wildfire sheet metal design

Wildfire SHEETMETAL Design 2/18/2011

Presented by Henry Schille

Terms and DefinitionsTerms and DefinitionsBend: A feature that can be manufactured on a brake press.Brake press: a machine that uses radiused dies to bend sheetmetal.Deform area: material that is stretched or compressed in order to create a feature.Deform area: material that is stretched or compressed in order to create a feature.

Normally a deformation area will not create a reliable flat pattern.Flange: a bent sheetmetal wall.Miter: to join at a corner by various methods.Obro nd A rectang lar c t ith one end f ll ro ndedObround: A rectangular cut with one end fully rounded.Relief: a cut in the metal which allows the adjacent material to be formed.Stretch Relief: A deformation of the material that would otherwise be cut away.Rip: A cut through the material.p gSheetmetal: a sheet of metal.SHEETMETAL: The Wildfire (or Pro-E) module to design sheetmetal parts. Stress concentration: an area of high stress. The place a part will break or fail first.Stress relief: a feature such as a corner round which reduces a stress concentrationStress relief: a feature such as a corner round which reduces a stress concentration.

References:•Several references to a Sheetmetaldesign pdf are made throughout thisSeveral references to a Sheetmetaldesign.pdf are made throughout this document. This pdf can be found at G:\Public\HenrySchille\sheetmetaldesign.pdf

Wildfire SHEETMETAL Best PracticesWildfire SHEETMETAL Best Practices• The purpose of this presentation is to provide a feature overview and

training on the best way to create SHEETMETAL wall features in Wildfire and when to use the features It does not cover all SHEETMETALand when to use the features. It does not cover all SHEETMETAL functionality.

• If you know the part is going to be mostly symmetric, create only one half of the part and mirror it about a datum plane or surface.o e pa a d o abou a da u p a e o su a e– Non symmetric features can be added after the Mirror feature.– Modifying, redefining, or creating features on one side will all be

automatically updated on the other side (if the feature exists priorautomatically updated on the other side (if the feature exists prior to the Mirror feature).

• Screen pick on the part name in the Model Tree to highlight the part.• Choose Edit>Mirror>Screen pick the plane or surface to mirror about• Choose Edit>Mirror>Screen pick the plane or surface to mirror about.

– Note: File>Mirror Part creates a new part. It is a referenced mirror image of the parent part. This also can be useful, but is very different.different.

– If the part is symmetric about two planes, two mirror features can be created and only ¼ of the part needs to be designed.

Wildfi SHEETMETAL O iWildfire SHEETMETAL OverviewThe following will be covered (in order of icon):1 Protrusion feature1. Protrusion feature2. Conversion feature3. Flat (Flat Wall)4 Fl f t4. Flange feature5. Flat feature>Revolve/Blend/Offset6. Extended wall

d d d7. Bend>Edge Bend8. Unbend>Bend Back9. Corner Relief>Punch/Notch/Rip/Merge Walls10. Punch Form Tool>Quilt Form Tool/Die Form/Flatten Form/ Deform Area11. Flat Pattern

Initial SHEETMETAL FeatureInitial SHEETMETAL FeatureThere are three common types of initial SHEETMETAL

feature options:1) E t d U h t t t d h1) Extrude: Use when you want to extrude a shape,

such as a hat rail, a Z bracket, or an L shape as your first feature.

– Can be used with– Can be used with Sketch > Feature Tools > Thi k tThicken to dimension to both sides of the material:

Initial SHEETMETAL Feature (cont.)2) Unattached walls:

• Flat: Use when you want a basic flat feature as your initial feature. Sketch may include holes.

)

y y

• Revolve: Use when you want the initial feature to be a fully revolved feature Think “Tube”be a fully revolved feature. Think “Tube”.

• Blend: Use when you want the initial feature to be a blended feature. Think “Generally more complex y pthan we can manufacture at CarlisleIT”.

Initial SHEETMETAL Feature (cont )Initial SHEETMETAL Feature (cont.)

• Conversion: Use when you have a solid part or a surface feature 3) Conversion feature:

created outside the SHEETMETAL application that you want converted to a SHEETMETAL part in order to make a flat pattern. This feature will help convert the part into a manufacturable part by converting h i h b d f ld d fl i h i dsharp corners to either bends or folded flanges with rips, edge

conditions, and relief. It is designed to work with sharp corners.

Initial solid part in general shape of final sheetmetal partsheetmetal part.


– With the unconverted part in the active window, choose 3) Conversion feature (cont.):

Applications > Sheetmetal.» Convert a constant wall thickness part using Driving Srf» Convert a block part using Shell which will allow you to Co e t a b oc pa t us g S e c a o you to

choose surfaces to be removed.» If a part will not convert, it is usually because a constant wall

thickness cannot be achieved.

