Training Guide Sheet Metal Basics

Transcription

1 Training Guide Sheet Metal Basics

2 2015, Missler Software. 7, Rue du Bois Sauvage F Evry, FRANCE Web: All rights reserved. TopSolid Design Sheet Metal Basics 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. TopSolid is a registered trademark of Missler Software. TopSolid is a product name of Missler Software. The information and the software contained within this document are subject to change without prior warning and should not be construed as a commitment by Missler Software. The software covered by this document is supplied under license, and may only be used and duplicated in compliance with the terms of this license. Version 7.9 Rev.02 Note: If you are experiencing problems using this training guide, please feel free to send your feedback and comments at edition@topsolid.com. ii Missler Software

3 TopSolid Design Sheet Metal Basics Contents Exercise 1: Creation of a sheet metal on open sketch... 1 Exercise 2: Creation of a sheet metal on close sketch... 5 Exercise 3: Creation of a sheet metal with dragged edges... 8 Exercise 4: Creation of a sheet metal with swept flange Exercise 5: Creation of a sheet metal with flange Exercise 6: Creation of a hood Exercise 7: Creation of a box Exercise 8: Creation of a box with manual corner and edge reliefs Exercise 9: Creation of a counter Exercise 10: Creation of a container Exercise 11: Creation of a support Exercise 12: Creation of a sheet metal with forming flange Exercise 13: Creation of a sheet metal with ball corner Exercise 14: Forming component without added material Exercise 15: Forming component with added material Exercise 16: Creation of sheet metal from a casing Step file Exercise 17: Creation of a sheet metal from file recovery Annexes Notes Individual course evaluation form Missler Software iii

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5 TopSolid Design Sheet Metal Basics Exercise 1: Creation of a sheet metal on open sketch Exercise 1: Creation of a sheet metal on open sketch Concepts addressed: - Creation of a sketch - Creation of a sheet metal on sketch - Creation of an angle relief - Creation of an unfolding document Creation of a part Create a new project by clicking the New Project icon and rename it to Your name - Sheet Metal Training. From the Project tree, right-click on the project name and select Folder. Rename this new folder to Exercise 1 - Sheet metal on sketch. Create a new Part document and rename it to Keyboard support. Create the following sketch. From the Sheet Metal tab, select Sheet Metal on Sketch and complete the dialog box as follows. Missler Software 1

6 Exercise 1: Creation of a sheet metal on open sketch TopSolid Design Sheet Metal Basics Note: The Sheet Metal on Sketch function can also be accessed by right-clicking on the sketch. Create a rectangular sketch on the top face of the sheet, centered on the 280mm length, and then finish dimensioning it to produce the following result. Use the Pocket function to create the following pocket on this sketch. From the Limit field, select Through all in the drop-down list. 2 Missler Software

7 TopSolid Design Sheet Metal Basics Exercise 1: Creation of a sheet metal on open sketch Create 10mm fillets on the sheet s side faces using the Angle Relief function from the Sheet Metal tab. Note: Only the edges on the sheet s side faces can be selected. Save the document. In the Entities tree, you can find the following system parameters in the Parameters > System Parameters folders. Note: Once the document has been saved, TopSolid automatically creates the Thickness parameter and the Sheet Metal Boolean parameter. TopSolid does no longer recognize the part as a general mechanical part, but as a sheet metal part that can be unfolded. Therefore, the parts. Unfolding function is only available on sheet metal You can use these elements to search for previously created sheet metal parts. For example, if you search for a sheet metal part whose thickness is 2mm, you can do the following: Click the TopSolid 7 icon at the top left of the screen, and select View > Search to display the Search window. Click the double arrow icon to display the advanced search box. In the Type field, specify that you search for a Part document and click the Apply button. In the Property field, select Standard > Dimension > Thickness. In the Operator field, select Equals. In the Value field, enter 2mm. Click the Refresh icon to start the search. Missler Software 3

8 Exercise 1: Creation of a sheet metal on open sketch TopSolid Design Sheet Metal Basics Parts that match the defined criteria appear in the search window. Right-click on the sheet metal and select Others > Analyze Sheet Metal in the Shape 1 section. Warning: You can only create sheet metals with the same thickness in a part document. Creation of the unfolding Right-click on the Keyboard support part document s upper tab and select Unfolding. Choose Blank Template and validate. Validate the Unfolding dialog box. Notes: The part document must be saved to have the Unfolding function displayed in the context menu. You can hide the part by right-clicking on shape 1 and selecting Hide. Save the unfolding document. 4 Missler Software

9 TopSolid Design Sheet Metal Basics Exercise 2: Creation of a sheet metal on close sketch Exercise 2: Creation of a sheet metal on close sketch Creation of an assembly From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 2 - Sheet metal on close sketch. Create an Assembly document and rename it to Keyboard support set. Drag the Keyboard support part document into the Keyboard support set assembly document. Creation of the side (in place) Right-click on the keyboard support s side face and select In Place Part. Use a blank template and validate. A new part document is then created. Because the part is created "in place" in the assembly, the document is included in the assembly document s node in the Project tree, and not outside of this node like the Keyboard support document. Draw the following sketch. Missler Software 5

