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Prior to using the training materials in this course, you must read the
information in the following pages. This information explains how to:
Download the exercise files and configure your computer for the class
The first module is typically a process module. In the process module, you are
introduced to the generic high-level processes used during the course and after
the course is completed. This module also typically contains an exercise.
Most courses also have a project module, which encapsulates the knowledge
gained in the course. The project will contain one or more exercises that provide
the process steps, but remove much of the detail from the procedure, task, and
detailed step levels. Thus students are encouraged to remember or reuse the
information provided in the course.
Note that not all courses have process or project modules.
You can position the Pro/ENGINEER window so it spans to the far right of
the screen if you wish.
Position the instructions on the left of the Pro/ENGINEER window as
shown in the following figure. This will enable you to easily view the
instructions window while working.
It is recommended that you maximize the amount of working area on
your screen by setting your monitor to the highest resolution setting, for
example 1600x1200.
To make the labs as concise as possible, each begins with a header. The header
lists the name of the lab and a brief scenario. The header lists the working
directory, the file you are to open, and the initial datum display.
An example of a Procedure is shown below, but Exercises follow the same
general rules:
not display datum axes, datum points and datum coordinate systems.
Before beginning the lab, set the icons in the datum display toolbar to
match those shown in the header.
7. Task Name - Labs are broken into distinct tasks. There may be one or
more tasks within a lab.
8. Lab Steps - These are the individual steps required to complete a task.
Other items of note for labs:
1.
extrude_1.prt
Perform this task only if you are running the labs on a computer
outside of a training center, otherwise proceed to Task 2.
2. 1. Extract the zipped class files to a root level drive such as C: or D:.
The extracted ZIP will create the default course folder path
automatically, such as C:/users/student/course_folder.
2. Locate your existing Pro/ENGINEER shortcut.
Select the Shortcut tab and set the Start In location to be the
same as the course folder, for
exampleC:/users/student/course_folder.
1.
Step 2. Close all open windows and erase all objects from memory to
avoid any possible conflicts.
1. Notice the two icons indicated in the header.
2. Click Close Window
grays out.
1.
Step 3. Browse to and expand the module folder for this procedure and
set the folder indicated in the header as the Pro/ENGINEER working directory.
1. Notice the folder indicated in the header.
2. If necessary, select theFolder Browser
Alternatively you can use the cascading folder path in the browser to
navigate to the topic folder, and then right-click and select Set
Working Directory from the browser.
1.
Step 4. Open the file for this procedure and set the initial datum display
according to the icons shown in the header.
1. Notice the lab model is specified in the header.
3. You are now ready to begin the first task in the lab:
Objectives
After successfully completing this module, you will be able to:
Create a drawing to detail both the formed and flat states of sheetmetal
design.
Create a bend order table and add it to a drawing along with associative
notes.
Scenario
In this exercise, you create an enclosure for an electronic device that contains
walls, bends, notches, and forms. You will create the model, add a flat state and
a bend order table to it, and then create a drawing to document both the
formed and flat states of the model.
Process
1.
Create New
1.
2. Right-click anywhere in the main display area and select Define Internal
Sketch.
3. Select the TOP datum plane from the model tree as the Sketch Plane
reference.
4. Verify that the Reference field defaults to the RIGHT datum plane and that
the Orientation field defaults to Right and clickSketch.
5. Right-click and select Rectangle.
6. In the dashboard for the primary flat wall, type 0.50 in the thickness field
and click Complete Feature .
7. Press CTRL + D to orient to the Standard Orientation.
1.
2. Zoom in and select the lower edge on the right side of the model as the
reference for the flat wall.
3. Select Trapezoid from the Shape drop-down menu to override the Flat
default.
4. Double-click the wall height dimension, type 50 and press ENTER.
5. In the radius field type 2.0 and press ENTER. The model should now
appear, as shown.
1.
2. Zoom in and select the lower edge on the front of the model as the
reference for the flat wall.
3. Press SHIFT and select the surface as shown to select the surface loop.
5. Double-click the wall height dimension and type 50 and press ENTER.
1.
Step 5. Create points and pattern them to use as references for notch
features.
1. Rotate the model approximately as shown in the figure.
6. Double-click the vertical dimension and type 20.0 and press ENTER.
7. Double-click the horizontal dimension and type 25.0 and press ENTER.
8. Click OK from the DATUM POINT dialog box.
1.
Step 6. Create three sheetmetal notch features using the points you
created in the previous task as references.
1. Click Punch
1.
5. Select the Placement tab, and select the first reference from the form
model.
8. Click New Constraint from the placement tab. Select the FRONT datum
plane from the form model and the TOP datum plane from the sheetmetal
model. Select Mate as the constraint type.
9. Click New Constraint from the placement tab. Select the RIGHT datum
plane from the form model and the RIGHT datum plane from the
sheetmetal model. Select Mate as the constraint type.
10. Click Plane Display
1.
Note that the form feature was not flattened automatically. You will
need to complete this task manually in the next step.
9. In the FLATTEN Feature Creation dialog box, click Form > Define.
10. Select the top surface of the form feature, as shown.
11. Click Done Refs from the menu manager and click OK from the
FLATTEN dialog box to complete the Flatten Form feature.
12. Click File > Close Window from the main menu.
Note how the form is not flattened in the original model. This is
because the Flatten Form feature was added in the ENCLOSURE_FLAT1
file when you had it open. The feature was added as an item in a
family table for the model and was set to Yes in the instance and No in
the generic.
1.
10. When prompted to select a bend to add to the current sequence, select
the bend surface near the front of the model, as shown.
12. When prompted for a plane or edge to remain fixed, select the flat
surface, as shown.
13. When prompted to select a bend to add to the current sequence, select
the bend surface on the right end of the model, as shown.
17. Click Info in the menu manager to review the finished bend order table.
18. When you are finished reviewing the bend order table, click Close to
close the information window.
19. Click Done/Return > Done/Return from the menu manager.
20. Click Save
21. Click File > Close Window from the main menu.
1.
Step 10. Begin creating a new drawing to document the formed and flat
state for the ENCLOSURE.PRT.
1. Click New
5. The New Drawing dialog box appears. Notice the default template is set to
a0_drawing.
1.
Step 11. Continue the drawing creation process by adding a second sheet
to document the flat state of the model.
1.
Step 12. Add the bend order table, bend notes, and auto ordinate
dimensions to the drawing.
1. Select the Annotate tab in the Drawing ribbon.
2. Click Show Annotations
3. Select the Datums Tab
Click Select All
Note the appearance of the bend axes for each of the bends.
Click OK.
Note that the bend notes are associative. The note leader for each is
attached to the corresponding bend axis for each bend.
10. Click Select Base Line from the menu manager and select the bottom
most edge of the model's geometry, as shown.
1.
Step 13. Save the models and erase them from memory.
1. Click Save
Objectives
After successfully completing this module, you will be able to:
Constant thickness
Developed length
Formed State
Flat State
Sheetmetal models are solid parametric models that have a constant thickness throughout. Therefore, they do not
represent real world models that undergo deep drawing forming operations or other manufacturing processes that
large amounts of plastic deformation of the material during formation.
Sheetmetal models have a driving side and an offset side. When displayed as a wire frame, the driving side of the
shown in green and the offset (or driven side) is shown in white. The side surfaces of sheetmetal models are form
after the driving and offset surfaces have been regenerated. You can see and example of this in the figure on the l
the slide.
Sheetmetal models can be displayed in either the formed design state (bent into the final shape used in the design
state (unbent to show the "blank" of metal needed prior to bending). An example of the formed state is shown in
on the upper right side of the slide, while an example of the flat state for the same models can be seen in the figur
lower right side of the slide.
Pro/ENGINEER Wildfire can accurately calculate the developed length of most bends in a sheetmetal model. Th
you to design the model in its formed state. If you unbend it later to form the flat state, you can apply the develop
to each of the bends in the model so that an accurate flat model can also be generated for manufacturing.
Best Practices
Because of the general thinness of a sheetmetal part, you should select flat surfaces as references when placing a
a flat surface is not applicable, edges are more convenient than side surfaces. When you orient a sheetmetal part,
selection must be a planar surface or a datum plane and the second selection may be an edge. This is contrary to o
non-sheetmetal solid parts (where it is recommended that the second reference be a surface instead of an edge). E
often references in sheetmetal models.
