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Training Guide Advanced Sheet Metal

TopSolid’Design Advanced Sheet Metal

ii Missler Software

© 2015, Missler Software. 7, Rue du Bois Sauvage F-91055 Evry, FRANCE Web: www.topsolid.com E-mail: [email protected] All rights reserved. This information is subject to change without warning. No material may be reproduced or transmitted, regardless of the manner, electronic or mechanical means used or purpose, without formal written consent from Missler Software.

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Version 7.9 Rev.01

Note: If you are experiencing problems using this training guide, please feel free to send your feedback and comments at [email protected].

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TopSolid’Design Advanced Sheet Metal

Missler Software iii

Contents

Exercise 1: Creation of a round square hopper .................................................................................................. 1

Exercise 2: Creation of a round rectangle hopper .............................................................................................. 6

Exercise 3: Creation of standard extruded bars ............................................................................................... 18

Exercise 4: Creation of a complex hopper ........................................................................................................ 28

Exercise 5: Metalworking - Design of a guard-rail ............................................................................................ 34

Exercise 6: Metalworking - Design of an emergency staircase .......................................................................... 44

Exercise 7: Metalworking - Design of a sliding gate .......................................................................................... 62

Notes ............................................................................................................................................................. 68

Individual course evaluation form .................................................................................................................. 71

TopSolid’Design Advanced Sheet Metal Exercise 1: Creation of a round square hopper

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Exercise 1: Creation of a round square hopper

Concepts addressed:

- Creation of a transition sheet metal - Creation of slots - Creation of partial parts - Creation of the unfolding

Creation of a part

Create a new project. In this project, create a new folder named Exercise 1 - Round square hopper.

Create a new Part document and rename it to Round square hopper.

From the Sheet Metal tab, select Transition Sheet Metal and create the following sheet metal.

Exercise 1: Creation of a round square hopper TopSolid’Design Advanced Sheet Metal

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Using the Slot function, create the following two slots.

Save the document.


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From the Surface tab, create two distinct shapes using the Removing function.

Note: This is done to create two different shapes in the part document.

From the Entities tree, drag Shape 2 into Simplified Representation, Design Representation, and then Detailed Representation.

Note: This allows both shapes to be displayed as entities.

In a drawing, the two shapes will be represented.

Exercise 1: Creation of a round square hopper TopSolid’Design Advanced Sheet Metal

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From the Tools tab’s pull-down menu, select Derivations > Partial Parts to create the two partial parts.

Once validated, the following documents are now visible in the Project tree.

Save the document.


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Creation of unfoldings

From the Project tree, right-click on the part document Round square hopper.Shape 1 and select

Unfolding. Use a blank template.

Validate the Unfolding dialog box.

Save the unfolding document.

Repeat the above steps for the part document Round square hopper.Shape 2.

Exercise 2: Creation of a round rectangle hopper TopSolid’Design Advanced Sheet Metal

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Exercise 2: Creation of a round rectangle hopper

Concepts addressed:

- Creation of a point on the fly - Creation of flanges on a plane

Creation of a part

From the Project tree, create a new folder named Exercise 2 - Round rectangle hopper.

Create a new Part document and rename it to Round rectangle hopper.

Create the following transition sheet metal.

TopSolid’Design Advanced Sheet Metal Exercise 2: Creation of a round rectangle hopper

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Perform four slots in Open and Iso parametric modes on the radiused portions by creating points on profiles in Middle mode.

The four slots should look like the next image.


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Create four flanges on the rectangle’s radiused external edges. From the Bending angle field, select Hooked on plane.

Use the icon to create a 3mm offset plane via a plane passing through the three points selected on the hopper’s internal edges.


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Create the following two recoverings on the left and right faces.

Repeat the operation on the other side of the hopper.


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Next create the following four coverings on the top and bottom faces. Specify a shift value of 0.1mm.

Save the document.

Create a rectangle on one flange’s top face, centered on the edges and bend edges.


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Right-click on the left upper point and select Not Internal to be able to create a drilling group.

Validate the sketch.

Right-click on the sketch and select Drilling Group.


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From the Shape tab, select Repetition and repeat the drilling group using a linear pattern. Here, we would like to link the total distance to the length of the segment selected on the sketch. To do this, use the Associative value option.


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Create four different shapes using the Removing function.

From the Entities tree, drag Shape 2, Shape 3 and Shape 4 into Simplified Representation, Design Representation, and then Detailed Representation.