10 Exercise 2: Creation of a sheet metal on close sketch TopSolid Design Sheet Metal Basics Right-click on the sketch, select Sheet Metal on Sketch, and then validate the dialog box. Rename the new document for the part created in place to Side. Change the color of the part using the Attributes function. Validate the in-place design by clicking on. Creation of the opposite side Duplicate the Side part by pressing Ctrl + left-click on the part. 6 Missler Software

11 TopSolid Design Sheet Metal Basics Exercise 2: Creation of a sheet metal on close sketch Constrain the duplicate part as shown below. Validate the positioning by clicking on. Save the document. Missler Software 7

12 Exercise 3: Creation of a sheet metal with dragged edges TopSolid Design Sheet Metal Basics Exercise 3: Creation of a sheet metal with dragged edges Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 3 - Sheet metal with dragged edges. Create a new Part document named Roof. Draw the following sketch. Right-click on the sketch, select Sheet Metal on Sketch and create a 2mm thick sheet metal on sketch along Z+. 8 Missler Software

13 TopSolid Design Sheet Metal Basics Exercise 3: Creation of a sheet metal with dragged edges Right-click on one shape s upper edge and select Flange. Right-click on a flange face, enable the following options and then click on OK. Note: By activating the Close neighbour borders option, TopSolid drags the borders laterally to add material. Missler Software 9

14 Exercise 3: Creation of a sheet metal with dragged edges TopSolid Design Sheet Metal Basics Right-click on the top flange s upper edge and select Flange. Repeat procedure on opposite edge. To do this, move the mouse cursor over the flange operation, press Ctrl + left click, and then drag the duplicate shape onto the opposite inner edge. Note: Do not hesitate to zoom in when using this function. If the flange is positioned in the opposite direction, right-click on the flange, select Edit, and then double-click on the flange s direction arrow. Save the document. 10 Missler Software

15 TopSolid Design Sheet Metal Basics Exercise 3: Creation of a sheet metal with dragged edges Add two new flanges to edges of the previously created flanges. Next create a flange on one side edge by selecting the flange face as the limitation plane. Specify a shift value of 0.1mm. Note: The shift MUST be defined, otherwise TopSolid merges the sheets. Missler Software 11

16 Exercise 3: Creation of a sheet metal with dragged edges TopSolid Design Sheet Metal Basics Repeat the flange operation on opposite side. Warning: Here it is not recommended to paste the operation using the Ctrl + left click combination because by default TopSolid will keep the previous limit face and you will have to edit the operation to reconnect the limit face to the good face. Right-click the inner edge of one of the two top flanges and select Hem Bend. Then select the inner edge of the other top flange. Warning: The bending radii must be directed towards the inside of the sheet. Save the document. 12 Missler Software

17 TopSolid Design Sheet Metal Basics Exercise 3: Creation of a sheet metal with dragged edges Creation of an unfolding rule Right-click on the shape and select Others > Analyze Sheet Metal in the Shape 1 section. The default unbending method is Neutral Fiber K Factor = 0.5. Right-click on the Roof part document s upper tab and select Unfolding. The unfolding document is created without trouble. However, we would like to use another unbending method than the default one. So we will create an unfolding rule. Return to the Roof part document. From the Sheet Metal tab, select Unfolding Rules. Enable the Predefined Rules dialog and select Steel Tables in the drop-down list. Return to the unfolding document. Missler Software 13

18 Exercise 3: Creation of a sheet metal with dragged edges TopSolid Design Sheet Metal Basics The Unfolding Building 1 - Unbending methods search failed error message appears in the graphics area, which is normal because we have modified the bending method. Click OK. From the Unfolding tab, select the Unbending Methods Check function to identify the problematic bends. The R1 and R5 bends display errors. Use the Search function to find the tables. Click the TopSolid 7 icon and select View > Search to display the Search window. Click the icon to create a new search. In the Type field, check the Unfolding Rules option from the Special tab and click on Apply. Click the Refresh icon to start the search. From the search results list, right-click on Steel Tables and select Show in project tree. The TopSolid Mechanical library opens. 14 Missler Software

19 TopSolid Design Sheet Metal Basics Exercise 3: Creation of a sheet metal with dragged edges From this library, copy the Steel Tables document and paste it in the current project, and then rename it to My steel table. Open the My steel table document and specify the description and part number. In the table, create the missing line for T=2 R=1. Repeat the operation for T=2 R=5. Missler Software 15

20 Exercise 3: Creation of a sheet metal with dragged edges TopSolid Design Sheet Metal Basics Save the My steel table document. Drag the My steel table document into the Roof part document. Save the part document. In the part document, check that the new unfolding rule has been taken into account by right-clicking on the sheet and then selecting Others > Analyze Sheet Metal in the Shape 1 section. Return to the unfolding document. No error message should be displayed. Save the unfolding document. 16 Missler Software

