/Edit . Select
the top flat surface of the part, as shown in the above figure.
3. Select the first two bends, as shown in the following figure. These
will be included in the first bend sequence.
4. Click Done Sel > Next . Specify the top same surface to remain
fixed. The system bends back the two selected bends and displays
the model, as shown in the following figure.
5. Select the bend for the second sequence, as shown in the following
figure.
Select this
bend for the
second
sequence.
6. Click Done Sel > Next , and specify the same top surface to remain
fixed.
7. The model should now have the bend in the second bend sequence
bent back, as shown in the following figure. Select the last bend, as
shown in the following figure.
8. Click Done Sel > Done , and specify the same surface to remain
fixed. The system should now inform you that the bending
sequence is successful.
9. Click Info to view the bend order table. The table should appear as
shown in the following figure.
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.
11. 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. Click [Unbend].
12. Click Regular > Done . Select the same top surface of the model to
remain fixed.
13. Click Unbend All > Done . Click OK to complete the unbend
feature.
14. Save the model and close the window. Make sure you close all
active windows, if open.
1. Create a new drawing. Click File > New . Click Drawing as the file
type. Type [DOC_CONV]. Remove the check mark from the Use
default template check mark at the bottom of the NEW dialog
box. Click OK .
5. Create a general view of the generic model. Click Views > Add
View > General > Full View > No Xsec > Scale > Done .
6. Select a point in the right upper corner of the drawing to place the
view.
7. Type [0.3] as the scale and press <ENTER>. Leave the view in the
default orientation. Click OK from the ORIENTATION dialog box.
8. Add the flat state instance to the drawing. Click Dwg Models >
Add Model.
10. Click Add View > General > Full View > No Xsec > Scale >
Done .
13. Orient the view. Select the top green surface as the FRONT
reference and the top green edge of the model as the TOP
reference. Click OK . If necessary move the view to locate it, as
shown in the following figure.
14. Click View > Show and Erase . This should open up the
SHOW/ERASE dialog box.
17. Click Insert > Dimension > New References . Create the
dimensions shown in the following figure.
Note:
Use the same technique to create dimensions as you would in
the sketcher. Select the entities. Middle-click to place the
dimension.
18. Click Return from the ATTACH TYPE menu. Make sure you are in
the DRAWING menu.
19. Create a second sheet to display the bend order table. Click Sheets
> Add > Done/Return . The system will add a sheet and make that
active.
22. Click Add View > General> Full View> No Xsec > Scale >
Done .
25. Select the top green side as the FRONT reference and the top green
edge as the TOP reference. Click OK from the ORIENTATION
dialog box. If necessary, move the view to locate it to the middle
of the drawing.
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.
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.
Objectives
After completing this module, you will be able to:
Page 14-1
NOTES
Calculating Measurements
Using the Measure option from the ANALYSIS menu, 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.
Analyzing Surfaces
One of the most common problems encountered when modeling
sheetmetal components is an inability to unbend the geometry. 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 the following figure.
Fringe Plot
surfaces with
non-developable
geometry
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 the following figure.
LABORATORY PRACTICAL
Goal
The goal of this laboratory 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 design
information about the sheetmetal part.
1. Open DOC_CABLEBOX.PRT.
Figure 6: DOC_CABLEBOX.PRT
2. Click Info > Feature from the pull-down menu and select the last
three features in the model tree, one by one, to review them. Close
the information window. Click Done Sel after reviewing the
features.
3. Clear the File check box to write output only to the screen. Click
OK .
4. 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, y-factor and k-factor.
5. 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. Select the two bends and
notice that the system highlights them on the model.
Note:
You may need to click View > Model Tree Setup >
Highlight Model in the MAIN window.
6. 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.
1. Create a radii report. Click Info > Sheetmetal from the pull-down
menu. Click Radii Report and clear the File check box to write
output only to the screen.
4. Four bends were created (on lines 10 through 17) with non-
suggested 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 and press <ENTER>. A Pro/TABLE
editor 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
equation involving R and T. The design rule value or equation is
always the minimum allowable value.
4. Assign the rule set to the part. From the RULE MGMT menu, click
Assign > From Part > RULE_SET1 . Note the message that
appears in the message area.