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From the Tools tab’s pull-down menu, select Derivations > Partial Parts to create the four partial parts.

Once validated, the following documents are now visible in the Project tree.

Save the document.


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Creation of multiple unfoldings

From the Project tree, right-click on the assembly document Round rectangle hopper and select

Multiple Unfoldings.

Use the Id.Qty.Des.PN.Mat.Mass BOM standard template.

Check that the selected assembly document is Round rectangle hopper and validate.

Note: This is a simple way of creating all the unfoldings in a single operation.

The following documents are now visible in the Project tree.

Exercise 3: Creation of standard extruded bars TopSolid’Design Advanced Sheet Metal

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Exercise 3: Creation of standard extruded bars

Concepts addressed:

- Creation of a plane - Creation of a sketch by intersection - Using standard extruded bars

Creation of an assembly

Create a new folder named Exercise 3 - Using standard extruded bars.

Create a new Assembly document and rename it to Hopper frame.

Drag the part document Round square hopper (Exercise 1) into this assembly document.

Create an offset plane.

TopSolid’Design Advanced Sheet Metal Exercise 3: Creation of standard extruded bars

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Create a sketch on this plane, and then from the 2D Sketch tab’s pull-down menu select Operations >

Intersection.



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Create a point on profile on the upper arc.

Note: To only select the desired arc, press and hold down the left mouse button on the relevant segment, successively press the right mouse button several times until the desired item is highlighted, and then release the left button to validate the selection.

Repeat the operation on the lower arc.

Draw a new sketch on that same plane as seen below.


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To create the tangency constraint, click the line, the arc, and then the point. The 100mm dimension must be centered on the points.


Create the following extruded bars. For each section, select the Hollow Square Section, ISO 4019 family and the 40 x 2 code.


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Repeat the procedure for all the following sketches and edges.

Create the miter trims.


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Repeat the operation for all the following trims.

Next create the main trims.


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Repeat the operation for all the following trims.

Draw the following sketch on a face of one the lower extruded bar’s end.


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Add extruded bars to the sketch as shown below.

Make the miter trims.


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Next create an extruded bar by two points.

- First point: Select the point at the angle of the bottom extruded bar. - Second point: Create a Cartesian point whose origin is the point at the angle of the bottom extruded bar.

o X = 350mm o Y = -100mm o Z = 0mm

Create the main trim.


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Using the Repetition function from the Tools tab, create a plane symmetry of the previously created point via the absolute XZ plane.

Then add an extruded bar by two points.

Note: It is not recommended to repeat the extruded bars using plane symmetry.

Finally, create the main trim.

Save the document.

Exercise 4: Creation of a complex hopper TopSolid’Design Advanced Sheet Metal

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Exercise 4: Creation of a complex hopper

Concepts addressed:

- Creation in surface mode - Reciprocal trim between two sheet metals

Create a new folder named Exercise 4 - Complex hopper.

Import the Complex hopper package in this folder.

Open the part document Complex hopper - Sketches. The document only contains the basic sketches of the hopper.

Note: In this exercise, we will mainly work in surface mode. It is also possible to work in assembly mode if you want to specify different thicknesses.

TopSolid’Design Advanced Sheet Metal Exercise 4: Creation of a complex hopper

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Transition sheet metal 1

Create a transition sheet metal. Check the Surface only option and choose the Point and point mode and a circular section of 200mm.

Note: In the case of a cylindrical hopper, the orientation is less important but must be specified anyway.


Create another transition sheet metal using the User section mode.

- First Section: Click the circle sketch. - Second Section: Click the oblong sketch.


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Create a new transition sheet metal by selecting the Point and point mode, and then a first rectangular section of 1000 x 600mm and a second circular section of 300mm.


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This time create an extruded shape in surface mode. Check the Surface option.

Note: This shape contains one too many faces.

Delete this face using the Removing surface function in None heal mode.


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Front and rear closing sheets

Create a flat surface by selecting the sketch 4.

Cut the front face by performing a trim by profile using the sketch 3. Make sure the arrow is in the right direction.

Create a flat surface by selecting the sketch 5.


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Hopper trims

Here we need to manage the connection between the circular hopper and the oblong hopper.

To do this, select Reciprocal Trim.

Note: Be sure to indicate the correct cutting direction; the preview must match the expected result. If not, reverse the direction using the colored arrows.

