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How to improve sheet metal part design

SolidWorks software includes enhancements for sheetmetal part design capabilities. This technical tip will highlight some of these features.

Using the CommandManager

One feature of the user interface that will make working with sheetmetal parts easier, and other modeling tasks easier also, is the CommandManager. Figure 1 shows the Sheetmetal CommandManager being selected.

Figure 1 – Sheetmetal CommandManager

The purpose of the CommandManager is to make the appropriate commands available when you need them. This replaces docking all the toolbars around the graphics area. The CommandManager keeps the commands that you need for a specific task active and in one common area.

To add the Sheetmetal button to the CommandManager, place the mouse over the CommandManager buttons, right click and select Customize CommandManager and then select Sheetmetal. The Sheetmetal button will appear as shown in figure 1.

Edge Flanges

When creating an edge flange, multiple linear edges can be selected to create multiple flanges with on operation. SolidWorks will trim the edged to 45 degrees if the edge flanges intersect with one another.

Figure 2 – Edge flange

Figure 1 also shows the preview displayed while the edge flange command is active. The gray handle shown can be used to drag the flange shorter or longer. The yellow handles are used to flip the direction of the edge flange.

Closed Corners

The Closed Corner feature is used to create the geometry required to close the area between two sides of the part. The gap type can be set to butt, overlap, or underlap. The results are previewed, as shown on figure 4. Change the value and type and see the results before actually creating the feature.

An example is shown in Figure 1 (before) and Figure 2 (after). The Closed Corner feature is accessible within the Sheetmetal CommandManager.

Figure 3 – Before closing the corner

Figure 4 – After closing the corner

Rip

The rip feature can be used to create breaks (rip) the edges of a solid model so it can be made into a sheetmetal part. Figure 5 show a solid model with the edges selected for the rip feature. The preview indicators, shown as yellow handles in figure 5, indicate that the rip will be on both sides of the selected edge. To change this, just click on the handle to remove the rip from one side of the edge.

Figure 5 – Solid model showing the edges selected for the rip feature

Figure 6 – Sheetmetal part and flat pattern made after the rip and insert bends feature were added

Figure 6 shows the part after the rip and insert bends features were added to the part. The flat pattern is shown at the bottom of figure 6.

Flat patterns on drawings

After the flat pattern has been created from your sheetmetal part, there are additional options to help you covey the information on the drawing. When a flat pattern is shown on a drawing, there are options to display the bend lines (up and down), form features, hems, and model edges in different colors.

This option helps manufacturing better understand the requirements for the final part when looking just at the flat pattern.

Figure 7 – Sheetmetal flat pattern

Figure 7 shows a flat pattern with the bend notes shown with leaders. The options for the display of sheet metal flat patterns with a drawing is set through the Tools/Options/Document settings/Sheet Metal dialog box.

Conclusion
These features will help make your sheetmetal designs easier and better convey your design intent downstream to manufacturing.

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