Entered Value
Before Bend
N is the Neutral Axis
L = (/2 x R + y x T) /90
L= Developed Length
R = Inside Radius
T = Material Thickness
y = (/2) * K
K = /T
After Bend
Accurate developed length calculations (often referred to as bend allowances) enable you to capture your design
the solid model while also developing a precise flattened model that manufacturers can use when developing the
product. Physical sheetmetal parts are often manufactured by taking a flat piece of sheetmetal material and bendi
the finished part. This final shape is often referred to as the developed or formed model. When you bend or form
sheetmetal, the material on the outside of the neutral bend axis stretches while the material on the inside of the ne
axis compresses. The neutral bend axis itself remains the same before and after the bend because it is neither stre
compressed. You can account for this material behavior by establishing appropriate material descriptions and for
accurately calculating the bend allowance. It is very helpful to be able to provide the manufacturers of your shee
models with the overall dimensions of the flat stock (often referred to as the blank) that they need to begin the
manufacturing process. Pro/ENGINEER can create a blank that incorporates the developed lengths of the formed
the flat model.
The developed length of a bend depends on the thickness, bend radii, bend angles, and other material properties (
the hardness of the material). The developed length calculation compensates for stretching in the area of a bend.
The developed length of a bend is determined in Pro/ENGINEER Wildfire using one of four methods:
Entered Value
By default, Pro/ENGINEER Wildfire uses a default bend formula to calculate the developed length that uses y-fa
factor values.
The equation, shown in the figures here, is stated as L = (/2 x R + y x T) /90 Where: L = developed length. R =
radius. T = material thickness. = bend angle (deflection angle, in ) and y = y-factor.
Note that the bend angle is measured as the angle of deflection, and not the inside an
For example if a flat wall section was bent 30, the bend angle () is 30, not 150.
The y-factors and k-factors are part constants defined by the location of the sheetmetal material's neutral bend lin
largely based on the hardness of the material. The k-factor is a value that expresses a parameterized location of th
bend axis. It is calculated as k = /T. In the figure, you can see that is the distance away from the inside radius w
neutral bend axis lies. Therefore, a value of k = 0 would indicate that the neutral bend axis is on the innermost su
bend, while a value of k = 1 would indicate that the neutral bend axis is located on the outermost surface of the b
Both the k-factors and y-factors increase as the hardness of the material increases. Therefore, harder materials ha
developed lengths than softer materials.
The y-factor is calculated with the equation y = k * /2. The default value for the y-factor is 0.50.
Entered Values
Another way to control the developed length of a given bend is to override whatever value is given to the bend (b
table or the default equation) with a user supplied value. This approach can be useful when the developed length
heuristically from some source (such as a manufacturing vendor) and just needs to be incorporated in the model.
Best Practices
Before beginning the development of sheetmetal models in Pro/ENGINEER Wildfire, determine how the develo
will be calculated. Accurate developed length calculations will enable you to capture your design intent in the so
and to create accurate flat models that manufacturers can use to develop the actual product.
1.
widget.prt
Note that the value for the developed length of the bend is currently
4.14 (highlighted in red in the image).
2. From the main menu, click Edit > Setup > Bend Allow > Y-factor >
Enter.
Type .70 when prompted to type a new y-factor and click Accept
Value .
Note that the value for the developed length of the bend is now 4.54
(highlighted in red in the image).
1.
Task 2. Unbend the model and measure the length of the flat model.
1. Click Unbend
2. Verify that Regular is selected in the menu manger and click Done.
3. Click Unbend All > Done > OK.
4. From the main menu, click Analysis > Measure > Distance. Select the
edges shown in the figure (highlighted in red) as the From and To
references.
5. Click Accept
1.
4. Click Regenerate
5. Click Analysis > Measure > Distance from the main menu. Measure
the distance between the same two edges you measured in the previous
task.
Note that the distance measured is now 72.1200. This is because the
user-defined value for the developed length of the bend is now being
used to drive the flat length of the model instead of the y-factor
calculated value.
6. Click Accept
7. Click Save
8. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
1.
machine.asm
4. In the Creation Options dialog box, verify that the Copy From
Existing radio button is selected.
Note that the default template in the Copy From field is for a solid part
not a sheetmetal part. While in Assembly mode, Pro/ENGINEER Wildfire
does not discriminate between solid and sheetmetal parts. Therefore,
you will select a sheetmetal template in the next step.
Note that once the new FRONT_ENCLOSURE sheetmetal part has been
activated, the Sheetmetal icons appear in the feature toolbar,
indicating that the part is both a solid part and a sheetmetal part.
12. Click File > Erase > Current > Select All
from memory.
1.
Create New
2. Select Part as the Type, if necessary and select Sheetmetal as the Subtype.
3. Type bracket in the Name field.
4. Clear the Use default template check box.
5. Verify that the dialog box appears, as shown, and click OK.
Note the presence of the sheetmetal options in the Part toolbar on the
right side of the screen. This is one way to know you are in a
sheetmetal part.
1.
Task 2. Explore some of the entities that are in the part as the result of
using the MM_KG_SEC_SHEET.PRT template part.
1. In the model tree, click Show
and then Layer Tree and note that
several layers have already been created.
2. From the main toolbar, click Tools > Parameters and note the presence
of three parameters.
3. Click Cancel to close the Parameters dialog box.
The layers and parameters exist in the new sheetmetal part because
the MM_KG_SEC_SHEET.PRT was used as a template. All of these
entities (and others) existed in the template file and were copied into
the new file.
4. Click Save
5. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
1.
convert.prt
You will need to either query select these surfaces or rotate the model
so that you can select the surface directly.
1.
Note the addition of the FIRST WALL feature. Also note that the
Sheetmetal mode icons have been added and the Solid mode icons
have been removed in the feature toolbar on the right.
2. Rotate the model to examine the surfaces that have been removed from
the back of the model.
3. Click Save
4. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
Objectives
After successfully completing this module, you will be able to:
Sheetmetal Walls
Sheetmetal walls are the main method of adding solid geometry to a sheetmetal model. They are sim
Protrusion feature in normal, non-sheetmetal solid Pro/ENGINEER models. There are two main types
of walls that you can create in sheetmetal models: primary wall and secondary wall features.
Primary Walls
Primary walls are sheetmetal wall features that do not need to reference existing sheetmetal features
are always the first sheetmetal feature in a sheetmetal model: they form sheetmetal geometry which
sheetmetal features can reference. None of the sheetmetal features except for the primary wall
features are available until a primary wall has been created.
You can continue to create primary walls after an initial primary wall has been created, but these wall
created as unattached primary walls and can later be attached to existing sheetmetal geometry.
Secondary Walls
Unlike primary wall features, secondary wall features need to reference existing sheetmetal geometry
the first step in creating a secondary wall is to select an edge of an existing sheetmetal wall to which
attach the secondary wall.
Attached versus Unattached Walls
By definition, secondary walls are attached walls as the name suggests, they are attached to an
existing wall. However, since primary walls can be created without referencing any other existing shee
geometry, it is possible to create more than one primary wall in a Pro/ENGINEER sheetmetal design.
One such example can be seen in the figures on bottom of this example: the first wall was created
as a primary wall (marked #1 in the figure), and then another primary wall was created (marked #2
figure). A secondary wall flange wall (marked #3 in the figure) was then attached to wall #1
(shown by the green arrow) because the top edge of the wall #1 where the green arrow is was select
reference for the wall.
This secondary wall (#3) is later attached to wall #2 with a merge feature along the edge where the
red arrow is shown. Once wall #3 is attached at both ends, the geometry becomes one continuous
piece of sheetmetal geometry and other useful sheetmetal features (such as the unbend feature)
can be applied to it.
This type of approach is often useful in top-down designs where the location of some geometry is
known and other geometry is needed to bridge between these known locations.
blank.prt
1.
Note that the thickness set for this wall will modify the value of the
thickness parameter (SMT_THICKNESS), which controls the thickness of
the entire sheetmetal part. Editing the first wall feature will display the
thickness dimension since it is the first wall feature in the sheetmetal
model.
10. From the main menu click View > Orientation > Standard
Orientation.
12. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
beam.prt
1.
8. From the dashboard, click Options and select the Add bends on sharp
edges option.
9. Type 5.0 in the Radius field and verify that the dimension side is set
to Inside. The Options menu appears, as shown.
10. Type 500 in the dashboard depth field and type 3.5 in the thickness
field. The dashboard appears, as shown.
12. From the main menu click View > Orientation > Standard
Orientation.
14. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
Revolve
1.
You may need to locate the icon on the flyout menu, as shown.
5. Sketch the two lines, the arc, and the centerline, as shown. The vertical
centerline acts as an axis of revolution and as a dimensioning reference
for the revolved diameter dimensions.