Convert all the surface shapes into sheet metals using the Sheet Metal by Thickening contextual feature.

Exercise 5: Metalworking - Design of a guard-rail TopSolid’Design Advanced Sheet Metal

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Exercise 5: Metalworking - Design of a guard-rail

Concepts addressed:

- In-place design - Sketch in the assembly - Creation of extruded bars - Operation in the assembly: Trim by profile - Parameters

Create a new folder named Exercise 5 - Guard-rail.

Create a new Assembly document and rename it to Guard-rail.

Structure sketch

Draw the following sketch on the XZ plane.

TopSolid’Design Advanced Sheet Metal Exercise 5: Metalworking - Design of a guard-rail

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Plate sketch

Draw a new sketch on the same plane as sketch 1.

Sketch of the bars

Characteristics of the guard-rail:

- The structure is made up of full flat sections of 60 x 14. - Bars are made up of full square sections of 14. - The distance along which bars will be placed is 1000mm. - The minimum distance between bars is 110mm. - Calculation of the number of bars: 1000/110 i.e. 9.09 rounded to 10. - Real step = 1000/10 i.e. 100mm.

In a new sketch, draw a vertical line and add the 100mm dimension as shown below.


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Creation of extruded bars

Creation of the post

Add a full flat section NF A 45-005 of 60 x 14 to the left-hand vertical segment by clicking the icon from

the Modeling tab, or by right-clicking directly on the segment and selecting Extruded Bar.

Creation of the top rail

Next add a hollow circular section NF A 49-646 of 60 x 3 to the upper horizontal segment.

Flat section trim

Create a new sketch on the front face of the flat section as shown below.


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Cut the section using the Trim by Profile function.

Add a new full flat section 60 x 14 to the lower horizontal segment.

Then add a full square section of 14 to the bar sketch.


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Design of the plate

Create a new in place part.

From the plate sketch, create a sheet metal on sketch of 10mm, 80mm wide and oriented upwards.

Add the two fixing holes: Ø14mm through holes centered on the width and located at 25mm from the edge.

Using the Angle Relief function, break the angles with 10mm fillets.

Validate the in-place design.


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Trim the full flat section by a planar trim: top face of the plate.

Plate repetition

Perform a circular repetition of the plate and the flat section around the Z axis by specifying a total count of 2.

Section trims

Trim each of the sections by making two main trims:

- The square section of 14 at the upper and lower ends. - The full flat section of 60 x 14 at the left and right ends.


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Repetition of the bars

Make a linear repetition of the full square section 14 along the X axis by specifying a spacing distance of 100mm and a total count of 9.

Save the document.

The result should look like the next image.

Free exercise

Generate a bill of materials and a draft for the assembly.


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Guard-rail parameters

The guard-rail can be parameterized to be reused later with other values.

Edit the sketch 1 and change the dimension of 1000mm to L=1000. Do the same with the dimension of 1100mm and enter H=1100.


Calculation of the number of bars

Create a real parameter, Length type: STEP = 110mm.

Then create another real parameter, Factor type: Nb = L/STEP i.e. 1000/110mm = 9.0909.

Modify the formula to round this result to the higher whole number. This includes using an expression.

Extracted from the Online Help:


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Edit the Nb parameter and modify it as follows: Nb = ceil(L/STEP;1).

Calculation of the new step

Create a new real parameter, Length type: R_STEP = L/Nb i.e. 100mm. Note: The Nb and R_STEP parameters are created as operations in the design sequence. They have to be moved before sketch 3.

Edit the sketch 3 and replace the dimension value with the R_STEP parameter.



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Edit the pattern of the repetition 2 (bars) and replace the spacing distance with R_STEP and the total count with Nb-1.

Test the parameters with the following values.

Exercise 6: Metalworking - Design of an emergency staircase TopSolid’Design Advanced Sheet Metal

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Exercise 6: Metalworking - Design of an emergency staircase

Concepts addressed:

- Background document - Document sharing - Component with process - Process repetition

Environment design

Create a new folder named Exercise 6 - Emergency staircase.

Create a new Part document and rename it to Environment.

Draw the following sketch on the XZ plane.

Create an extruded shape of 200mm.

Save the document.

TopSolid’Design Advanced Sheet Metal Exercise 6: Metalworking - Design of an emergency staircase

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Landing design

Create a new Assembly document named Landing, and then include the Environment document.

Draw the following sketch on the opening plane.