Converted part using Shell. Notice topShell. Notice top surface is removed.


Point Reliefs: Creates a relief at a datum point

3) Conversion feature (cont.):

placed along a curve. This is a useful feature to split surfaces for application of boundary conditions.

Edge Rip: Add edge rips to all edges you do notEdge Rip: Add edge rips to all edges you do not want to be bent. Each edge chosen is called a Rip Piece.

– Either inside edge or outside edge can be g gchosen. No difference in result.

– Default edge miter condition is Open.– Edge miter condition can be changed by

selecting Redefine>Piece # X.» Bug alert: trying to redefine edge miter

condition after Conversion creation causes failurefailure.

– Bends are auto chosen between Rip Pieces.


Rip Connect: Must be defined to connect Rip Pieces

3) Conversion feature (cont.):

Rip Connect: Must be defined to connect Rip Pieces across a flat surface.

Bends: May be chosen instead of Edge Rip to model an extruded part (Think “extruded box”).p ( )

– Edges chosen are called Bend Pieces.– Default bend value is 1X thickness.– May be changed by Double Clicking y g y g

Bends>Piece #X.– Many also be changed by editing the Smt

Conversion feature.Corner Reliefs: May be added to remove sharp

corners at bend corners.– Best practice is to use Obround, 2X Thickness.

S lik it l b h ith S l t All– Seems like it can only be chosen with Select All.– Bug alert: Corner relief does not work on

anything but open type corners.

Initial SHEETMETAL Feature (cont )Initial SHEETMETAL Feature (cont.)3) Conversion feature (cont.):

Edge Rips(all blue edges)

Bends(all magenta edges)(all magenta edges)

Rip Connect(yellow)

Point Relief(Choose Datum point

added as a

(yellow)

feature)

Shelled part in process usingShelled part in process using Conversion feature.


Edge Rips(default open shown)

Bends

Rip Connect

Point Relief

Shelled part after using Conversion feature.


Corner Relief shows up in flat pattern.

h l

Flat Pattern of shelled part after using Conversion feature May show up in less

complex folded model.

using Conversion feature.


1 P i h ll hi k 2 Converted using Driving Srf

Another example of the

1. Part with constant wall thickness 2. Converted using Driving Srf

Another example of the use of Conversion.

3. Sharp Bends rounded with Conversion>Bends.

Extrude (wall mode):• Use when you want an extruded unattached wall(s).

Each line ill be a all 1X mate ial thick– Each line will be a wall 1X material thick. – Feature is unattached. Normally used as 1st feature.

• Extrude (wall mode) functionality:( ) yChoice between extrusion and surface feature.Extrude to a specified depth (dimension controlled).Extrude in both directions an equal amount (dimension controlled).q ( )Extrude to a surface. (dimensionless)(Next to depth dimension) Changes direction of extrusion from sketch plane.Toggles between cut mode (default-remove mat’l) and wall mode (add mat’l)gg ( ) ( )Tells you that you are making a thin sketch. Not functional in wall mode.(Last icon) Changes material side of sketch (inside to outside or top to bottom).

Options: Adds 2 sided blind depth functionality; adds bends to sharp cornersOptions: Adds 2 sided blind depth functionality; adds bends to sharp corners functionality; allows Capped ends on initial feature; controls which side is green (driving surface).

Extrude t ude(cut mode):

• Use when you want an extruded shape cut through one• Use when you want an extruded shape cut through one or more surfaces.– Alternate for Insert>Hole.

• Extrude (cut mode) functionality:Largely same functionality as wall mode with the following additions:Extrude through to next surface (dimensionless)Extrude through to next surface (dimensionless).Extrude through all (dimensionless).Extrude up to and including a surface. (dimensionless)Thicken Sketch: Toggles between a thin cut (each line has width) and a cutThicken Sketch: Toggles between a thin cut (each line has width) and a cut

similar to a non-SHEETMETAL cut.Use the following for a cut with sketching plane at an angle to a surface: Removes material normal to both surfaces. (A sketched circle becomes a slot)e o es ate a o a to bot su aces ( s etc ed c c e beco es a s ot)Removes material normal to green surface. (A sketched circle becomes an oval)Removes material normal to other surface. (A sketched circle becomes an oval)

Fl t d Fl ( ll )Flat and Flange (walls):• Features are similar, but different. A comparison:

a) Sketch looks at wall face.b) Can be used to make flat

(no bend) wall.) l b d

a) Sketch looks at wall profile.b) Can not be used to make flat

wall.) b d l lc) Can only be used on one

edge at a time.d) Can not be used on

curved edges

c) Can be used on multiple edges at once.

d) Can be used on curved edgescurved edges.

e) Can make inconsistent wall sketch.

f) Feature considered

edges.e) Can only make constant wall

sketch.f) Feature not consideredf) Feature considered

planar.g) Can be length controlled,

offset, and relieved.

f) Feature not considered planar even if it is.

g) Can be length controlled, offset, and relieved.

h) Multiple edges cannot be chosen at the same time.

h) With multiple edges chosen, miter type can be specified.