6. When you finish sketching and dimensioning the geometry, click Done
Section
to leave Sketcher mode.
7. Click Okay from the menu manager to accept the direction of thickening,
as shown.
8. Click 360 > Done from the menu manger to define the angular rotation
of the section.
9. Click OK from the FIRST WALL feature creation dialog box to create the
feature.
10. From the main menu click View > Orientation > Standard
Orientation.
12. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
1.
funnel.prt
You may need to locate the icon on the flyout menu, as shown.
2. Verify that Parallel, Regular Sec, and Sketch Sec are selected in the
menu manger and click Done.
3. Verify that Straight is selected in the menu manger and click Done.
4. When prompted for a SKETCHING PLANE, select the FRONT datum plane
from the model tree. Click Okay from the menu manager to accept the
direction of feature creation.
5. When prompted for a reference for sketching, click Default from the
menu manager.
6. Sketch a circle and make its diameter 120. Right-click and select Toggle
Section to go to the second section, as shown.
10. Click Okay from the menu manager to accept the direction of
thickening, as shown.
11. When you are prompted to type a DEPTH for section 2, type 75 and
click Accept Value .
12. When you are prompted to type a DEPTH for section 3, type 75 and
click Accept Value .
13. Click OK from the FIRST WALL feature creation dialog box to create the
feature.
14. From the main menu click View > Orientation > Standard
Orientation.
15. Click Save
case.prt
icon
1.
You may need to locate the icon on the flyout menu, as shown.
2. When prompted for a surface to offset from, select the surface, as shown.
3. When you are prompted for an offset distance type 25.0 and click Accept
Value .
Note that other items are available in the FIRST WALL feature creation
dialog box (such as the Offset Type and Thickness) for which you will
be accepting the default settings.
5. Click OK from the FIRST WALL feature creation dialog box to create the
feature.
6. Click Save
7. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
Before Thicken
After Thicken
of construction entities that are offset from the geometry you have sketched.
You can select the side and distance to which the offset occurs, and this in turn
sets the direction and thickness of the solid sheetmetal geometry.
The most useful aspect of this set of offset entities is the ability to dimension to
them. You can dimension the inside radius of a sketch even if the geometry you
have sketched is the outside radius. Furthermore, you can dimension to offset
entities in order to match the dimensioning scheme of your feature to the
design intent of your model. An example of this is shown in second figure. The
offset entity is used to create an inside radius 5.00 mm dimension and the
29.00 mm dimension. Both of these dimensions belong to the offset entities
created by the Thicken tool.
Best Practices
Outside radius dimensions that are left as weak dimensions prior to using the
Thicken tool will change to weak inside radius dimensions after you use the
Thicken tool.
1.
brace.prt
Note the presence of the weak 25.00 and 5.00 dimensions in the
sketch.
You can also click Sketch > Feature Tools > Thicken from the main
menu.
8.
9.
10.7. Click Flip from in the menu manager to flip the arrow to the right.
Once the arrow is facing right, click Okay from the menu manager.
11.8. If necessary specify a thickness of 2.0.
12.9. Click Accept Changes
14. Click View > Orientation > Standard Orientation from the main
menu.
15. Click Save
16. Click File > Erase > Current > Yes to erase the model from memory.
Swept Blend
Helical Sweep
From Boundaries
direction are shown in red while the boundaries in the second direction
are shown in blue.
Blend Section to Surfaces The Blend Section to Surfaces option
creates a primary wall as a blend that goes from a sketched section to
a selected surface or surfaces and is tangent to that selected surface.
In this example, the blend section is shown in blue, the surface it
attaches to is grey, and the resulting primary wall is shown in
transparent purple.
Blend Between Surfaces The Blend Between Surfaces option creates
a primary wall feature that is a smooth surface between two selected
surfaces. In this example, there is no figure for this primary wall
creation method.
Blend from File Imports a blend from an .IBL file. In this example,
there is no figure for this primary wall creation method.
Blend Tangent to Surfaces The Blend Tangent to Surfaces option
enables you to create a blended surface tangent to surfaces from an
edge or a curve. This surface then becomes the driving surface for a
sheetmetal primary wall. In this example, there is no figure for this
primary wall creation method.
Objectives
After successfully completing this module, you will be able to:
Flat
Flange
Extruded
Extend
Twist
Merge
Secondary Walls
You can create secondary walls by referencing at least one primary wall. A
secondary wall is always a child feature of the primary wall it references.
You can create any primary wall type as a secondary wall. In addition to the
primary walls, there are six other wall features that can ONLY be created as
secondary walls:
Flat You can create a secondary flat wall using the Flat
icon (as
opposed to a primary flat wall that is created using the Flat
icon). You
create it by referencing the edge of an existing wall and then using a
modifiable predefined shape (rectangle, trapezoid, L, or T) or a userdefined sketch. You use an open sketch that is attached to the referenced
edge to define the shape of the wall. You can specify the angle of the
attachment as well as the radius of an optional bend.
Flange A flange wall takes a commonly used predefined shape, a
common hem shape, or user-defined shape and sweeps it along a
trajectory of referenced edges. You can create it using theFlange
icon.
Extruded The extruded wall is very similar to a flange wall. For this
type of secondary wall, a single straight edge is selected to act as an
extrude direction and a sketched section is created that follows along this
edge to create the sheetmetal geometry.You can use the Extrude
Tool
to create this type of wall.
Extend An extend wall lengthens an existing wall. You can extend the
wall from a straight edge on an existing wall to either a planar surface or
a specified distance. You can use the Extend Tool
to create this type
of wall.
Twist You can create a twist wall by selecting a straight edge on an
existing planar wall. It is formed by extending the wall and twisting it
around an axis that typically runs through the center of the wall (although
a different point on the wall can be specified. The distance of extension
and degrees of twist are specified by the user.
Merge The Merge Wall tool combines two or more unattached walls that
are tangent and touching each other into one contiguous wall. You can
use the Merge Walls
icon to create the feature.
This is similar to the use of separate parts in assembly mode, where you have
parts of the model that are completely separate from other parts of the model.
However, eventually these unattached primary walls need to be attached (with
the Merge Wall tool) to the primary wall in order to have a valid sheetmetal
model, for example, a single contiguous piece of sheetmetal in the a part
model.
Once the unattached wall has been attached via the Merge Wall tool, it comes a
child of the Merge Wall feature. Since it is dependent on another wall feature, it
becomes a secondary wall.
Rectangle
Trapezoid
Rectangle
Trapezoid
Drag handles You can right-click in the display area and select Edit
Shape. Drag handles appear on the model that enable you to click and
drag the shape to a new location while the preview geometry updates in
real-time.
Wall Angle
You can also control the angle of the wall from 0 to 180 degrees. A 0 degree
wall inserts the wall parallel to the existing wall. You cannot use a negative
angle or an angle greater than 180 degrees to make the wall angle reverse its
direction. Instead you must select the sheetmetal edge on the opposite side of
the edge you selected as the attachment reference.
1.
blank.prt
Alternatively, you can preselect the edge first and then click Flat
4. Double-click the 2.00 Inside dimension and type 5.0 and press ENTER.
5. Click the angle drag handle and drag the wall to a 110 degree angle, as
shown.
6. Drag the drag handle for the taller side of the L wall to a value of 40, as
shown.
7. Click Shape from the dashboard and edit the height of the shorter side of
the L wall to 20 and press ENTER.
8. Click Sketch from the Shape tab to start Sketch mode.
10. Modify the fillet radius dimension to 10.0 and click Done Section
complete the sketch.
11. Click Complete Feature
feature.
to
12. Click View > Orientation > Standard Orientation from the main
menu.
13. Click Save
14. Click File > Erase > Current > Yes to erase the model from memory.
Z
Arc
S
Open
Flushed
Duck
Flange Walls
A flange wall is a folded sheetmetal wall that is attached to straight or swept edges. You select an
edge or a set of adjacent edges (they must form a continuous path) to which you will attach the
flange wall. You can then specify the profile of the wall as well as other dashboard options.
Flange Wall Profiles
There are three basic types of flange wall profiles.
In all cases, care must be taken not to use angles, bends, or geometry that would cause the flange
wall to double over itself. If this happens, the geometry can not be formed and the yellow
preview geometry will stop being generated.
Flange Wall Dashboard Options
In addition to having the dashboard options that are common to both secondary flat and
secondary flange walls, you can also set the following options that are specific to flange walls:
Miter Cuts
If you decide to disable the Miter Cuts option, the yellow preview
geometry will not be available in situations where the geometry
intersects itself.