Add UPE Beam DIN 1026-2 sections of 160, positioned downwards and included in the sketch.

Draw a new sketch on the same plane as sketch 1. The line is constrained on the midpoints of the horizontal segments.


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Add an IPE Beam NF A 45-205 section of 160, positioned downwards and centered.

Creation of the section trims

Create a miter trim for the belt.

Then create a main trim for the central reinforcement.

Create a new in-place part by clicking the blade plane of the IPE.

Draw the following sketch. Create a midpoint and add a centering constraint on the UPE.


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Create a 12mm sheet metal on sketch pointing outwards.

Break the angles with a 10mm chamfer.

Definition of the symmetry plane

Create a midplane between the largest faces.

Use the Tools > Symmetries > Plane Symmetry command and select the previously created plane.

Rename the document to Fixing plate.

Save the document.



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Plate repetition

Create a plane by point and normal to the sketch 2’s line.

Repeat this plate using a plane symmetry of this plane.

Insertion of fixing components

Insertion of the screw

Open the Search window and enter H%screw to find hexagon screws.

Select Hexagon Screw ISO 4017 from the list and drag it into the graphics area.

Choose a M14 x 40 screw.

Position the screw using the Screw on Top Head mode at 25mm from the edge and centered in the axis as shown below.

Create the Clearance hole process.

Make a linear repetition along the Y axis or select the edge along this direction, by specifying a spacing distance of 50mm and a total count of 2.


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Insertion of the nut

From the Search tool, enter H%nut.

Select Hexagon Nut ISO 4034.

Position the nut on the opposite face on the section side and coinciding with the screw axis, and then make a linear repetition using the same repetition as the screws.

Create a new repetition of the screws and nuts by symmetry using the first repetition of the plate.

Create the drilling processes for the two screws using the Process Repetition function.

Save the document.


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Design of the staircase

Characteristics of the staircase:

- 12mm sheet metal stringboards - 4mm sheet metal steps - Height of climb: 2500mm - Theoretical height of steps: 178mm - Width of steps: 900mm

Create a new Assembly document and rename it to Staircase.

Background document

When it comes to working with several people on a big project, or if a project has to be divided into several functional sub-sets, it is sometimes difficult to share work efficiently.

The concept of background document can help with this problem.

Each designer in charge of a part of the project, or each functional sub-set, will then be able to put this document as the background of the sub-assembly he is working on: he will rely on the background document’s building elements in an associative way.

When a change is made to the background document (for example: modification of the opening, modification of the landing dimensions…), the assemblies related to that background document will be updated when loading the final assembly.

Create a background document via File > Background Document and select the Landing document from the list.

The background document appears in transparency in the Staircase document.

Close the Landing document.

Create a new sketch on the plane of the front face of the environment.


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Calculation of the number of steps

- Height of climb = 2500mm - Theoretical height of steps = 178mm - Number of steps = 2500/178 i.e. 14.0449 rounded to 14 - Calculation of the height of climb = 2500/14 i.e. 178.57mm

Create a new sketch on the same plane as sketch 1. The line corresponding to the step is in construction and not internal to the sketch.



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Design of the stringboards

Create a new in-place part.

Create a 12mm sheet metal on sketch from the assembly sketch and normal to this sketch.


Make a linear repetition along the normal direction to the face, by specifying a spacing distance of 912mm (900 + 12) and a total count of 2.

Design of the steps

Create a new in-place part, and then create a new sketch on the external face of the first stringboard.

Project the construction line.

Create a 4mm sheet metal on sketch pointing downwards and to the inner face of the second stringboard.


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Create 50mm flanges in opposition to each other.

Rename the document to Step and save it.


Draw the following sketch on the same plane as sketch 1.



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Make a linear repetition along the staircase direction, by specifying a spacing distance equal to the length of the sketch 3’s line and a total count of 13 (14 - 1).

Design of the fixing plates

Bottom fixing plate

Add a full flat section NF A 45-005 of 100 x 12 as shown below, either on the edge, or on two points.

Edit the in-place part.


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Add a Ø16mm through hole centered on the length and located at 50mm from the edge.

Create a midplane between the two small faces of the flat section.

Perform a repetition by plane symmetry using the previously created plane.

Declare the midplane as the symmetry plane.

Break the angles by adding 20 x 20mm chamfers.

Save the document.


Create a plane by point and normal: midpoint of the step edge and normal to this edge.

Repeat the plate by plane symmetry using the previously created plane as the symmetry plane.


