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    Sheet Metal

    In this lesson, you create the sheet metal part. This lesson demonstrates:

    Creating a base flange

    Adding a miter flange

    Mirroring the part and creating new bends

    Adding an edge flange and editing its sketch profile

    Mirroring a feature

    Adding and bending a tab

    Adding a cut across a bend

    Folding and unfolding bends

    Creating a closed corner

    Creating a sheet metal drawing

    Adding bend line notes

    Next

    Creating a Base Flange

    When you develop a sheet metal part, you generally design the part in the folded state. This allows you

    to capture the design intent and the dimensions of the finished part.

    To create a sheet metal part, you sketch an open profile and use the base flange feature to create the thinfeature and the bends.

    1. Open a new part.

    2. Click Base Flange/Tab (Sheet Metal toolbar).

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    3. Select the Front plane.

    A sketch opens on the Front plane.

    4. Sketch and dimension the profile.

    Expand the Line flyout menu on the Sketch CommandManager and sketch a Centerline

    (Sketch toolbar) through the origin, then use Add Relation (Sketch toolbar) to add a

    Symmetric relation between the three vertical lines. Later, this allows you to mirror aboutthe Right plane.

    5. Click Exit Sketch (Sketch toolbar).

    6. In the PropertyManager, underDirection 1:

    Select Blind in End Condition.

    Set Depth to 75.

    What are Sheet Metal Gauges?

    7. Under Sheet Metal Parameters:

    Set Thickness to 3.

    Set Bend Radius to 1.

    8. Click .

    The sketch is extruded and the bends are added.

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    Next

    FeatureManager Design Tree

    A base flange feature creates the following features in the FeatureManager design tree:

    Sheet-Metal1. Contains the default bend parameters including bend radius, bend allowance,and relief type. To edit, right-clickSheet-Metal1 and on the context toolbar, clickEdit Feature

    .

    Base-Flange1. Designates the first solid feature of the sheet metal part. To edit the Base-

    Flange parameters, right-clickBase-Flange1 and on the context toolbar, clickEdit Feature .

    Flat-Pattern1. Flattens the sheet metal part. The flat pattern is suppressed by default becausethe part is in its bent state. To flatten the part, right-clickFlat-Pattern1 and on the context

    toolbar, clickUnsuppress .

    When the Flat-Pattern feature is suppressed, new features are automatically inserted above theFlat-Pattern feature in the FeatureManager design tree. When the Flat-Pattern feature is

    unsuppressed, new features go below it in the FeatureManager design tree and are not shown inthe folded part.

    Next

    Adding a Miter Flange

    You can add flanges to your sheet metal part with corners that are automatically mitered. First you add anotch to limit the propagation of the miter flange. Then you add and dimension the sketch for the miterflange.

    1. Click Extruded Cut (Features toolbar), and select the bottom face.

    2. Sketch and dimension a circle with its center coincident to the midpoint of the edge, as shown.

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    3. Close the sketch.

    4. In the PropertyManager, clickLink to thickness underDirection 1, and then click .

    5. Click Wireframe (View toolbar).

    Next

    Adding a Miter Flange (continued)

    6. Click Miter Flange (Sheet Metal toolbar).

    7. Select the inside vertical edge as shown to create a sketch plane normal to the selected edge withits origin at the closest endpoint of the edge. Make sure to select the upper portion of the edge.

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    8. Click Bottom (Standard Views toolbar).

    10. Starting at the origin, sketch as shown.

    9. Click Zoom to

    Area (View

    toolbar) and zoomto the sketch origin.

    a. Horizontal Line(Sketch toolbar), with anapproximate length of20.

    b. Tangent Arc(Sketch toolbar), with anapproximate radius of

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    indicates tangency.

    11. ClickSmart Dimension (Dimensions/Relations toolbar) and dimension as shown.

    Miter Flange - Arc Sketches

    Next

    Adding a Miter Flange (continued)

    Now you create the miter flange.

    1. Click Zoom to Fit (View toolbar).

    10.

    c. Line (Sketchtoolbar) tangent to thearc, with an approximatelength of 6.

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    2. Click Isometric (Standard Views toolbar).

    3. Click Exit Sketch (Sketch toolbar).

    4. Click Propagate .

    The miter flange is propagatedto the tangent edges, stopping at the notch.

    5. In Miter Parameters, underFlange position, clickMaterial Outside .

    6. Click .

    7. Click Shaded With Edges (View toolbar).

    8. Save the part as Cover.sldprt.

    Next

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    Mirroring the Sheet Metal Bends

    When you mirror a sheet metal part, many of the bends are mirrored as well.