Edge Treatment The Edge Treatment options (shown below) enable
you to specify how you would like walls placed on adjacent nontangent edges to behave where they meet each other.
Open
Gap
Blind
Overlap
1.
blank2.prt
and Line
9. Click View > Orientation > Standard Orientation from the main
menu.
10. Click Edge Treatment from the dashboard. Verify that Edge
Treatment #1 is selected and select Gap from the Type drop-down
menu. Type 2.00 for the gap dimension and press ENTER.
11. Repeat the above step for Edge Treatment #2 and Edge Treatment
#3.
12. Click Miter Cuts from the dashboard and type 2.00 for the gap
dimension and press ENTER.
15. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
Constant thickness
o Thickness set by primary wall
No automatic bends
No automatic attachment
Invalid Attachment
The Extruded Wall
Flat and flange secondary walls enable you to automatically add a bend at the
attachment edge. However, if you use flat and flange type walls you can only
add constant radius type bends. If you need to create an elliptical or any other
non-circular type bend, you can use the Extrude Tool
in sheetmetal to
create such a wall. An example an elliptical bend wall is shown in the top figure
of this example.
You can also use the Extrude tool to create an extruded sheetmetal wall. All
extruded solid features will be the same thickness as the rest of the sheetmetal
walls in the model.
In addition to creating sheetmetal walls, you can also use the Extrude
tool to create solid cuts and surfaces in your sheetmetal model.
When you use the Extrude tool to create a sheetmetal wall, Pro/ENGINEER
requires you to specify the attachment details. You must add any necessary
bends in the sketch, make sure that the material is added on the correct side of
the extruded section, take care of any tangencies that are necessary for the
feature, and integrate the new extruded wall feature into the existing primary
walls using the Merge Wall tool. Some example of thickness being added to the
wrong side and an inappropriate attachment to the existing walls are shown in
the figures in this example.
Best Practices
In most cases, unless you have a special need that requires the Extruded Wall
tool (such as an elliptically shaped bend) it is far easier to use a flange type wall
attached along a single edge to generate this type of geometry.
1.
extrude_blank.prt
4. Accept the defaults for the reference plane by clicking Sketch in the
Sketch dialog box.
The above step directs Pro/ENGINEER to create a solid from the sketch
instead of a cut. Note how the yellow preview geometry appears.
Note how the wall preview has now flipped to the correct side of the
sketch.
8. Click View > Orientation > Standard Orientation from the main
menu.
9. Drag the depth handle to drag the depth of the extruded wall to 50, as
shown.
Note that although you have overextended the wall beyond the
attachment edge, the extruded wall geometry did not stay attached
beyond the point of overextension. Instead, it continued creating the
shape exactly as it was sketched.
14. Click File > Erase > Current > Yes to erase the model from memory.
Placement
Shape/Prof
ile
Offset
Relief
Bend
Allowance
Properties
Thickness
Side
Bend/No
Bend
Bend
Radius
I/O Bend
Dimension
Offset: None
Offset: Add to
Part Edge
Offset:
Automatic
Offset: By
Value
Placement The sketch (for flat walls) or the edge chain (for flange
walls).
Shape/Profile The shape or profile used to build the wall. Shape is for
flat walls, profile is for flange walls.
Offset The Offset option enables you to decide how far to offset the
newly added geometry from the attachment edge. By default, this option
is disabled and the wall is added to the geometry as though the sketch
was connected to the attachment edge for flat walls and common profile
flange walls (specifically, the I, Arc, and S profiles). If you are adding a
flange wall using a hem profile, the wall is added as though you were
using the Add to Part Edge setting detailed below.If you activate the
offset option by selecting the Offset wall with respect to attachment
edgecheck box, you will have three settings available:
o Automatic This setting offsets the new wall and trims the wall it
is attached to so that the new wall's furthest extent aligns with the
old location of the attachment wall's edge.
o Add to Part Edge This setting appends the new wall to the
attachment edge without trimming the wall to which it is attached.
o By Value This setting enables you to offset the wall a specific
distance by using a drag handle or adjusting the numeric offset
value.
An example of each offset setting can be seen in this example. The
existing wall displays in gray and the new wall that would result from
each of the offset options displays in transparent yellow.
Relief Pro/ENGINEER offers a number of different types of relief. For
partial secondary flat and partial secondary flange walls (walls that do not
extend to the end of the referenced edge or edge chain) five different
types of bend relief are available: No relief, Rip, Stretch, Obround, and
Rectangular. For secondary flange walls that use an edge chain that
consists of non-tangent entities, five different types of corner relief are
also available: No relief, V Notch, Circular, Rectangular, and Obround.
Bend Allowance Using this dashboard option enables you to set the
bend allowance for the wall to an allowance specific to the feature instead
of using the default bend allowance for the entire part.
Properties The properties field enables you to specify the name of the
feature. There is also an information tool which enables you to gather
information about the feature you are building.
Thickness Inside
Thickness Outside
Dashboard
1.
options.prt
from the
Thickness Outside
1.
Thickness Inside
You can select the Offset option from this menu or from the dashboard
panel.
Note how the feature is added to the existing wall without consuming
any of it.
5. Right-click the offset drag handle again and select By Value. Drag the
drag handle for the offset dimension (currently 7.00) to 3.00 below the
attachment edge, as shown.
1.
4. Click View > Orientation > Standard Orientation from the main
menu.
5. Click Save
6. Click File > Erase > Current > Yes to erase the model from memory.
Creation Methods
Bend Relief
Full Wall
Overextended Wall
Partial Wall
Flat Walls When creating secondary flat walls there are three ways to
create a partial or overextended wall:
1. Change a standard shape's dimensions such that it starts and/or
ends along the attachment edge somewhere other than endpoints.
2. Use drag handles to drag the start or end points of a standard
shape such that it starts and/or ends along the attachment edge
somewhere other than endpoints.
3. Sketch a custom shape with its ends dimensioned or constrained
such that it starts and/or ends along the attachment edge
somewhere other than endpoints.
Flange Walls As discussed in the Using Flange Walls concept you can
use the following icons to control where a flange wall begins and ends
along an edge chain that it is attached to:
Note also that all of these techniques can be used to create partial or overextend a
walls.
Adding Bend Relief
When you create a partial secondary wall that includes a bend at the
attachment point, it is possible that the bend will extend back into the existing
attached wall. Additionally, when you create an overextended secondary wall
that includes a bend at the attachment point, it is possible that the bend will
extend into the existing attached wall. You may need to specify a bend relief so
that Pro/ENGINEER knows how to transition from the existing wall to the partial
secondary wall.
Typically no relief is needed when both ends of a secondary wall terminate at the
endpoints of the attachment edge.
There are five different settings you can use to provide bend relief for a
secondary wall when necessary: No relief, Rip, Stretch, Obround, and
Rectangular.
1.
partial.prt
Task 1. Create a new partial flat wall feature that is overextended on one
end.
1. Click Flat
3. Drag the drag handle near the top of the screen down to 5.00. Drag the
drag handle near the bottom of the screen down to 7.00.
4. When the model appears, as shown, click Complete Feature
dashboard to complete the feature.
1.
from the
Task 2. Change the order of Flange 1 in the model tree and change the
length options such that it becomes a partial and overextended wall.
1. Select Flange 1 from the model tree and drag it below the Flat
1 feature you just created, as shown.
2. Right-click Flange 1 from the model tree and select Edit Definition.
Note that the length options for the ends of the flange wall are
currently set to Use First End
3. Drag the drag handle near the top of the screen down until the wall is
15.00 inside the edge of the wall it is attached to, as shown.
Note that the length option for the first end has automatically changed
to Trim First End
5. Select the side surface of the overextended edge of the flat wall, as
shown.
6. Click Complete Feature
7. Click View > Orientation > Standard Orientation from the main
menu.
8. Click Save
9. Click File > Erase > Current > Yes to erase the model from memory.
Understanding Relief
Bend reliefs and corner reliefs are often necessary when
creating secondary walls.
No Bend Relief
No Corner Relief
Types of Relief
There are two primary types of relief available for secondary walls:
Bend Relief
Often the creation of partial secondary walls results in the new wall either extending into the wall
it is attached to (for partial walls), or the wall it is attached to extending into the new wall. In
these cases, it is often necessary to specify a bend relief to enable Pro/ENGINEER to transition
from the existing wall to the partial secondary wall. There are five types of bend relief that you
can use.