1. Click Modify > Query Sel and select the rectangular form, as
shown in the following figure.
Use Query
Sel to select
this
rectangular
Form
feature.
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.
Click the 0.75 dimension and change it to [0.85]. Regenerate the
model.
3. Click Info > Sheetmetal > Design Check . Use the RULES
VIOLATIONS DIAGONISTICS window to verify that the
modification eliminated the violation.
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.
Page A-1
NOTES
3. Select datum plane FRONT as the sketching plane and Flip the
arrow for the direction of feature creation.
4. Select datum plane TOP as the Top reference and sketch the first
section, as shown in the following figure.
Pag e A- 2 F u n d a m e n t a l s o f Sh e et m e t a l De s i g n
NOTES
5. Click Sketch > Feature Tools > Toggle Section (or click Toggle
Section from the pop-up menu) to toggle to sketch the second
section.
Tip:
If you need to change the start point of one of the blend
sections, select 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, and press <ENTER>. The part should display as shown in
the following figure.
Pag e A- 4 F u n d a m e n t a l s o f Sh e et m e t a l De s i g n
NOTES
3. Select datum plane FRONT as the sketching plane and datum plane
TOP as the Top reference.
Pag e A- 6 F u n d a m e n t a l s o f Sh e et m e t a l De s i g n
NOTES
Task 2. Retrieve the sweep sheetmetal part and create a swept wall.
1. Open SWEEP.PRT.
3. Click Tangnt Chain and select the green edges indicated in the
following figure. Note the location of the start point, and click
Start Point to change its location if necessary.
Start point
here
5. When you have finished sketching, click No Relief > Done > OK .
The part displays as shown in the following figure.
Pag e A- 8 F u n d a m e n t a l s o f Sh e et m e t a l De s i g n
NOTES
2. Select the green or white lower edge of the wall, as indicated in the
following figure.
Select bottom
edge to attach the
twist wall
4. Type [2.0] as the start width and press <ENTER>. The default
value is the length of the selected edge.
6. Type [2.5] as the twist length (length after twisting) and press
<ENTER>.
1. Create a regular Angle bend using the part bend table and an inside
radius. Sketch the section shown in the following figure on the
large front face of the part.
BS = bend side
FS = fixed side
BS FS
2. Specify the bend and fixed sides, as shown in the following figure.
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
display as shown in the following figure.
5. Create the same bend on the other side of the part as shown in the
following figure.
1. Click Analysis > Measure . Click Distance from the TYPE pull-
down menu.
2. Select the two surfaces shown in the following figure. 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
1. Click Modify and select the left bend. The dimensions should
display as shown in the following figure. The developed length (L)
is 1.70.
5. Click Add . The relation you need is the equation for the BLA. For
this example in the following figure, the relation is d9= d14 -
(d13+ d8). Enter your relation. Be sure to use your dimension
symbols. Press <ENTER> twice.
7. Measure the distance again to ensure that the surfaces are coplanar.
1. Create a new solid part named RIP.PRT using the default template.
4. Accept the default value of [0.1000] for the thickness. The system
automatically converts the part into a sheetmetal part.
2. Select all four edges shown above in the above figure (you can
select 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 display
as shown in the following figure.
Objectives
After completing this module, you will be able to:
Page B-1
NOTES
Click Help > Contents and Index from the main menu as shown in the
following figure.
Pag e B- 2 Append ix B
NOTES
In the left frame of the window, you see a list of topics arranged in a tree
structure. By clicking on each higher level topic, you can access sub-
topics, and by clicking the sub-topics you can access detailed instructions,
explanations, and tips.
5. In addition, you will also notice at the lower left there is a See
Also link which on clicking provides a list of related topics that
may be of immediate interest.
Pag e B- 4 Append ix B
NOTES
Pag e B- 6 Append ix B
NOTES
Objectives
After completing this module, you will be able to:
Page C-1
NOTES
Please use the following format (or download the template from
www.ptc.com/cs/doc/copen.htm):
Pag e C- 2 Append ix C
NOTES
The Technical Support Engineer will ask you for the following
information when logging a call:
When the call is resolved your data will be deleted by the Technical
Support Engineer. Your data will not be divulged to any third party
vendors under any circumstances. You may also request a Non-Disclosure
Agreement from the Technical Support Engineer.
