Flattening Embosses

Problem 2004 you create an embossed part with a few holes added with the
embossing tool. When you go to flat pattern either you show the embos if
it's final state or you suppress it and show nothing. It would be nice if
the holes were atleast projected or something. When going to our plasma
machine the CAM software drops the whole profile of the emboss and wants to
cut the outer shape. Anyway anyone know of any related improvements with
2005.

Corey

 

not sure about your particular application but typically embosses are done
as a sheetmetal forming tool. it will show up in flat using this method.

 

nevermind

 

Im not sure what you're getting at....

your PLASMA wont do embosses so its the fault of Solidworks?

If you insist on leaving geometry in your Flat pattern that your machine cant
manufacture, then DONT TOOLPATH THE GEOMETRY!

and if you made the entire part in a punch, would it actually be any easier ?

 

OK I am using Forming tools to flange a hole. Since the Forming tools can
cut a hole I don't pre cut it on my model. When sending the flat pattern
to the cam since the Forming tool doesn't flatten out I end up with the
major diameter of the flanged hole instead of the hole diameter. My point
is It sure would be nice to see what the hole should be before It gets
flanged. So I can cut it at my plasma machine. Anyway I guess I am the
only one.

Corey

easier ?

 

like a tapped extrusion? anyway, i get minor diameter.

 

once again, nevermind.

 

OK I am using Forming tools to flange a hole.

My workaround is to twiddle the Flat Pattern Configuration. Activate
the Flat pattern Configuration, suppress the Form tool FEATURE, but
keep the sketch unsuppressed.

Generate a new cut feature in the flat configuration, using the sketch
of the form tool feature as a base to dimension off of. Make the Cut
your minor diameter.

You will probably have to go back and suppress this new cut feature in
your parent config.

 

When sending the flat pattern

Hi Corey -

My practice with this sort of thing has been to model the pre-hole and
then drop the forming tool down on it after, which makes both features
configurable.

I actually have gotten completely away from the forming tool for this
scenario because of the inherent "externalized geometry" and
"thickness only" problems. I usually create the pre-hole which is
present in the flat blank, then create a larger cut hole of almost
arbitrary size and then I do a revolve to form my extrusion or flanged
hole. Since most of these features like small extrusion never have a
rim of one material thickness, I find that the extrude makes for
better (i.e. more lifelike) geometry. For these types of features, I
like to make the die clearance about 1/2 to 5/8 material thickness
because it gets a straighter side.

I know that you know all the ins-and-outs of sheet metal modeling &
fabrication, so nothing here is any news to you. But, you might be
happy modeling a pre-hole because it helps the fidelity of the flat
blank. Somebody somewhere needs to know what pre hole you wanted them
to use, right? It's also useful to show "what we did to make those
parts" two years down the road once everyone has forgotten the
particulars of the job.

Later,

SMA

 

Not the answer I was hoping for but sound advice. This has been the way I
have been doing it and you are quite right about having a reference to what
the desired hole size should be.
Rocheey had a good method too. I was hoping there was a new method in 05
that would make things better.

thank you all
Corey

 

I'm not sure if you have seen 05 yet, but they have not done diddly
for sheet metal, except adding the ability to mirror flanges
(something I don't feel intrinsically excited about anyways). Maybe
there is some new crafty thing that they have hidden in there, but it
looks doubtful.

There's always the future though. Man I would love to see them add an
extrusion wizard, complete with configurable pre-hole, and a user
definable backside (die side). Dream on sean - this would actually
be useful.



Later,

SMA

 

SW sheetmetal can flatten a lot more shapes than it used to. But embosses
from the wrap feature might be too much for it. I think this is what you
are getting at.

 

what about embosses from sheetmetal tool, can they be flattened?

 

They can be suppressed, but this doesn't really acheive the same thing as
flattening. Embosses may draw some material from around it when formed, so
the flat pattern would need to bulge in some way, and SW on its own doesn't
do that.

If you want software that estimates the flat pattern of drawn/formed parts
(non-brake press operations), you might want to try Logopress or
Blankworks. Logopress will actually help you layout and design progressive
dies. It's pretty slick, actually.

matt