As the name suggests, the option is used when you wish to provide
no bend relief. However, in some cases (particularly with partial
walls) if this option is used, Pro/ENGINEER will create a stretch-like
relief that runs to the end of the wall.
No Relief
Rip
Stretch
The rectangular
relief create a
rectangular cut of
specifiable
dimensions.
Rectangular
Obround
Corner Relief
Corner relief helps control the sheetmetal material behavior and prevents unwanted deformation.
You can add corner reliefs using an option available in the flange wall dashboard or as a separate
feature by using the Corner Relief
icon.
No Relief
V Notch
Circular
Rectangular
Obround
1.
relief.prt
Task 1. Edit the existing Flange 1 wall and explore the bend relief options.
1. Right-click the Flat 1 feature and select Edit Definition.
Note the relief on both ends of a wall defaults to the rip type relief.
Note the appearance of the stretch relief at both ends of the wall
instead of the rip relief.
7. After you are done viewing the result, click Resume Feature
8. Select Relief on the dashboard to activate the relief dashboard tab again.
9. Select the Define each side separately check box.
10. Select the Side 2 radio button.
11. Select Obround from the Type drop-down menu.
12. Select the Up to Bend option and type 12.0 and press ENTER.
13. Click Complete Feature
feature.
15. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
The twist wall is then created by selecting the a straight edge to attach to the
wall. You can then select a datum point along the edge to rotate the wall around
or the wall can rotate around the middle point of the attachment edge.
The next step is to specify the following dimensions:
Start width
End width
Overall length
Degrees of twist
Developed length
The twist wall is then created by beginning with an isosceles trapezoid (where
the base angles are symmetrical) that has a base equal to the starting width, a
top equal to the end width, and a height equal to the overall length. This shape
is then placed symmetrically about the axis of rotation (the point you selected
or the middle point of the attachment edge) and is rotated by the degrees of
twist to create the twist wall.
The developed length is used anytime the twist wall is in its flat or unbent state.
The wall is stretched out to the length you specified for the developed length.
The twist wall in this example was created by using PNT0 as the reference for
the axis of rotation, a start width of 20, an end width of 10, an overall length of
50, 225 degrees of twist, and a developed length of 60.
1.
twist.prt
3. For the twist axis, select PNT0 from the display area.
4. When prompted for the start width, type 20.0 and press ENTER.
5. When prompted for the end width, type 10.0 and press ENTER.
6. When prompted for the twist length, type 50.0 and press ENTER.
7. When prompted for the twist angle, type 225 and press ENTER.
8. When prompted for the developed length, type 60.0 and press ENTER.
9. Click OK in the Twist Feature Creation dialog box to create the feature.
1.
Task 2. Measure the current and developed length of the twist wall.
1. Click Analysis > Measure > Distance from the main menu. Select
the two surfaces for the From and To references, as shown.
2. Click Accept
3. Click Unbend
4. Click Regular > Done > Unbend All > Done from the menu manager.
5. Click OK from the Feature Creation dialog box to create the unbend
feature.
6. Click Analysis > Measure > Distance from the main menu. Select the
same two surfaces you selected as references for the distance
measurement above.
Note that the distance is now measured as 60.0 mm. The developed
length of the feature in the flat state is the dimension you specified for
the developed length when you created the twist feature.
7. Click Save
8. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
Extend Tool
Edge
Up To Plane
Original Model
1. Edge For the edge reference, you must select a straight wall you
want to extend.
2. Distance To complete the distance element, you can select one of
two options:
o Up To Plane This option enables you to extend the wall up to a
plane. You can select an existing datum plane or make a new
datum plane.
o Use Value This option extends the wall a distance that you
specify. You can select a default value from the menu or click
ENTER, and type the exact distance value.
The following is a brief description of the figure in this example. In all cases, the extend wall that
was added is shown in yellow, and the edge referenced for extension is highlighted in red.
Lower left: The model after the addition of an extend wall using the
Use Value Extend option. The value was set to 10 mm.
Lower right: The model after the addition of an extend wall using the
Up To Plane option. The hidden side of the wall extended in the lowerleft figure was used as the Up To Plane reference.
1.
extend.prt
2. Select the edge highlighted in red as the edge reference for the extend
wall feature, as shown.
3. Click Use Value > Enter from the menu manager.
4. Type 10.0 and press ENTER.
5. Click OK from the Wall Feature Creation dialog box to create the extend
wall feature.
1.
Task 2. Use the extend wall feature to extend a wall up to an existing wall
using the Up To Plane depth option.
1. Click Extend
2. Select the edge highlighted in red as the edge reference for the extend
wall feature, as shown.
3. In the menu manager, verify that the Up To Plane and Plane options are
selected. Select the hidden surface on the back side of the wall you
extended in the previous task as the planar reference, as shown.
4. Click OK from the Wall Feature Creation dialog box to create the extend
wall feature.
5. Click Save
6. Click File > Erase > Current > Yes to erase the model from memory.
This completes the procedure.
Creation Elements
Basic Refs
Merge Geoms
Merge Edges
Keep Lines
The walls must be touching one another and be tangent to each other at
the edges of contact.
The driving sides of the wall must match before you use the Merge
feature. If they do not match, you must edit the definition of the
unattached feature(s) and, use the Set driving surface opposite of
sketch plane check box in the dashboard or the Swap Sides element in
a feature creation dialog box. Which option you need to use depends on
the type of unattached wall you are using.
When creating a merge wall feature, you will need to specify four different
elements in the Merge Wall feature creation dialog box:
Basic Refs To complete this element, you must select all surfaces of the
base wall(s) to which you will merge.
Merge Geoms To complete this element, you must select all of the
surfaces of the walls you will be merging to the base wall(s).
Merge Edges This element is an optional element. It enables you to add
or remove edges deleted by the merge
Keep Lines This element is also optional. It enables you to control the
visibility of merged edges on surface joints. It defaults to Do not Keep
Lines.
The last two optional elements do not change anything structurally
about the Merge Wall feature. They simply enable you to selectively
include all, some, or none of edges that would be consumed by the
Merge Wall feature.
Best Practices
Displaying tangent edges as something other than solid can be useful when
using the Merge Wall feature. For example, if you are merging a cylindrical
surface to a flat surface and the display of tangent edges is set to solid, the
edge between the two walls would appear the same before and after the merge,
as shown in the figure on the lower left. However, if the display of tangent
edges is set to phantom, the edge would appear as a solid edge before the
merge, and as a phantom edge after the merge, as shown in the figure on the
lower right.
Merge
1.
merge.prt
5. Click Wireframe
model.
1.
Task 2. Create a merge wall feature between the horizontal flat wall and
the adjacent extruded wall feature.
1. Click Merge Walls
This icon is located in the third icon flyout menu from the bottom of
the sheetmetal dashboard and is displayed as Corner Relief
default.
by
2. To complete the Basic Refs element in the Wall Options: Merge Feature
Creation dialog box, select the surface, as shown, and click Done Refs.
3. To complete the Merge Geoms element in the Wall Options: Merge Feature
Creation dialog box, attempt to select the surface, as shown.
4. Click Cancel > Yes from the Merge Wall Feature Creation dialog box.
6. Complete the Basic Refs element by selecting the same surface you
selected in step #2 above, then click Done Refs.
7. Complete the Merge Geoms element by selecting the same surface you
selected in step #3 above, then click Done Refs.
8. Click OK from the Merge Wall Feature Creation dialog box to complete the
feature.
Note how the edge between the two surfaces has disappeared now
that the walls are attached.
9. Right-click the wall feature you just created in the model tree and
click Delete > OK.
1.
Task 3. Create a single merge feature to attach all three unattached walls.
Instead of deleting the merge wall feature you created in the previous
task, you could have left it and created another separate merge wall
feature to connect the vertical primary base wall to the extruded wall.
However, the purpose of this task is to show you that you can merge
more than two walls.
3. 2. Press CTRL and select the two surfaces as references, as shown, for
the Basic Refs element and click Done Refs from the menu manager.
4.
5. 3. Press CTRL and select the two surfaces, as shown, as references for
the Merge Geoms element and click Done Refs from the menu manager.
6.
7. 4. Click OK from the Merge Wall Feature Creation dialog box to complete
the feature.
Note that the solid line that existed between the vertical and
cylindrical surfaces now displays as a phantom line due to the
sheetmetal being contiguous at this point due to the merge feature.
Also note the disappearance of the line between the two planar
8.
9. 5. Click View > Display Settings > Model Display... from the main
menu.