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Landing fixing plate

Add a full flat section NF A 45-005 of 100 x 12 as seen below.

Edit the in-place part.

Add a Ø16mm through hole centered on the length and located at 50mm from the edge.

Create a midplane between the two small faces of the flat section.

Perform a repetition by plane symmetry using this midplane.

Declare the midplane as the symmetry plane.

Add the 20 x 20mm chamfers.


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Design of the staircase guard-rail

Create the following new sketch on the front face of the stringboard by enabling the Sketch 2D > Options > Semi-automatic mode.


Add full flat sections NF A 45-005 of 50 x 12 (positioned underneath and in front of the support sketch).


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Create a plane by point and normal: middle of the edge and normal on the first vertical flat section.

Create the following new sketch on this plane.


Add full circular sections NF A 45-003 of 20mm.

Create the main trims.


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Make a linear repetition along the Z axis, by specifying a spacing distance of 110mm and a total count of 4.

Make a linear repetition by 2 points (midpoints of the posts), by specifying a spacing distance and a total count of 2.

Create the trims on the top rail.


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Full staircase

Create a new Assembly document, and then assemble the landing.

Note: The landing is fixed by default because it is the first assembled document.

Then assemble the staircase.

Note: Since the Staircase document is already open, you can use the Inclusion function by checking the Inclusion at origin option.

Position the staircase using the appropriate constraints.

Intermediate final result:

Free exercise

Note: Use the background document to design the posts and guard-rail of the landing.

Design the posts of the landing.

Design the guard-rail of the landing.


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Final result:

Exercise 7: Metalworking - Design of a sliding gate TopSolid’Design Advanced Sheet Metal

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Exercise 7: Metalworking - Design of a sliding gate

Concepts addressed:

- In-place design - Sketch in the assembly - Using extruded bars - Component assembly - Operation in the assembly: Partial trim by profile - Creation of representations

Create a new folder named Exercise 7 - Sliding gate.

Characteristics of the sliding gate:

- The structure is made up of hollow rectangle sections of 80 x 40 x 2. - Bars are made up of hollow square sections of 40 x 2. - The minimum distance between bars is 110mm.

Create a new Assembly document and rename it to Sliding gate. Next draw the following sketch on the XZ plane.

Add hollow rectangle sections NF A 49-646 of 80 x 40 x 2.

TopSolid’Design Advanced Sheet Metal Exercise 7: Metalworking - Design of a sliding gate

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Section trims

Create the main trims to adjust the upper and lower crossbars/vertical sections.

Bars

- The distance along which bars will be placed is 4000 - (2*80-40) i.e. 3880mm. - The minimum distance between bars is 110 + 40 (square tubes of 40 x 2) i.e. 150mm. - Calculation of the number of bars: 3880/150 i.e. 25.86 rounded to 26. - Real step = 3880/26 i.e. 149.23mm at the axis which gives 109.23 from face to face of the tubes of 40.

Create a new sketch on the same plane as sketch 1.

Create a vertical line and add the dimension in relation to the vertical segment of sketch 1. This dimension is equal to (80 -20) + 149.23.

Note: The dimensioning is done in relation to the axis; this will help to prevent any invalidities when changing the sections of the vertical tubes.


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Add a hollow square section ISO 4019 of 40 x 3.

Repeat this section in linear mode along the direction of the bars (X axis) by specifying a spacing distance of 149.23mm and a total count of 25 (26 - 1).

Result:

Modification of a tube section

Note: For rigidity reasons, the section for the support tube of the wheels is larger.

Edit the bottom rectangular tube and modify the section to 100 x 50 x 2.

Create a new sketch on the support face of the wheels, at the bottom of the 100 x 50 tube, at 500mm from the closing side and at 1000mm from the guiding side.


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Perform a trim by profile in partial mode.

Save the document.


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Wheel import

Import the Wheel.x_t file without converting the assembly structure.

Wheel assembly

Return to the Sliding gate document and assemble the wheel using the Inclusion function.

Add the following positioning constraints.


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The final result should look like the next image.

Notes TopSolid’Design Advanced Sheet Metal

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Notes

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TopSolid’Design Advanced Sheet Metal Notes

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Notes TopSolid’Design Advanced Sheet Metal

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TopSolid’Design Advanced Sheet Metal Individual course evaluation form

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

TopSolid’Design 7 – Advanced Sheet Metal

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?

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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