    1. Click Back (Standard Views toolbar).

    2. Zoom to the right corner of the model's back face.

    3. Click Mirror (Features toolbar).

    4. Select one of the back planar faces, as shown, forMirror Face/Plane .

    5. Click Bodies to Mirror, and select the sheet metal body as shown, forSolid/Surface Bodies to

    Mirror .

    6. Click .

    7. Click Isometric (Standard Views toolbar).

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    8. ExpandMirror1 in the FeatureManager design tree to view new bends for the mirrored geometry.

    Next

    Creating an Edge FlangeCreate an edge flange using the edit sketch profile and offset options.

    1. Click Edge Flange (Sheet Metal toolbar).

    2. Select the outer edge as shown.

    3. Drag the edge flange as shown, and click.

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    4. In the PropertyManager:

    UnderFlange Length, set Length to 30.

    UnderFlange Position:

    Select Material Outside .

    Select Offset.

    Set Offset Distance to 15.

    UnderFlange Parameters, clickEdit Flange Profile to display the Profile Sketch dialogbox.

    5. Select the end points along the base flange (inside edge) and drag them towards the center asshown.

    Repositioning the end points removes the relation between the width of the base flange andthe width of the edge flange.

    6. Click Smart Dimension (Dimensions/Relations toolbar) and dimension the edge flange asshown.

    7. Click Finish to close the Profile Sketch dialog box and complete the edge flange.

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    Next

    Mirroring a Sheet Metal Feature

    You can mirror sheet metal bodies as well as selected sheet metal features. Use the Right plane to

    mirror the edge flange feature.

    The plane used to mirror the sheet metal feature must be centered between the edges of the baseflange.

    1. Click Mirror (Features toolbar).

    2. Expand the FeatureManager design tree, and in the PropertyManager:

    a. Under Mirror Face/Plane, select Right forMirror Face/Plane .

    b. UnderFeatures to Mirror, select Edge-Flange1 forFeatures to Mirror .

    3. Click .

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    Next

    Adding a Tab

    1. Select the face as shown, then clickBase Flange/Tab (Sheet Metal toolbar).

    A sketch opens on the selected face.

    2. Sketch a rectangle, making one edge of the rectangle coincident to the upper edge of the edgeflange.

    3. Dimension the rectangle to stick out 20 from the edge flange and be 40 long.

    4. Clear the Dimension tool.

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    5. Add a coincident relation between the midpoint of one of the long lines of the rectangle and theedge flange:

    a. Right-click one of the long lines of the rectangle, and clickSelect Midpoint.

    b. ClickAdd Relation (Dimensions/Relations toolbar).

    c. Right-click the long edge of mirrored edge flange, and clickSelect Midpoint.

    d. In the PropertyManager, underAdd Relations, clickCoincident, then click .

    6. Click Exit Sketch (Sketch toolbar).

    7. Click .

    The tab is added to the part. The SolidWorks software links the thickness of the tab to thethickness of the base flange.

    Next

    Bending a Tab

    Now you specify how to bend the tab.

    1. Select the top face of the tab, then clickSketched Bend (Sheet Metal toolbar).

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    2. Sketch a horizontal line of any length. Dimension it as shown.

    The bend line does not need to be the exact length of the face you are bending.

    3. Click Exit Sketch (Sketch toolbar).

    4. In the PropertyManager underBend Parameters:

    a. Select the face with the sketch below the bend line forFixed Face .

    b. ClickMaterial Outside .

    c. Set Bend Angle to 90.

    d. Select Use default radius.

    5. Click .

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    6. Save the part.

    Next

    Adding a Cut Across a Bend

    To cut across a bend, you start by unfolding only the bend that you want to cut across. Unfolding onlyone bend results in faster system performance.

    1. Click Unfold (Sheet Metal toolbar).

    2. In the graphics area, select the face and bend as shown forFixed face andBends to unfold

    .

    You can only select bends when the Bends to unfold box is active.

    3. Click to unfold the selected bend.

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    Next

    Adding a Cut Across a Bend (continued)

    Next, you create a cut through the bend.

    1. Click Extruded Cut (Features toolbar).

    2. Select the face shown, and clickNormal To (Standard Views toolbar).

    3. Sketch and dimension a rectangle, and add a Collinear relation between the rectangle edge andthe edge of the edge flange as shown.

    4. Click Exit Sketch (Sketch toolbar).

    5. In the PropertyManager, underDirection 1, select Through All in End Condition, then clickto cut through the bend region.

    6. Click Isometric (Standard Views toolbar).

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    Next

    Adding a Cut Across a Bend (continued)

    Now, fold the bend back to its bent state.

    1. Click Fold (Sheet Metal toolbar).

    2. In the PropertyManager, clickCollect All Bends to add all unfolded bends to Bends to fold .

    3. Click to return the part to its bent state.

    Next

    Creating Closed Corners

    Now add a closed corner to one side of the base flange. A closed corner extends a flange so that the gapbetween two flanges is narrowed.