10.6. Select the Edge/Line tab
11.7. Select Solid from the Tangent Edges drop-down menu.
12.8. Click OK to close the Model Display dialog box.
13.9. Click Save
14.10. Click File > Erase > Current > Yes to erase the model from
memory.
This completes the procedure.
Objectives
After successfully completing this module, you will be able to:
Bends
A bend feature adds a bend to a flat section of the part.
Types of Bend
Features:
Angle Bend
Roll Bend
Angle Bend
Roll Bend
Bend Features
While manufacturing sheetmetal parts, you bend flat sheets using bending
tools. Pro/ENGINEER Wildfire 5.0 enables you to create bends and other
geometry to reflect the true manufacturing process. You can bend a sheet using
various tools like Angle Bend or Roll Bend. You use bend lines to determine the
location and shape for the bend geometry in your sheetmetal parts. A bend line
is also a reference point to calculate the developed length. Pro/ENGINEER
Wildfire 5.0 enables you to sketch the bend lines, thus enabling you to control
the behavior of the bend geometry.
A bend feature adds a bend to a flat section of the part. To create a bend
feature, you sketch a bend line and determine the bend's direction with
direction arrows on your sketching view.
The bend line is a reference point for calculating the developed length and
creating the bend geometry.
You can add bends at any time during the design process.
Depending on where you place the bend in your sheetmetal design, you
may need to add bend relief.
A bend cannot be added where it crosses another bend feature.
While you can generally unbend zero-radius bends, you cannot unbend
bends with slanted cuts across them.
You can modify the developed length of a bend area. If you do modify the
developed length, remember that revising the developed length only
affects unbent geometry and does not affect the bend back features.
Bends are made along the axis of the radius.
can bend forms that have been placed on the model and also unbend bends that
cross over form features.
Procedure: Bends
Scenario
Create an angle bend and a roll bend on a part.
Bends
1.
BENDS.PRT
Click Done.
Click Thickness.
5. Click OK.
1.
6. Click OK.
Bend Options
There are three options associated with any roll or angle
bend.
Bend Options:
Regular
Transition
Planar
Planar Sketch
Planar Bend
Bend Options
For each angle or roll bend, there are three options to choose from:
Regular
Transition
Planar
The regular bend is the bend you will use most often. It has no transition
surfaces.
Transition Bend Option
A bend with a transition deforms the surface between the bend and an area that
is to remain flat. To create a bend with the transition option, you:
You can create one or more transition areas for each with a transition bend.
Each transition area sketch must consist of two lines. One line needs to be
adjacent to the bend area. Sketch this line first, followed by a second line that is
used to complete the transition area.
Transition bends do not accept bend relief. If your design calls for a cut in a
transition area, either create it before you make the transition bend or unbend the
bend, making the cut and using the bend back feature.
Planar Bend Option
A planar bend creates a bend feature around an axis that is perpendicular to the
green surface and the sketching plane. The neutral point for planar bends is
placed according to the current y-factor and bend tables are not applicable.
A planar bend forces the sheetmetal wall around an axis that is normal
(perpendicular) to the surface and the sketching plane. You sketch a bend line
and form the planar bend around the axis using direction arrows. While this
type of bend is not utilized in the manufacturing process, it can help you reach
your overall design intent.
1.
OPTIONS.PRT
1. Click Bend
5. Click Sketch > References and select the bottom edge of the model.
6. Click Close in the References dialog box.
7. Click Line
9. Click Both > Okay to define the bending and fixed areas.
10. Click Sketch > References and select the five additional references, as
shown.
11. Click Close in the References dialog box.
1.
7. Click Line
9. Click Okay > Flip > Okay to define the bending and fixed areas.
Unbend Features
You can unbend both a wall and a bend as long as the
material is developable and able to unbend.
You can unbend developable and
undevelopable surfaces.
Regular
Xsection Driven
Transition
Regular Unbend
When creating an unbend, you select a surface or edge to remain fixed. Your
choice changes the default view of your model.
Try to pick major surfaces that you want to keep in the same position.
If possible, be consistent and use the same surface when creating several
unbend features.
The defining rule is that all surfaces that you unbend must either have an
outside edge or be adjacent to an area that has an outside edge. The outside
edge or adjacent area serves as a way for the deformation to escape and the
material to stretch.
Transition Unbends
A transition unbend feature flattens non-developable geometry that cannot be
unbent with a regular unbend feature. Non-developable geometry bends in
more than one direction. The transition geometry is temporarily removed from
the model, so you must define that geometry to utilize the feature. The
developable surfaces can then unbend. The transition geometry is placed back
into the flat pattern.
Regular Unbend Tool with Deformation Area
You can create the deformation area during the unbend. The system defines the
deformation area automatically, but you can add to the set of surfaces.
Best Practices
BODY.PRT
Unbend
1.
1.
Task 2. Unbend one side of the toaster body using the Xsec Driven
method, by selecting the Xsec Curve.
1. Click Unbend
1.
Task 3. Unbend the other side of the toaster body using the Xsec Driven
method, by sketching the Xsec Curve.
1. Click Unbend
7. Click Right and select datum plane RIGHT from the model tree.
8. From the main toolbar, click No hidden
9. Select the end vertices of the edge that is selected as the fixed edge, as
references and click Close.
Formed Model
If you partially bend back a regular unbent surface containing a deform area,
the original bent condition might not be obtainable. Pro/ENGINEER Wildfire 5.0
examines the contours of each bend back section. Contours partially
intersecting a bend area are highlighted. You are prompted to confirm whether
the section should bend back or remain flat.
You cannot bend back a cross-section (Xsec-Driven) unbend.
BENDBACK.PRT
BendBack
1.
4. Click No hidden
Task 3. Bend the part back, but leave the center tab straight.
1. Click Bend Back
5. Click Done Refs > Yes > Yes > OK to complete the feature.
Flat Pattern
A flat pattern is equivalent to the unbend all feature.
Select a fixed surface:
Fixed Surface
Flat Pattern
Flat Pattern
A flat pattern is equivalent to the unbend all feature. It flattens any curved
surface, whether it is a bend feature or a curved wall. However, unlike the
unbend all, the flat pattern feature automatically jumps to the end of the model
tree to maintain the flat model view.
The flat pattern feature automatically appears at the end of the model tree to
maintain the flat model view. The flat pattern feature is suppressed at the time
of new feature creation and positions itself as the last feature after the new
feature is added, in case you add any feature to the part after creating the flat
pattern.
The flat pattern is helpful if you are constantly toggling between the solid and
flat versions of the design. If you add new features to your design the flat
pattern is temporarily suppressed.
You can create a flat pattern early in your design process so that you can
simultaneously create and detail your sheetmetal design. You can only create
one flat pattern per part. After you create it, the flat pattern option becomes
unavailable.
1.
FLAT.PRT
2. Select the wall to remain fixed while unbending the other walls, as shown.
1.
Task 2. Add another wall and observe the behavior of the flat pattern.
1. Click Flange
Notice that the system immediately starts Insert mode, and the Flange
wall is located prior to the Flat Pattern feature in the model tree.
4. Observe that the flat pattern feature is resumed, and placed at the end of
the regeneration order.
Deform Area
Deformation areas stretch to help you unbend a sheetmetal
part.
Undevelopable Area
Undesirable Unbend
Desirable Unbend
You can either create the deformation area before unbending the section using
the Deform Area tool or you can define it while using the Regular Unbend tool.
The deformation area acts as a bridge between the multiple direction bend
section and the outside edges of the part. The deformation area must be
tangent to both the undevelopable surface and an outside edge.
The developed length of unbent sheetmetal geometry reflects the proper values.
Pro/ENGINEER Wildfire 5.0 approximates the deformation area geometry by
attaching vertices with a line segment. The geometry does not become thinner
or thicker and, because the developed length is typically determined empirically,
you sketch the deformation area geometry.
If an appropriate surface does not exist on the model, you can break up a
surface into multiple patches by creating a deformation area, then specifying
this area as the area to deform during the unbend operation. This gives you the
advantage of creating geometry that closely reflects the developed part.
In addition to using the deform area feature during unbending, you can also use
it to define edges for edge rips or to split surfaces for bend line development.
Sketching Technique
Select a common edge between the undevelopable region and the deformation
area. Use the Entity from Edge tool. Then select the outside edge of the deform
area and two points on that outside edge as vertices. Connect the two outside
edge vertices to the vertices of the undevelopable surface on the common edge.
1.
DEFORMATION.PRT
Select the top surface of the tray to remain fixed during the
unbend, as shown.