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e C- 3
NOTES
Call
Customer question
Support Engineer
solves issue or
reports it
to Development (SPR)
SPR
Software Performance Report
Update CD to customer
Pag e C- 4 Append ix C
NOTES
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e C- 5
NOTES
ONLINE SERVICES
After you have registered you will have full access to all Online Tools.
You can search our Knowledge Base using a Search-Engine. Our Online
Support Applications controls the status of calls (Call Tracker) and SPRs
(SPR Tracker) and adds comments to these. If you add a comment, the
Technical Support Engineer assigned to your call will be notified
automatically.
The Software Update Tool allows you to request the latest software
updates for any PTC product.
Pag e C- 6 Append ix C
NOTES
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e C- 7
NOTES
2. Select the PTC Product or Module for which you want to get
information.
3. You will receive daily e-mail with update information; this can
help you by upgrading to a new PTC product or to a new release.
Pag e C- 8 Append ix C
NOTES
CONTACT INFORMATION
PTC Technical Support Worldwide Electronic
Services.
These services are available seven days a week, 24 hours a day.
Web:
www.ptc.com/support/index.htm (Support)
www.ptc.com/company/contacts/edserv.htm (Education)
E-mail:
ftp.ptc.com
E-mail:
cs-feedback@ptc.com
Telephone:
www.ptc.com/cs/doc/feedback_nums.htm
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e C- 9
NOTES
Telephone
For assistance with technical issues, contact the Electronic Services noted
in the previous section, or the Technical Support line as listed in the Phone
and Fax Information sections below.
800-477-6435
Outside the United States and Canada:
781-370-5332
781-370-5513
Maintenance:
888-782-3774
Education:
888-782-3773
Pag e C- 10 Append ix C
NOTES
Belgium 0800-75376
Denmark 8001-5593
Finland 0800-117-092
Eastern Europe 44 1252 817 078
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e C- 1 1
NOTES
France 0800-14-19-52
Germany 49 (0) 89-32106-0
Ireland 1-800-409-1622
Italy 39 (0) 39-65651
Netherlands 0800-022-0543
Norway 8001-1872
Portugal 05-05-33-73-69
Russia 44 1252 817 078
Spain 900-95-33-39
Sweden 020-791484
Switzerland 41 (0) 1-8-24-34-44
United Kingdom 0800-31-8677
Benelux 31-73-644-2705
France 33-1-69-33-65-50
Germany 49 (0) 89-32106-325
Italy 39-039-65-65-652
39-039-6565-1
Spain/Portugal 34-91-452-01-00
Sweden 46-8-590-956-00 (Malmo)
46-8-590-956-46 (Upplands Vasby)
Switzerland 41 (0) 1-820-00-80
United Kingdom 44-0800-212-565 (toll free within UK)
44-1252-817-140
Australia 1800-553-565
China* 10800-650-8185 (international toll free)
108-657 (manual toll free)
Hong Kong 800-933309
India* 000-6517
Pag e C- 12 Append ix C
NOTES
Indonesia 001-803-65-7250
7-2-48-55-00-35
Japan 120-20-9023
Malaysia 1-800-80-1026
New Zealand 0800-44-4376
Philippines 1800-1-651-0176
Singapore 65-830-9899
South Korea 00798-65-1-7078 (international toll free)
080-3469-001 (domestic toll free)
Taiwan 0080-65-1256 (international toll free)
080-013069 (domestic toll free)
Thailand 001-800-65-6213
*Note: Callers dialing from India or China must provide the operator with
the respective string:
China MTF8309729
India MTF8309752
The operator will then connect you to the Singapore Technical Support
Center.
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e C- 1 3
NOTES
Japan 81-3-3346-8268
Malaysia 03-754 8198
Singapore 65-8309866
South Korea 82-2-3469-1080
Taiwan 886-2-758-8600 (Taipei)
886-4-3103311 (Taichung)
886-7-3323211 (Kaohsiung)
ELECTRONIC SERVICES
Up-to-Date + Worldwide = Maximum
Information ISO 9000 Productivity
Certification with
Quality Control
PTC
System
Products
Pag e C- 14 Append ix C