21 TopSolid Design Sheet Metal Basics Exercise 4: Creation of a sheet metal with swept flange Exercise 4: Creation of a sheet metal with swept flange Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 4 - Sheet metal with swept flange. Create a new Part document and rename it to Door with swept flange. Draw the following sketch. Right-click on the sketch, select Sheet Metal on Sketch and create a 2mm thick sheet metal on sketch along Z+. Create the following sketch on one side face. Missler Software 17

22 Exercise 4: Creation of a sheet metal with swept flange TopSolid Design Sheet Metal Basics Validate the sketch by clicking on. From the Sheet Metal tab, select Swept Flange and create the following swept flange on the four border edges. Save the part document. 18 Missler Software

23 TopSolid Design Sheet Metal Basics Exercise 4: Creation of a sheet metal with swept flange Creation of the unfolding Right-click on the Door with swept flange part document s upper tab and select Unfolding. Select Blank Template and validate. Validate the Unfolding dialog box. Save the unfolding document. Creation of the draft Use the Draft function to create the drawing of the Door with swept flange part. Select the Part A3 ISO Landscape template. Missler Software 19

24 Exercise 4: Creation of a sheet metal with swept flange TopSolid Design Sheet Metal Basics Drag the unfolding document into the draft document. Save the draft document. 20 Missler Software

25 TopSolid Design Sheet Metal Basics Exercise 5: Creation of a sheet metal with flange Exercise 5: Creation of a sheet metal with flange Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 5 - Door with flange. Create a new Part document and rename it to Door with flange. Draw the following sketch. Right-click on the sketch, select Sheet Metal on Sketch and create a 2mm thick sheet metal on sketch along Z+. Missler Software 21

26 Exercise 5: Creation of a sheet metal with flange TopSolid Design Sheet Metal Basics Right-click on one shape s upper edge and select Flange. 22 Missler Software

27 TopSolid Design Sheet Metal Basics Exercise 5: Creation of a sheet metal with flange Right-click on the previously created flange s upper edge and select Flange. Then select the three other border edges. Note: When selecting several edges, if the flanges intersect, then a trim is automatically performed. The default trimming gap value is 0.1mm, but it can be modified in the Advanced Options dialog. Missler Software 23

28 Exercise 5: Creation of a sheet metal with flange TopSolid Design Sheet Metal Basics Right-click on the previously created flange s upper edge and select Flange. Then select the three other border edges. Save the part document. 24 Missler Software

29 TopSolid Design Sheet Metal Basics Exercise 6: Creation of a hood Exercise 6: Creation of a hood Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 6 - Hood. Create a new Part document and rename it to Hood. Draw the following sketch. Extrude the sketch to a height of 50mm. Missler Software 25

30 Exercise 6: Creation of a hood TopSolid Design Sheet Metal Basics From the Sheet Metal tab, select Sheet Metal by Thickening and complete the dialog box as seen below. Validate the created sheet metal by thickening. 26 Missler Software

31 TopSolid Design Sheet Metal Basics Exercise 6: Creation of a hood Right-click the upper edge on the left side of the shape and select Flange. Note: By enabling the Create sketches option, TopSolid creates a rectangular sketch for each flange. You can then modify the flange shape by editing the corresponding sketch. Validate the created flange. Missler Software 27

32 Exercise 6: Creation of a hood TopSolid Design Sheet Metal Basics Right-click on the flange thus created, select Edit Sketch and modify the sketch as shown below. Use the Parallelism constraint. Note: For the 100mm and 70mm dimensions, use the Constraint function. Click on both entities, then right-click in the graphics area and select Linear Dimension. Validate the sketch by clicking on. Note: You can modify the sketch to your liking, or add material to the sides or the front of the part. Right-click on the back flange and draw the following sketch. 28 Missler Software

33 TopSolid Design Sheet Metal Basics Exercise 6: Creation of a hood Right-click on this sketch and select Trim by Profile. Note: Be sure to check the Straighten lateral faces option in order to make the edges perpendicular to the sheet metal faces. The Lateral Faces Straightening function is also available directly from the Sheet Metal tab. Right-click on the lower face and create the following sketch. Validate the sketch by clicking on. Missler Software 29

34 Exercise 6: Creation of a hood TopSolid Design Sheet Metal Basics From the Sheet Metal tab, select Bend Along a Line. Warning: The Trimming Profile option allows you to trim the face to bend by a profile (open). This profile must have two intersections with the bend line. 30 Missler Software

35 TopSolid Design Sheet Metal Basics Exercise 6: Creation of a hood Hide the sketch. From the Shape tab, select Repetition and repeat the bend along a line operation using a linear pattern. Enable the Operations option and disable the Replay operations option. In the Linear Pattern dialog box, specify the following: - Direction: Select Absolute Y axis from the drop-down list. - Total distance: Enter 93mm. - Total count: Enter 3. Missler Software 31

36 Exercise 6: Creation of a hood TopSolid Design Sheet Metal Basics Right-click on the lower face and create the following sketch. Validate the sketch by clicking on. 32 Missler Software