1.
and select
4. Click Default.
5. From the main toolbar, click No hidden
For your convenience, deform areas have been defined in the other
areas on the model.
1.
Sheetmetal Cuts
Sheetmetal cuts are created normal to the part surface while
solid cuts are created normal to the sketch plane.
Types of Cuts
Sheetmetal Cut
o Solid
o Thin
Solid Cut
You remove the material using cuts from a sheetmetal part. The cut is made
normal to the sheetmetal surface, as if the part were completely flat, even if it
is in a bent state. The cut adopts the sheetmetal material's natural behavior,
like bending and warping, when the part is bent.
You sketch cuts on a plane and then project them onto the sheetmetal wall.
Either the driving (green) or offset (white) side of the sheetmetal wall can
determine the cut direction.
You can create sheetmetal cuts using the Extrude tool.
The sheetmetal cut can be created normal to the driven surface, offset surface,
or both surfaces.
Types of sheetmetal cuts:
You can use the Insert menu to access advanced options such as Revolve,
Sweep, Blend and so on, to make advanced cuts in the sheetmetal wall. Note
that cuts can be made on an edge.
To make a defined-angle cut, you must click the Normal To Surface
icon in
the dashboard, which disables the three normal to surface options, and makes
the cut normal to the sketch plane. See the Part Modeling Functional Area from
the Help menu in Pro/ENGINEER for information about advanced cuts.
Creating Cuts in Design State
You may create cuts in a design or bent state. When you unbend the parts, the
cuts also unbend along with the parts.
You can see this in the figures shown above. A circular sheetmetal cut is added
to the model as shown in the left figure. The part is then unbent from its design
state. Note that the unbent model now shows the cut that was added in the
design state.
While creating circular cuts, individual datum axes are automatically created for
each circular cut that intersects more than one sheetmetal wall. The created
axes behave like all other axes. They have an ID, can be referenced, can be
turned on/off on the main tool bar and follow the cut during any bending and
unbending. The circular cut that was added in the design state was only one
feature, but two separate axes are created in the unbent state.
Creating Cuts in the Unbent State
To meet your design intent, you may create cuts in the unbent state. The figure
illustrates unbending a model, creating a straight lip around the bent area using
a thin cut, and then selectively bending the part back.
1.
SMCUTS.PRT
Task 1. Create a cut, using the existing datum curve, that is normal to the
sketch plane.
1. Select the datum curve, as shown.
to disable it.
.
Notice that the cut runs normal to the plane that the datum curve was
sketched on.
1.
Task 2. Edit the definition of the cut and make it normal to the wall
surface.
1. Right-click Extrude 2 in the model tree and click Edit Definition.
2. Click Normal To Surface
3. Click Complete Feature
to enable it.
.
Notice that the cut now runs normal to the surface of the main wall.
1.
Task 3. Create a circular cut through the model and unbend it to observe
the result.
1. Press CTRL + D to orient to the Standard Orientation.
2. Click Extrude Tool
3. Click Through All
.
.
1.
to display axes.
3. Click Unbend
Any convex surface must have a radius that is larger than the thickness of
the sheetmetal or equal to zero if the form is mated to the sheetmetal
geometry.
Any concave surface must have a radius that is larger than the thickness
of the sheetmetal or equal to zero if the form is aligned to the sheetmetal
geometry.
The form can contain a combination of convex and concave geometry,
creating hollows. The hollows in the form must not drop below the base
plane or mating surface, meaning all the form geometry must be on the
same side of the base plane.
1.
FORMS.PRT
13. Select the surface of the mount form as the bounding plane.
14. Select the top surface of the mount form as the seed surface.
15. In the Form dialog box, select Exclude Surf and click Define.
16. Press CTRL. Select the three surfaces from the mount form, as shown.
17. Click OK > Done Refs.
1.
On Surface Csys
Interfaces
Constraints
Options
Auto-Round Edges
Exclude Surfaces
Merge or Inheritance
Punch A punch shapes the sheetmetal wall using only the reference
part geometry. Punch forms use the entire form reference part to
create the correct geometry.
Auto Round Edges You can select to round the edges of the resulting
sheetmetal form, even if the punch form model did not contain rounds.
Placement or non-placement edges can be selected.
Exclude Surfaces You can select surfaces for the punch model to
exclude them from the operation, resulting in these surfaces being
deleted from the resulting form feature. The surfaces to exclude can
also be pre-specified by using a Punch Model Annotation feature.
Merge or Inheritance These dashboard icons enable you to reference
the punch model by performing a merge operation, or you can copy
the punch model geometry by creating an inheritance feature.
Tool Name and Coordinate System Specify these options for
sheetmetal manufacturing.
Placing by Reference You can place a form feature so that it references the original forming
model at all times. If the original form model changes, the geometry on the sheetmetal part also
changes.
Copying the Geometry When you do not want to associate the geometry of the form to the
reference model, you can place the form model by copying all of the form geometry into the
sheetmetal model. This copy operation creates a completely independent version of the form
geometry.
Creating and Using Reference Parts
You can create the form or reference part as a standard solid part or as a sheetmetal part. If you
use a sheetmetal model, the form should conform to the green side of the sheetmetal component.
The reference parts can have shapes that are convex, concave, or are a combination of both.
When creating reference parts, you should keep the following points in mind:
Any convex surface must have a radius that is larger than the
thickness of the sheetmetal or equal to zero if the form is mated to the
sheetmetal geometry.
Any concave surface must have a radius that is larger than the
thickness of the sheetmetal or equal to zero if the form is aligned to
the sheetmetal geometry.
The form can contain a combination of convex and concave geometry,
creating hollows. The hollows in the form must not drop below the
base plane or mating surface, meaning all the form geometry must be
on the same side of the base plane.
1.
punch.prt
Double-click LOUVER_FORM.PRT.
4. Drag the handles to the front and right surfaces of the model.
5. Select the Placement tab and enable Add rotation about the first
axis.
1.
Double-click GUSSET_FORM.PRT.
Creating Annotation
round_form.prt
punch_annotations
1.
1.
Task 2. Create a punch form utilizing the defined punch model annotation.
1. Click Open
Double-click ROUND_FORM.PRT.
5. Drag the handles to the front and right surfaces of the model.
Flatten Form
Form features can be flattened using the Flatten Form tool.
Forms are unbent using the Flatten
Form tool.
You typically create flatten form features at the end of the design process,
when you are preparing your model for manufacture.
The flatten form option adjusts the width of the part after flattening,
ensuring that the material volume after flattening is the same as before
flattening.
The formed area is retained upon unbend and bend back, to visualize
location.
You create edge treatments (stamped edges with chamfers or rounds) using
solid class features. As you prepare your sheetmetal design for manufacture,
you need to flatten your design. In order to accurately flatten the stamped
edges, you should create a flatten form feature with the Edge Treat element.
The flatten form calculates the flat pattern for the stamped edges. This is based
on the assumption that the volume of the material in the part is the same, both
before and after it is flattened.
The top image in the slide illustrates the adjustments made to the developed
length of the part after flattening, ensuring that the material volume before and
after flattening, is the same.
1.
FLATTEN.PRT
1.
5. With the Flatten feature still selected, right-click and click Pattern.
6. Click Complete Feature
Rip
You can add rips to your models to help flatten otherwise
unbendable geometry.
Regular
Surface
Edge
Rips Added
Adding Rips to the Geometry
Part Unbent
You can unbend sheetmetal geometry using rips. A rip shears or tears your
sheetmetal walls, especially along seams. If your part is a continuous piece of
material, it cannot be unbent without ripping the sheetmetal.
Create a rip feature before unbending. When you unbend that area of the
model, the material breaks along the rip section. In general, a rip is a zerovolume cut.
There are three types of sheetmetal rips available:
Regular Rip Creates a saw cut along a sketched rip line. You select a
surface and sketch the rip line. You can select boundary surfaces to
protect certain surfaces from the rip.
Surface Rip Select a surface patch on the geometry and exclude the
entire surface from the model by creating a cut in the geometry.
Edge Rip Creates a saw cut along an edge. You select the edge to rip.
The resulting corner edges can be open, blind, or overlapping.
While edge rips are intended for unbending your part, you can customize the
corner type to be open, overlapping or cut/extended to a specific depth. You can
create rips with open or overlapping corners.
You can create multiple versions of a regular rip by setting a bounding surface a surface that will not be ripped. The rip extends around the model until it
meets the edges of the bounding surface. If your rip design requires most of the
surfaces not to be ripped, you can exclude all the surfaces (as bounding
surfaces) and select/remove the desired surfaces that need to be ripped.
