Chapter 10 Sheet Metal Design

1. Chapter 10Sheet Metal Design

2. Chapter 10 - Objectives • After completing this chapter, you will be able to perform the following: • Start the Autodesk Inventor sheet metal environment • Modify settings for sheet metal design • Create sheet metal parts • Modify sheet metal parts to match design requirements • Create sheet metal flat patterns • Create drawing views of sheet metal parts

3. Sheet Metal Fabrication • Sheet Metal Examples • Enclosures • Brackets • Structures or Frames

4. Sheet Metal Fabrication • Bend Tables • L=A+B-x Construction • L Unfolded Length • A Length of folded face 1 • B Length of folded face 2 • x Adjustment from bend table • Measurements A and B are to the intersection of the extended outer faces on either side of the bend. This intersection is used when the angle of the bend is less than or equal to 90 degrees.

5. Sheet Metal Fabrication • Bend Tables • L=A+B-x Construction • L Unfolded Length • A Length of folded face 1 • B Length of folded face 2 • x Adjustment from bend table • Use these measurements when the bend angle is greater than 90 degrees. The measurements are parallel to the face, and tangent to the outer surface of the bend. The same formula is used to determine the unfolded length of the part.

6. Sheet Metal Parts • Sheet Metal Design Methods • Folded State • Flat State • Disjointed Solids • Shelled Parts

7. Sheet Metal Parts • Sheet Metal Part Template(s) • Convert part to Sheet Metal part • Model tab • or Environment tab

8. Sheet Metal Tools • Sheet Metal Rules • Click the Sheet Metal tab > Setup panel • Sheet metal specific parameters driven by rules

9. Sheet Metal Tools • Sheet Metal Styles • Bend Tab

10. Sheet Metal Tools • Sheet Metal Styles • Bend Transitions • Controls the intersection of edges across a bend in the flattened sheet.

11. Sheet Metal Tools • Sheet Metal Styles • Corner Tab • Relief Shape • Jacobi Corner

12. Sheet Metal Tools • Sheet Metal Unfold Method • Linear – KFactor Value • Bend Table

13. Custom Equation Method • Additional control to unfold model • Bend Compensation • Bend Allowance • Bend Deduction • KFactor

14. Sheet Metal Tools • Sheet Metal Defaults • After you define sheet metal rules • Use the Sheet Metal Defaults tool to select the rule that is active for the sheet metal part

15. Sheet Metal Tools • Sheet Metal Face • Extrudes a closed profile a distance equal to the sheet metal thickness • Unfold Options • Relief Options

16. Sheet Metal Tools • Contour Flange • Created from an open sketch profile • Bends are added at sharp intersections

17. Sheet Metal Tools • Flange • Creates a sheet metal face and bend to an existing face • Extends the full length of the selected edge • Corner Edits – click glyph in corner

18. Exercise 10-1 • Creating Sheet Metal Parts

19. Contour Roll • Create from an open sketch profile • No radius required between sketch lines • First or secondary feature • Unfolded • Flat pattern

20. Lofted Flange • Create transitions from one shape to another • Two sketches • Output • Die form • Press break

21. Rip • Open a closed sheet metal part • Rip options • One sketch point • Two sketch points • End points • Work point • Midpoint of an edge

22. Exercise 10-2 • Lofted Flanges, Contour Roll, and Rips

23. Sheet Metal Tools • Hem • Eliminate sharp edges • Strengthen an open edge of a face • Material is folded back over a face with a small gap

24. Exercise 10-3 • Hems

25. Sheet Metal Tools • Fold • Turns a flat pattern into a folded model • Add folds at sketched lines

26. Sheet Metal Tools • Bend • Child objects of other features • When two faced connect • Connect disjointed face

27. Exercise 10-4 • Modifying Sheet Metal Parts

28. Sheet Metal Tools • Cut • Sheet Metal tab > Modify panel > Cut • Distance of the cut is equal to the Thickness parameter • Project Flat Pattern • Cut Across Bend • Define Distance

29. Sheet Metal Tools • Unfold/Refold • Unfold selected or all bends • Add feature • Refold selected or all bends

30. Exercise 10-5 • Cut Across Bend

31. Sheet Metal Tools • Corner Seam • Created when three faces meet • Create mitered gaps between coplanar faces

32. Sheet Metal Tools • Corner Round • Sheet Metal specific Fillet tool • Corner Chamfer – Sheet Metal specific Chamfer tool

33. Sheet Metal Tools • Create Punch • iFeature • Center Point • Parameters • Punch ID • Custom Depth • Simplified Sketch

34. Sheet Metal Tools • Punch Tool • Center Point required • Creates Cuts and 3D Deformations • Dimples • Louvers • Set Punch Folder • Applications Options > iFeature tab • Flat Pattern • Representation

35. Exercise 10-6 • Punch Tool

36. Sheet Metal Tools • Flat Pattern • Represents the starting point for sheet metal part manufacturing • Creates a 3D model of the unfolded part • Displayed in a 2D drawing view • Flat Pattern – Browser • Flat Pattern – Extents, area

37. Sheet Metal Tools • Flat Pattern • Extents, area • Edit Definition • Punch Representation • Flat Patten Features • Effect Flat Pattern Only

38. Sheet Metal Tools • Common Tools – Sheet Metal tab • Holes • Work Features • Feature Patterns • Mirror • Parameters

39. Detailing Sheet Metal Designs • Detailing Sheet Metal Designs • 3D Model and Flat Patterns

40. Exercise 10-7 • Documenting Sheet Metal Designs

41. Applying Your Skills • Skill Exercise 10-1

42. Checking Your Skills • The base feature of a sheet metal part is most often a: • Revolve • Face • Extrude • Flange • What is the correct procedure to change the edges connected by a bend feature? • Suppress the existing bend, and add a new bend. • Delete the existing bend, and add a new bend. • Edit the bend, and select the new edges. • Create a corner seam between the desired faces. • Which command would you use to create a full-length rectangular face off of an existing face edge? • Flange • Extrude • Face • Bend • What action is required to update a flat pattern model? • Right-click on the flat pattern in the browser, and select Update. • Erase the existing flat pattern, and recreate it. • Create a new flat pattern drawing view. • The flat pattern is updated automatically. Continued….

43. Checking Your Skills - continued • True__ False__ Sheet metal parts can contain features created with Autodesk Inventor modeling tools. • True__ False__ Sheet Metal Style settings cannot be overridden; a new style must be created for different settings. • True__ False__ During the creation of a sheet metal face, the face can extend to meet another face and connect to it with a bend. • True__ False__ A sheet metal cut that used the Distance extents option must be created equal to the Thickness parameter. • What is a common term for a three-bend intersection? • True__ False__ When creating a sheet metal punch, you can select an alternate 2D representation to display in flat patterns and drawing views.