37 TopSolid Design Sheet Metal Basics Exercise 6: Creation of a hood From the Sheet Metal tab, select Bend Along a Line. Save the document. Missler Software 33

38 Exercise 7: Creation of a box TopSolid Design Sheet Metal Basics Exercise 7: Creation of a box Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 7 - Box. Create a new Part document and rename it to Box. Draw the following sketch. Extrude the sketch to a height of 50mm. 34 Missler Software

39 TopSolid Design Sheet Metal Basics Exercise 7: Creation of a box From the Sheet Metal tab, select Sheet Metal by Thickening and create the following sheet metal. Save the part document. Missler Software 35

40 Exercise 7: Creation of a box TopSolid Design Sheet Metal Basics Creation of the unfolding Right-click on the Box part document s upper tab and select Unfolding. Select Blank Template and validate. Validate the Unfolding dialog box. Save the unfolding document. 36 Missler Software

41 TopSolid Design Sheet Metal Basics Exercise 8: Creation of a box with manual corner and edge reliefs Exercise 8: Creation of a box with manual corner and edge reliefs Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 8 - Box with manual corner and edge reliefs. Create a new Part document and rename it to Box with manual corner and edge reliefs. Draw the following sketch. Extrude the sketch to a height of 50mm. Missler Software 37

42 Exercise 8: Creation of a box with manual corner and edge reliefs TopSolid Design Sheet Metal Basics From the Sheet Metal tab, select Sheet Metal by Thickening and create the following sheet metal. Select Corner Relief and create the following corner reliefs. 38 Missler Software

43 TopSolid Design Sheet Metal Basics Exercise 8: Creation of a box with manual corner and edge reliefs Next select Edge Relief and create the following edge reliefs. Using the Bend on Edge function, create the following bends. Save the part document. Missler Software 39

44 Exercise 8: Creation of a box with manual corner and edge reliefs TopSolid Design Sheet Metal Basics Creation of the unfolding Right-click on the part document s upper tab and select Unfolding. Select Blank Template and validate. Validate the Unfolding dialog box. Return to the part document and edit the corner relief operations. In the Advanced Options dialog, check Extract on unfolding. Save the part document. Return to the unfolding document to view the result. TopSolid has automatically updated the unfolding by extracting the corner reliefs. Save the unfolding document. 40 Missler Software

45 TopSolid Design Sheet Metal Basics Exercise 9: Creation of a counter Exercise 9: Creation of a counter Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 9 - Counter. Create a new Part document and rename it to Counter. Draw the following sketch. Extrude the sketch to a height of 600mm. Missler Software 41

46 Exercise 9: Creation of a counter TopSolid Design Sheet Metal Basics Via the Sheet Metal by Thickening function, create the following sheet metal. Generate the edge reliefs and bends using the Relief Assistant function. 42 Missler Software

47 TopSolid Design Sheet Metal Basics Exercise 9: Creation of a counter Right-click the lower edge on the left side of the shape and select Flange. Then select the lower edge on the right side of the shape as shown below. In the Bending Angle field, choose Direction from the dropdown list, and then select the lower edge as shown below. Missler Software 43

48 Exercise 9: Creation of a counter TopSolid Design Sheet Metal Basics Right-click on the lower edge as seen below and select Flange. Then click the edge on opposite side. Next select the Covering function and do the following. 44 Missler Software

49 TopSolid Design Sheet Metal Basics Exercise 9: Creation of a counter Still using the Covering function, create another covering operation on opposite side. Draw the following sketch on the shape s front face. Position the sketch as shown below. Missler Software 45

50 Exercise 9: Creation of a counter TopSolid Design Sheet Metal Basics Right-click on the sketch and select Pocket. 46 Missler Software

51 TopSolid Design Sheet Metal Basics Exercise 9: Creation of a counter Right-click on the pocket operation and select Others > Repetition. Save the document. Missler Software 47

52 Exercise 10: Creation of a container TopSolid Design Sheet Metal Basics Exercise 10: Creation of a container Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 10 - Container. Create a new Part document and rename it to Container. From the Shape tab, select Block and create the following shape. Draw the following sketch on the side face. 48 Missler Software

53 TopSolid Design Sheet Metal Basics Exercise 10: Creation of a container Right-click on the sketch and select Trim by Profile. Draw the following sketch on the top face. Next create the new following sketch on the oblique front face. Missler Software 49

54 Exercise 10: Creation of a container TopSolid Design Sheet Metal Basics From the Surface tab, select Imprint. From the Sheet Metal tab, create the following sheet metal using the Sheet Metal by Thickening function. 50 Missler Software

55 TopSolid Design Sheet Metal Basics Exercise 10: Creation of a container Select the Slot function and create a first slot as seen below. Missler Software 51

56 Exercise 10: Creation of a container TopSolid Design Sheet Metal Basics Then create a second slot as seen below. Note: The extra thicknesses correspond to the tool extrusions on the top and bottom faces. 52 Missler Software

57 TopSolid Design Sheet Metal Basics Exercise 10: Creation of a container Use the Corner Relief function to create the following corner reliefs. Use the Edge Relief function to create the following edge reliefs. Finally, use the Bend on Edge function to create the following bends. Missler Software 53