    To create a closed corner, first add an edge flange to the base flange.

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    1. Click Edge Flange (Sheet Metal toolbar).

    2. Select the edge as shown.

    3. In the PropertyManager:

    a. Under Angle, set Flange Angle to 75.

    b. UnderFlange Length:

    Set LengthEnd Condition to Blind.

    If the preview faces down, clickReverse Direction .

    Set Length to 85.

    c. Under Flange Position, select Material Outside .

    d. Under Custom Relief Type:

    In Relief Type, select Rectangle.

    Select Use relief ratio.

    Set Ratio to 0.3.

    4. Click .

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    Next

    Creating Closed Corners (continued)

    Next, add a closed corner by extending the face that is adjacent to the angled edge flange you just added.

    1. Click Closed Corner (Sheet Metal toolbar).

    2. Select the face of the base flange as shown forFaces to Extend .

    3. Select Butt forCorner type.

    4. Click .

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    Next

    Flattening and Folding the PartYou can flatten all the bends of a sheet metal part at once.

    1. Verify that the rollback bar is rolled to the end, then clickFlatten (Sheet Metal toolbar). Thisis the same as unsuppressing the Flat-Pattern feature that was created with the Base Flangefeature.

    The flattened sheet metal part appears with all of the bend lines shown. You may also see abounding box around the part. The bounding box is the smallest rectangle in which the flat

    pattern can fit.

    2. To fold the part back up, clickFlatten again.

    3. Save the part.

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    Next

    Creating a Sheet Metal Drawing

    Now create a drawing of the sheet metal part. Start with an isometric view of the folded model, and then

    add a view of the unfolded model.

    1. Click Options (Standard toolbar).

    2. On the System Options tab, clickDrawings, Display Style.

    3. Under Tangent edges in new views, select Visible, and clickOK.

    4. Click Make Drawing from Part/Assembly (Standard toolbar), then clickOK to open a

    drawing sheet.

    5. Drag the Isometric view from the View Palette to the upper-right corner of the drawing sheet.

    6. In the PropertyManager:

    a. Under Scale, select Use custom scale.

    b. Select User Defined in the list and type 1:3.

    c. Click .

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    Next

    Creating a Sheet Metal Drawing (continued)

    Next, add a view of the unfolded model. A flat pattern view is automatically added in thePropertyManager when you create a sheet metal part.

    1. Click Model View (Drawing toolbar).

    2. In the PropertyManager:

    a. Click .

    b. UnderOrientation, in More views select (A)Flat pattern.

    c. Under Scale, select Use custom scale. Select User Defined in the list and type 1:3.

    d. Click to place the view in the drawing sheet.

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    The view orientation of flat patterns in a drawing views varies, depending on such factors as

    the way you extruded the base flange. To rotate the view, select the drawing, clickRotate(View), and make your choices in the dialog box. You may also need to use Flip view in thePropertyManager.

    3. Click .

    4. Save the drawing as Cover.slddrw.

    ClickSave All to save both the drawing and the updated model if a message box notifies youthat the model referenced in the drawing was modified.

    Next

    Adjusting the Bend Notes

    First reduce the font size.

    You can set font size as well as other options as part of the drawing template.

    1. Box-select the drawing.

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    2. In the PropertyManager:

    UnderText Format, clearUse document font.

    ClickFont.

    3. In the Choose Font dialog box, select Points, 9 forHeight, and clickOK.

    4. Click the sheet to clear the block-select.

    Next

    Adjusting the Bend Notes (continued)

    Now adjust the bend notes for clarity by hiding, moving, and adding leaders to selected notes.

    In this example, the bend notes are positionedAbove Bend Line.

    1. Press Ctrl and select UP 59.04 R7 andDOWN 90.00 R1 from the miter flange located at the

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    bottom, as shown.

    2. Right-click and select Hide.

    3. Repeat steps 1 and 2 with the miter flange bend line notes at the top, as shown.

    4. Select UP 59.04 R7 from the miter flange located at the top, drag outside the part's shape to theleft, and click to position.

    5. In the PropertyManager, underLeader, clickLeader .

    You can change the angle of a bend note, the leader type, and the arrow style.

    6. Repeat steps 4 and 5 with the three remaining miter flange notes.

    7. Click to close the PropertyManager.

    8. Press Ctrl and select the five vertical instances ofUP 90.00 R1 andDOWN 90.00 R1 along thecenter of the drawing.

    9. In the PropertyManager, underText Format, set Angle to 0.

    10. Click to place the bend notes so the drawing view approximately resembles the image below.

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    11. Save the drawing.

    Congratulations!You have completed this tutorial.

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