Fl t ( ll)Flat (wall):• Use when you want a single straight wall.

S l t d it f th di ti f d i d b d di ti• Select an edge opposite of the direction of desired bend direction. Flat>Placement>Screen Pick

– Default wall is rectangle, flush with selected edge, with rip relief, 90°bend, with bend radius 1X thickness. All may be modified.

• Trapezoid, L, or T or can be chosen and then manipulated using the drop down box. User Defined is not functional.

• Shape>Sketch… allows a user defined sketch to be made.– The sketch must be continuous (holes not allowed)( )– Sketches may be saved/retrieved using Save As… / Open…

• Offset>Add to Part edge makes the bend tangent to the selected edge. Automaticcancels out any offset chosen. By value moves the wall out up to the value of the outside radius.

• Relief adds relief to bend ends– ObrndRelief is the most desirable from a stress andmanufacturing perspective.g p p– Note: Relief has no effect if

feature is tangent to part edge.

Fl t ( ll) ( t)Flat (wall) (cont):• Boxes on feature represent modifiable items:

Offset from edge

Offset from end

Bend Direction(Edge selected)

Length

Bend Angle

Length

Fl t ( ll) ( t)Flat (wall) (cont):• Other functionality:

This is non-functional.

This changes material side offset is dimensioned to.

This allows radius dimension to be changed from inside

These are an alternate method of modifying angle to be changed from inside

to outside.y g g

and radius.

Properties is an alternate t h thway to change the name

of a feature.

Fl t ( ll) ( t)• Helpful Hint:

Flat (wall) (cont):

– Add a Flat wall (no bend) with offset ends before creating a wall with a bend.

– This allows stress relieving corner radii to be added without needing to cut away undesirable geometry.

Fl ( ll)Flange (wall):• Use when you want a complex wall shape, multiple walls of the same shape,

or walls on a curved edgeor walls on a curved edge.• Select an edge opposite of the direction of desired bend direction.

Flange>Placement>Screen Pick. Holding down the Shift key allows multiple edges to be chosen.

– Several drop down shapes can be chosen, but all may be created using Shape>Sketch…– Length: options are duplicated in drop down boxes, but do not work properly for multiple

walls at the same time. Note: Negative value removes material, positive value adds material.– Edge Treatment: options are very useful and self explanatory. Only functional when

adjacent edges are chosen. Essentially specifies type of miter cut for each corner.• Helpful hint: Flush edges are usually not manufacturable. Add some gap.

– Miter Cuts: does not seem to be functional. Use Edge Treatment.– Relief: Bend Relief works pretty well for a single edge.

• Corner Relief works, but only seems to show up in a flat pattern.

– Other functionality is identical to Flat feature.

Fl t ( tt h d ll)Flat (unattached wall):• Use the first three icon options as first feature only, or for purely cosmetic

purposes Any other use will create an unattached feature Unattachedpurposes. Any other use will create an unattached feature. Unattached features may possibly be attached later (see Merge Walls), but a better option is Flat with no bend.

• The last icon, Offset, simply duplicates a wall at an offset distance. If a radiused edge is chosen, the offset wall radius will be increased/decreased by the offset dimension (same center).– Multiple surfaces cannot be chosen.

I have not seen an application for this feature– I have not seen an application for this feature.

E t dExtend:• Useful for tweaking edges of miter corners.

– Pulls adjacent bend material with itPulls adjacent bend material with it.– Does not work on Flange walls (not considered planar).– Both positive (add material) and negative (remove material) values are possible.

Unmodified part. Positive Extend value.

Negative Extend value.

Bend:Bend:• Useful for adding a bend to existing material.

– Feature not updated with Dashboard Interface.Plana Bends a e not gene all man fact able b t inte esting– Planar Bends are not generally manufacturable, but interesting.

– More information, including w/Transition info, can be found in sheetmetaldesign.pdf pages 129-142. (numbered pages 121-134.)

A l R l R l

What sketch should

Angle Regular Result.

What sketch should look like.

Angle Planar Result.A -90°flips direction.

Roll Regular Result.

Edge Bend:Edge Bend:• Useful for converting a sharp corner to a bend.

– An alternate, more direct method to convert sharp corners instead of using Conversioninstead of using Conversion.

Unmodified part. Edge Bend added to four sharp bends.