58 Exercise 10: Creation of a container TopSolid Design Sheet Metal Basics Note: By default, the bend is calculated up to the neighboring faces. The Delimit bends option allows you to create a bend only on the length of the selected edge. Next use the Corner Filler function by selecting the side faces of corners, or checking All corners. Note: The Maximum of material method fills the hole to its maximum and the Minimum of material method fills the hole to its minimum. From the Shape tab, select Pattern Union and use a symmetrical pattern. 54 Missler Software

59 TopSolid Design Sheet Metal Basics Exercise 10: Creation of a container The result should look like the next image. Save the part document. Creation of the unfolding Right-click on the Container part document s upper tab and select Unfolding. Choose Blank Template and validate. Validate the Unfolding dialog box. Save the unfolding document. Missler Software 55

60 Exercise 11: Creation of a support TopSolid Design Sheet Metal Basics Exercise 11: Creation of a support Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 11 - Support. Create a new Part document and rename it to Support. Use the Block function to create the following shape. Using the Sheet Metal by Thickening function, create the following sheet. 56 Missler Software

61 TopSolid Design Sheet Metal Basics Exercise 11: Creation of a support Draw the following sketch on the front face. Note: You can also use the Dynamic Symmetry option to create the sketch more quickly. Using the Slot function, create the following slots. Missler Software 57

62 Exercise 11: Creation of a support TopSolid Design Sheet Metal Basics Next select the Bend on Edge function and create the following bends. Right-click on the front upper edge and select Flange. 58 Missler Software

63 TopSolid Design Sheet Metal Basics Exercise 11: Creation of a support Right-click on the left upper edge and select Flange. Right-click on the right upper edge and select Flange. Missler Software 59

64 Exercise 11: Creation of a support TopSolid Design Sheet Metal Basics Right-click on the sheet metal edge of the left upper bend and select Covering. 60 Missler Software

65 TopSolid Design Sheet Metal Basics Exercise 11: Creation of a support Right-click on the sheet metal edge of the right upper bend and select Covering. From the Sheet Metal tab, select Unbending of Bend. Missler Software 61

66 Exercise 11: Creation of a support TopSolid Design Sheet Metal Basics Create the following sketch on the inner face. Center the circle in the middle of the bend using the Centering constraint. Right-click on the sketch and select Pocket. In the Limit field, select Through all in the drop-down list. From the Sheet Metal tab, select Rebending of Bend. 62 Missler Software

67 TopSolid Design Sheet Metal Basics Exercise 11: Creation of a support Still from the Sheet Metal tab, select Unbending of Bend. Draw the following sketch on the inner face. Right-click on the sketch and select Trim by Profile. Missler Software 63

68 Exercise 11: Creation of a support TopSolid Design Sheet Metal Basics From the Sheet Metal tab, select Rebending of Bend. The result should look like the next image. Save the part document. Creation of the unfolding Right-click on the Support part document s upper tab and select Unfolding. Select Blank Template and validate. Validate the Unfolding dialog box. 64 Missler Software

69 TopSolid Design Sheet Metal Basics Exercise 11: Creation of a support From the Unfolding tab, select Unfolding Dimensioning. Save the unfolding document. Creation of the draft Create a Draft document from the Support part document using the Part A3 ISO Landscape template. Drag the unfolding document into the draft document. Save the draft document. Missler Software 65

70 Exercise 12: Creation of a sheet metal with forming flange TopSolid Design Sheet Metal Basics Exercise 12: Creation of a sheet metal with forming flange Concepts addressed: - Creation of a sheet metal - Creation of a forming flange - Creation of a derived part - Forming flange straightening - Creation of the unfolding Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 12 - Sheet metal with forming flange. Create a new Part document and rename it to Keyboard support. Draw the following sketch. Right-click on the sketch and select Sheet Metal on Sketch. Create the following sheet metal. 66 Missler Software

71 TopSolid Design Sheet Metal Basics Exercise 12: Creation of a sheet metal with forming flange Right-click on the back upper border edge and select Flange. Draw the following sketch. Missler Software 67

72 Exercise 12: Creation of a sheet metal with forming flange TopSolid Design Sheet Metal Basics Right-click on the sketch and select Drilling Group. 68 Missler Software

73 TopSolid Design Sheet Metal Basics Exercise 12: Creation of a sheet metal with forming flange From the Sheet Metal tab, select Swept Flange and create a flange on the following border edges. Missler Software 69

74 Exercise 12: Creation of a sheet metal with forming flange TopSolid Design Sheet Metal Basics From the Tools tab s pull-down menu, select Derivations > Derived Part. In the current window, select the desired target project, and then validate. Leave the default entities checked and click on. The derived part thus created then appears in the Project tree. Note: A part derivation creates a setup document in order to make 3D modifications. Here we would like to straighten the forming flange which is not a simple bending. We could have straightened it directly in the part document, but the changes made would not have been visible in the related documents. 70 Missler Software