Unbend and Bend Back:Unbend and Bend Back:• Useful for adding cuts across bends in the flat state.

– Not optional after an unattached wall.– More information available in sheetmetaldesign.pdf pages 142-149 (numbered pages 134-141.)

Unmodified part. Unbend area(s) t b difi d

Add cut(s) across b d( )

Bend Back all.to be modified. bend(s).

Corner Relief:Corner Relief:• Marginally Useful for adding corner relief to ripped corners.

– This is an optional method to specify relief to ripped edge corners. Otherwise use Conversion.Not an option to se on Flange feat es Define co ne elief fo Flange feat e in the feat e– Not an option to use on Flange features. Define corner relief for Flange feature in the feature.

– Will not override corner relief set by Conversion, but will add to it.– Bug Alert: Does not show up until part is unfolded.– Bug Alert: Once feature is created it seems it cannot be redefined.– Helpful hint: Ignore Corner Relief altogether. Add it with a Protrusion cut before the walls are

created. Or, add it by creating an Unbend>Unbend All, cut an obround into all the sharp corners, then create a Bend Back.

• This will allow the corner relief to display in the folded condition.• This will allow better control of what you will actually get and want• This will allow better control of what you will actually get and want.• This will allow the gaps and corners to be dimensioned as they should appear.

Ripped corner with Same corner Corner relief added Same cornerRipped corner with Corner Relief.

Same corner, unfolded.

Corner relief added as a cut after an Unbend.

Same corner, folded.

Punch and Notch:Punch and Notch:• Useful for adding UDF defined cuts to SHEETMETAL parts.

– More information available in sheetmetaldesign.pdf pages 123-129 (numbered pages 115-121 )115-121.)

– Punches are useful for placing predefined cut geometry into a part.• An excellent example would be to set up UDF defined punches for disconnect bracket cutouts.• Nut plate cutouts could also be set up as a UDF punch.

RiDisconnect Cutout

Rip:• Useful for adding infinitely thin saw like cuts to SHEETMETAL parts.

– More information available in sheetmetaldesign pdf pages 99-102

Example.

– More information available in sheetmetaldesign.pdf pages 99-102.

Unmodified part. Rip added. (Sketch is Zigzag line)

Flat Pattern now possible.

Merge Walls:Merge Walls:• Useful for joining unattached walls to your model.

– Normally, having unattached walls is the result of poor modeling techniques.Can be sed to “fi ” model so a flat patte n can be made– Can be used to “fix” model so a flat pattern can be made.

Punch Form Tool / Quilt Form Tool/Punch Form Tool / Quilt Form Tool/ Die Form:

• Useful for adding deformation features to SHEETMETAL parts.• Punch Form Tool uses a model of the core. Die Form uses a model of the cavity.

• Mate flat surface to SHEETMETAL part. This is also your Bound Plane and must completely surround the form.• The colored surfaces (see below) are Exclude Surfaces and result in a cutout of that shape.• Seed Surface is one surface on the form which is used to select all surfaces of the form.• CAUTION: This feature can “stretch” material in ways that is not physically possible. For instance, if the 4MCU-DEF

part below were used without the exclude surfaces, then the resulting feature would include a large extruded oval attached to the deformation with all material at 1X thickness. Note that in real life, this type of feature would be stretched very thin if not to the point of breaking.

• Helpful Hint: If your feature fails it is often because a constant wall thickness cannot be achieved, often because an outside radius is not large enough to result in the inside radius being greater than zero.

Quilt Form Tool: I assume this feature allows you to deform a quilt much like you would sheetmetal. I have not tested this however.

4MCU-DEF Used to make 4MCU tray deformation.

Flatten Form:Flatten Form:• Useful for “flattening” a Punch Form, a Die Form, or a chamfer.

– Not a very useful feature as a Punch Form or Die Form does not prevent a flat pattern from being created the form however is not flattened with Flat Patterncreated, the form however is not flattened with Flat Pattern.

– Holes created with Punch Form or Die Form are not retained with Flatten Form functionality.– This feature does not flatten Hole features with included chamfers.– I am not sure how this feature is more effective than just suppressing the Form.

f b f d h ld df ( b d )– More information can be found in Sheetmetaldesign.pdf pages 121-123 (numbered pages 113-115).

Deform Area:Deform Area:• Useful for defining an area to be distorted when unbending certain complex

geometry.– A very good example can be found in Sheetmetaldesign.pdf pages 152-153 (numbered pages 144-

145).

Flat Pattern:Flat Pattern:• Useful for flattening your SHEETMETAL part when the design is complete.

– A very good example can be found in Sheetmetaldesign.pdf pages 159-163 (numbered pages 151-155)155).

Questions?Questions?

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