75 TopSolid Design Sheet Metal Basics Exercise 12: Creation of a sheet metal with forming flange Open the Keyboard support (derived) part document, and then from the Sheet Metal tab select Forming Flange Straightening and perform the straightening on the four edges shown below. Save the part document. Creation of the unfolding Right-click on the Keyboard support (derived) part document s upper tab and select Unfolding. Choose Blank Template and validate. Validate the Unfolding dialog box. Missler Software 71

76 Exercise 13: Creation of a sheet metal with ball corner TopSolid Design Sheet Metal Basics Exercise 13: Creation of a sheet metal with ball corner Concepts addressed: - Creation of a sheet metal - Creation of a derived part - Opening a ball corner - Creation of the unfolding Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 13 - Sheet metal with ball corner. Create a new Part document and rename it to Tray. Create the following shape. Using the Sheet Metal by Thickening function, create the following sheet. 72 Missler Software

77 TopSolid Design Sheet Metal Basics Exercise 13: Creation of a sheet metal with ball corner From the Tools tab s pull-down menu, select Derivations > Derived Part. In the current window, select the desired target project and validate. Leave the default entities checked and click on. The derived part thus created then appears the Project tree. Open the Tray (derived) part document, and then from the Sheet Metal tab select Edge Relief and create the following edge reliefs. Missler Software 73

78 Exercise 13: Creation of a sheet metal with ball corner TopSolid Design Sheet Metal Basics Next use the Forming Flange Straightening function. Repeat the operation on every ball corner. The result should look like the next image. 74 Missler Software

79 TopSolid Design Sheet Metal Basics Exercise 13: Creation of a sheet metal with ball corner Using the Slot function, create the following slot. Save the part document. Creation of the unfolding Right-click on the Tray (derived) part document s upper tab and select Unfolding. Choose Blank Template and validate. Validate the Unfolding dialog box. Missler Software 75

80 Exercise 14: Forming component without added material TopSolid Design Sheet Metal Basics Exercise 14: Forming component without added material Concepts addressed: - Creation of a subtraction shape - Creation of parameters - Providing function - Creation of a family Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 14 - Forming component without added material. Create a new Part document and rename it to Keyhole. Draw the sketch shown here and create the following parameters: - D1 = Large diameter - D2 = Small diameter - A = Center distance Extrude the sketch to a length TH = 2mm. Warning: The height of the extruded shape must be equal to the thickness parameter of the sheet metal. 76 Missler Software

81 TopSolid Design Sheet Metal Basics Exercise 14: Forming component without added material Providing the sheet metal function From the Tools tab s pull-down menu, select Publishings > Provide Function. Note: Here we only need to perform a subtraction operation. Select the Standard Forming Subtraction function and check the Create parameter option. After validation, hide the rectangle shape. Now we will associate the parameters and the shape with the function. From the Entities tree, open the Functions folder and double-click on the Standard Forming Subtraction function. Note: In our case, the parameter, the thickness, the positioning frame and the shape are enough. Define the document as a virtual document via File > Virtual Document. Save the document. Missler Software 77

82 Exercise 14: Forming component without added material TopSolid Design Sheet Metal Basics From the Project tree, right-click on the part document Keyhole and create a Family document. In the Entities tree, from the Generics folder move the D1, D2, A and TH parameters into the Drivers folder of the family. Note: This is done to create dimensional drivers when inserting the family in the part file. Save the document and check the document into the vault. Create a new Part document and rename it to Front. Draw the following sketch. 78 Missler Software

83 TopSolid Design Sheet Metal Basics Exercise 14: Forming component without added material Then create the following sheet metal on sketch. Select the Standard Forming function. Save the document. Missler Software 79

84 Exercise 15: Forming component with added material TopSolid Design Sheet Metal Basics Exercise 15: Forming component with added material Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 15 - Forming component with added material. Create a new Part document and rename it to Hook. Create the following sheet metal corresponding to the added material. Warning: The sketch MUST be created on the XZ plane. Create the tool shape corresponding to the hook housing. Reminder: The height of the extruded shape must be equal to the thickness parameter of the sheet metal. 80 Missler Software

85 TopSolid Design Sheet Metal Basics Exercise 15: Forming component with added material Providing the sheet metal function From the Tools tab s pull-down menu, select Publishings > Provide Function. Select the Standard Forming Subtraction and Union function and check Create parameter. After validation, hide the two shapes. Change the value of the sheet metal thickness = Function thickness. Change the value of the extruded shape = Function thickness. Missler Software 81

86 Exercise 15: Forming component with added material TopSolid Design Sheet Metal Basics Now we will associate the parameters and the shape with the function. From the Entities tree, open the Functions folder and double-click on the Standard Forming Subtraction and Union function Save the document. Using the component Create a new Part document and rename it to Front. Draw the following sketch. 82 Missler Software

87 TopSolid Design Sheet Metal Basics Exercise 15: Forming component with added material Then create the following sheet metal on sketch. Select the Standard Forming function. Note: If this component is only used on 2mm sheets, it is not necessary to create a family of parts to manage the thickness. Save the document. Missler Software 83

88 Exercise 16: Creation of sheet metal from a casing Step file TopSolid Design Sheet Metal Basics Exercise 16: Creation of sheet metal from a casing Step file Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 16 - Creation of a sheet metal from casing step file. Right-click on this folder and select Import/Export > Import File with Conversion. Open the file named Casing.stp. Uncheck the Translate free curves and Translate free surfaces options, and then from the Simplification and sewing tab check the Simplify geometry and Sew sheet bodies options. 84 Missler Software

89 TopSolid Design Sheet Metal Basics Exercise 16: Creation of sheet metal from a casing Step file From the Sheet Metal tab, select Sheet Metal Recognition. Save the part document. Missler Software 85

90 Exercise 17: Creation of a sheet metal from file recovery TopSolid Design Sheet Metal Basics Exercise 17: Creation of a sheet metal from file recovery Concepts addressed: - 3D file recovery - 3D file modification - Creation of a partial part - Creation of the unfolding Creation of a part From the Project tree, right-click on the project name and create a new folder. Rename this folder to Exercise 17 - File recovery. Right-click on this folder and select Import/Export > Import File with Conversion. Open the file named Box.stp. In the Document type for assemblies field, select Part from the drop-down list, which will allow the file to be recovered in a part document. 86 Missler Software

91 TopSolid Design Sheet Metal Basics Exercise 17: Creation of a sheet metal from file recovery From the Simplification and sewing tab, enable the Simplify geometry and Sew sheet bodies options. Analyze the file to know how to unfold and divide it. The solution retained in relation to production mean is to keep the welded side lugs. Missler Software 87

92 Exercise 17: Creation of a sheet metal from file recovery TopSolid Design Sheet Metal Basics From the Entities tree, open the Shapes folder and delete the shapes 5, 6, 8 and 10. From the Shape tab s pull-down menu, select Other Operations > Faces Modification. From the Shape tab, use the Boolean function. 88 Missler Software

93 TopSolid Design Sheet Metal Basics Exercise 17: Creation of a sheet metal from file recovery Right-click on the face shown below and draw the following sketch. Right-click on the sketch and select Trim by Profile. Missler Software 89

94 Exercise 17: Creation of a sheet metal from file recovery TopSolid Design Sheet Metal Basics From the Entities tree, expand the Representations folder and delete the shapes 2 and 7. From the Tools tab s pull-down menu, select Derivations > Partial Parts. This function has created all the part documents in the Project tree. From the Project tree, select the following parts: Box Caisson trappe coupe feu, Box.Shape 1, Box.Shape 3, Box.Shape 4, Box.Shape 9 and Box.Shape 10. Right-click and select SheetMetal, and then Sheet Metals Recognition. 90 Missler Software

95 TopSolid Design Sheet Metal Basics Exercise 17: Creation of a sheet metal from file recovery Validate the window. Note: All parts have been converted into sheet metal, so they can be unfolded. Missler Software 91

96 Exercise 17: Creation of a sheet metal from file recovery TopSolid Design Sheet Metal Basics Open the Box.Shape 9 part document. Right-click on the face shown below and draw the following sketch. Validate the sketch by clicking on. Right-click on the face shown below and draw the following sketch. 92 Missler Software

97 TopSolid Design Sheet Metal Basics Exercise 17: Creation of a sheet metal from file recovery From the Sheet Metal tab, select the Slot function. Missler Software 93

98 Exercise 17: Creation of a sheet metal from file recovery TopSolid Design Sheet Metal Basics Next use the Lateral Faces Straightening function. Select the Relief Assistant function. 94 Missler Software

99 TopSolid Design Sheet Metal Basics Exercise 17: Creation of a sheet metal from file recovery Creation of multiple unfoldings From the Project tree, right-click on the Box assembly document and select Multiple Unfoldings. Choose the Sheet Metal BOM template and click on. From the left Assembly window, check that the assembly document is Box. Validate. The following window appears. Validate. This is a simple way of creating all the unfoldings in a single operation. Missler Software 95

100 Annexes TopSolid Design Sheet Metal Basics Annexes Unfolding and unbending processes General considerations The unfolding process provides the part geometry as obtained after the first shaping by cutting operations: punching, shearing, fluid cutting. The machines used can also produce additional machining operations: local deformations, tapped holes, etc. Generally unbendable sheet metals and sheet metals which cannot be unbended may be distinguished. For unbendable sheet metals, the methods of calculating the lengths on the unfolding are described below. Methods for calculating the unrolled length of a bend When performing a bend, the material is compressed inside the bend and stretched outside the bend. Between these two zones, there is a part called "neutral fiber" which is neither stretched nor compressed. A bend is considered to be modeled by two cylindrical surfaces; one for the internal face and the other for the external face. These two faces are equidistant from the thickness value. This neutral fiber is modeled as being located at a constant distance from the internal face of the bend. Its position is therefore determined on the basis of a thickness coefficient. In practice, there is no guarantee that the neutral fiber is divided that easily between the two bend faces, or that these two bend faces are cylindrical and equidistant. However, this model is accurate enough for our purpose. 96 Missler Software

101 TopSolid Design Sheet Metal Basics Annexes In contrast, when unrolling a bend, we need to know the flat length to obtain. This length is a function of: - The material - The thickness - The bending angle - The inner bending radius - The bending process (even if it is highly correlated with the bending angle) The calculation of this flat length is usually obtained through the use of standard calculation methods. These calculation methods consist of two parts: - First the calculation of a basic length obtained by applying analytical formulas that model the bending/unbending process in a more or less accurate way. - Then the application of a correction to this basic calculation, whose values generally result from measurements made on actual cases. These calculation methods are extended by analogy to all the unrolling methods supported by the unfolding calculation (unrolling of a cone, unrolling of an extruded face, etc.). Methods for calculating the basic length - L: Unrolled length - T: Thickness - R: Inner bend radius - A: Bending angle (measured angle) - K: Neutral fiber coefficient Calculations by neutral fiber These calculations provide the length of a neutral fiber located at a given position. - User neutral fiber: L = (R + K. T). (Pi A). With K between 0 and 1, given by the user. - DIN6935 neutral fiber: L = (R + K. T). (Pi A). With K = ( log(r / T) ) / 2. - Theoretical neutral fiber: L = (R + K. T). (Pi A). With for K: Ratio = R / T K0 = 0 Ratio1 = 1 K1 = 0.27 Ratio2 = 4 K2 = 0.5 If Ratio < Ratio1, then K = K0 + Ratio. (K1 - K0) / (Ratio1-0). If Ratio > Ratio1 and Ratio < Ratio2, then K = K1 + Ratio. (K2 - K1) / (Ratio2 - Ratio1). If Ratio > Ratio2, then K = K2. Missler Software 97

102 Annexes TopSolid Design Sheet Metal Basics Loss calculations on draft The reported lengths correspond to the internal or external lengths obtained by deleting the bending radius. - Internal dimension + shift coefficient. L = 2. (R + K. T). Tan((Pi A) / 2). - External dimension + shift coefficient. L = 2. ((R + T) - K. T). Tan((Pi A) / 2). - External tangent dimension + shift coefficient. L = 2. ((R + T) - K. T). Tan((Pi Max(A, Pi / 2)) / 2). These lengths are calculated for the different types of basic calculations. Green is for the neutral fiber, blue for the internal dimension, orange for the external dimension and purple for the tangent dimension (shown in orange in the first two diagrams above). Corrections They result from measurements that are usually made by bending machine manufacturers or users. Equivalent K factor Regardless of the calculation mode of the flat length, particularly when applying a correction value to the chosen analytical calculation, it is always possible to derive an equivalent K factor. This concept is important because it shows that there are several different ways to calculate the right dimensions of an unfolding. Usual behavior of standard steels In general, the unfolding lengths on standard steels are reasonably well approximated by a neutral fiber calculation with K factor values between 0.3 and 0.5. More specifically, when R is close to T, we can set the K value close to 0.3. The more important the bending radius, the more the neutral fiber comes closer to the internal face of the bend (K approaches 0). When R gets large compared to T, K takes values close to 0.5. This can be assimilated to rolling processes. The "theoretical" basic calculation method gives a good overview of this behavior. 98 Missler Software

103 TopSolid Design Sheet Metal Basics Annexes Management of unfolding/unbending methods Strictly speaking, the bending die/punch combination totally determines the calculation mode to be applied. In this combination, the bending die is predominant since it imposes the radius of the bending punch, the V-width and thus the length of the shortest edge that can be bent. It also imposes the kind of bending (air bending or coining bottoming). The shape and the punch length depend on the bend to be performed. However, they determine the effort to be made to perform the bend. A bending die can be used to bend parts of different thicknesses, on different materials, but comparable in terms of mechanical behavior. To calculate the unfolding lengths of a given part, you will have to specify: - The basic calculation type, as well as associated parameters - The neutral fiber coefficient (K factor) - The correction value to be applied - Other user parameters Each of these data may vary depending on: - The part material - The part thickness - The die ( bending radius) - The bending angle - The tool used In the following table, only the bending radius is indicated without being associated with a bending tool. Amada sources. T = 1mm R 1.0mm 1.3mm 1.6mm 2.0mm A T K C T K C T K C T K C 0 CCT CCT CCT 0 1 CCT CCT CCT CCT CCT CCT CCT CCT 0 0 CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT CCT (180 ) CCT 0 - CCT 0 - CCT 0 - CCT 0 - Missler Software 99

104 Notes TopSolid Design Sheet Metal Basics Notes 100 Missler Software

105 TopSolid Design Sheet Metal Basics Notes Missler Software 101

106 Notes TopSolid Design Sheet Metal Basics 102 Missler Software

107 ... TopSolid Design Sheet Metal Basics Individual course evaluation form (To be completed and returned to the training instructor at the end of the course) TopSolid Design 7 Sheet Metal Basics Individual course evaluation form 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: Missler Software 103