In the images on the slide, the cubical surface has been applied an edge rip (to
create an open edge), a surface rip (to remove any undevelopable surface), and
then unbent.
Procedure: Rip
Scenario
Add rips to the model so that it can be unbent.
Rips
1.
RIPS.PRT
1.
1.
1.
You need to create UDFs in the sheetmetal application. UDFs created in Part
mode do not work on sheetmetal parts.
You save a notch or punch UDF in your directory and use it in multiple designs.
It carries the file name extension - .gph.
To create a notch or punch UDF, you use the following parameters that are
specific to sheetmetal design and manufacturing:
Create a cut feature. Be sure to include the coordinate system. When you
align and dimension, keep in mind the convenience of the eventual
placement of the UDF.
Create a UDF feature.
When the system prompts you to indicate whether you are defining this
UDF for a punch or a notch feature, acknowledge it.
In response to the system prompt, type the tool name.
Define the symmetry of the tool relative to the feature coordinate system.
Select one of the options.
Respond to prompts for the reference geometry.
Complete the UDF creation. The system creates and stores the UDF.
1.
NOTCH.PRT
Click Next and Previous from the MOD PRMPT menu to review the
prompts entered. Click Enter Prompt to modify any of the prompts, if
necessary.
1.
Task 3. Create the notch on one side using the NOTCH_RELIEF tool
defined as UDF.
1. Click Notch
11. Select reference #4 in the User Defined Feature Placement dialog box.
12. Rotate the part slightly and select the surface as reference #4
(Horizontal Surface Reference), as shown.
1.
Task 4. Create the notch on the other side using the NOTCH_RELIEF tool
defined as UDF.
1. Click Notch
Edge Bends
An edge bend converts non-tangent edges to bends.
Edge Bends
An edge bend converts non-tangent edges to bends. Depending on the material side you choose
to thicken, some edges appear rounded while others have sharp edges. The edge bend option
enables you to quickly round the edge.
By default, the bend parameters are set to the following values:
If your design requires different bend parameters you can either change the entire models bend
parameters or you can customize the values for each edge individually by redefining specific
edges.
1.
EDGE.PRT
3. Select the three edges shown (start with the edge on the right of the
image).
Notice that the bend table, radius type, and bend radius are all set by
default and you did not have to specify any information.
1.
1. With the edge bend still selected, right-click and select Edit
Definition.
2. Double-click Edge Bend from the EDGE BEND dialog box.
3. Click Piece # 1 > Done.
4. Double-click Radius in the BEND PIECES dialog box.
5. Click Enter Value.
6. Type 15 and press ENTER.
7. Click OK > Done Sets > OK.
8. The edge updates with the larger radius.
Corner Relief
Corner relief helps prevent unwanted deformation by
controlling the sheetmetal material behavior.
No Relief (default)
None
Circular
Obround
Default Relief
NONE
Circular Relief
Obround Relief
Corner Relief
Corner relief helps prevent unwanted deformation by controlling the sheetmetal material
behavior. To utilize the corner relief option you must have at least one ripped edge
and Annotation Element Display
enabled or annotations displayed in the model tree.
You can create four types of corner relief:
No Relief
None
Circular
Obround
Generates a circular
notch.
Generate an obround
notch.
There are four possible ways to apply corner relief to bends or converted parts:
Create the corner relief as a feature (Feature > Create > Corner
Relief).
Create default relief automatically while unbending (Setup >
Sheetmetal > Corner Relief).
Create default relief for all corners in the model or part templates
(Setup > Sheetmetal > Parameters).
Define the corner relief in the conversion feature dialog box
(Feature > Create > Conversion).
1.
CORNER.PRT
Task 1. Change the default corner relief type for all corners.
1. Note that the current relief is set to No Relief.
1.
The numbers associated with your model may not match those shown.
Use the corresponding numbers from your model tree.
Patterning Walls
You can now pattern walls using direction and reference
patterns.
Original Model
1.
pattern.prt
1.
Mirroring Walls
You mirror sheetmetal walls to create symmetric models.
Original Model
1.
mirror.prt
3. Notice that each mirrored wall is its own feature in the model tree.
1.
Task 2. Mirror the original and previously mirrored walls, then redefine a
wall.
1. With Mirror 1 still selected, press SHIFT and select Flat 1 from the
model tree.
2. Click Edit > Mirror from the main menu.
Click Yes.
Module Overview
While manufacturing sheetmetal parts, you bend flat sheets using bending
tools. Pro/ENGINEER Wildfire 5.0 enables you to create bends and other
geometry to reflect the true manufacturing process.
The order in which features are created can have a significant impact on how
your design appears when being detailed.
You use bend lines to determine the location and shape for the bend geometry
in your sheetmetal parts. A bend line is also a reference point to calculate the
developed length. Pro/ENGINEER Wildfire 5.0 enables you to sketch the bend
lines, thus enabling you to control the behavior of the bend geometry.
When you unbend sheetmetal parts, Pro/ENGINEER Wildfire 5.0 calculates the
developed length using a standard formula or using a standard bend table. To
suit your particular manufacturing process, you can override the default bend
calculations by modifying the factors in the formula or by using customized
bend tables.
You select a surface to remain fixed as the geometry bends. The resulting
geometry will differ depending on the geometry selected to be fixed.
Using family tables, you can create a flat state of the model, which is an
instance in the family table where the model is completely unbent.
Objectives
After successfully completing this module, you will be able to:
References
for feature
creation.
Order of
feature
creation.
Feature References
The references used to create sheetmetal features must be selected carefully. For example,
consider the model shown in the upper right figure. Instead of using the surface of the wall for
the sketching plane for the cut, the datum plane FRONT was used.
The end result is that the dimensions for the cut feature would be inappropriate for detailing or
manufacturing.
Feature Order
It is also important to consider the order in which features are created. Consider the example
shown in the lower left set of figures.
The cut was created in the sheetmetal wall, then the wall was bent to shape. When the bend was
created, the system established new surfaces, but the cut surfaces remain in their original
position. The end result is that the dimensions for the cut feature would be inappropriate for
detailing or manufacturing.
A better method of creating the cut is shown in the lower right set of figures.
In this case, the bend was created in the wall, the wall was unbent, the cut was created, and
finally the wall was bent back. In this case, the section stays with the wall feature, and yields the
desired result.
FeatureOrder
1.
7. Click Bend
9. Click Okay > Flip > Okay > No Relief > Done > Flip > Done >
Thickness > OK.
1.
1.
Task 3. Delete the cut and add it in again, after the bend.
1. Select Extrude 1 from the model tree.
2. Right-click and click Delete > OK.
3. Click Extrude Tool
1.
Task 4. Add an unbend feature, then edit the cut to observe where the
sketch resides.
1. Press CTRL + D to orient to the Standard Orientation.
2. Click Unbend
Click Done.
1.
BEND_LINE.PRT
1.
Select Saved from the drop-down list in the Distance dialog box.
Click OK.
5. Click Regenerate
6. Orient to the FRONT view. Notice that the distance is now 0.0.
1.
Right-click the bend feature in the model tree and select Edit.
Click Regenerate
2. Notice that the distance is still 0.0 due to the bend line adjustment
relation.
Bend Tables
You can use bend tables, instead of the system default equation, to calculate
the developed lengths of bends. Bend tables are files (a *.bnd file) that can be
stored in the part or on a hard drive for use in multiple models.
The values in the top row of the bend table (area #4 in the figure) are inside
radius values (R) while the values in the first column of the table (area #3
above) are for material thickness (T). The rest of the cells in the body of the
table (area #5 above) are populated with developed length values for a 90
bend that has the corresponding inside radius and material thickness that
makes them intersect in the first row and column (respectively) of the table.
For bends other than 90, the values are multiplied by /90, where is the
specific bend angle, in degrees.
If a bend is created in a model that does not have an exact corresponding inside
radius or material thickness in the table, the developed length is calculated in
one of two ways.
1. If the values for R and T fall inside the range of inside radii and material
thicknesses present in the table, the developed length is calculated by
interpolation from the surrounding values.
2. If the values for R and T fall outside the range of inside radii and material
thicknesses present in the table, the developed length is calculated by
using the Formula (area #1 above) that is present in the table.
If necessary, you can write logic statements into the Formula area of the bend
table. By doing so, you can assign different formulas to be applied based on
specific attributes of the bend. For example you can specify logic statements so
that the developed length for bends where 0 90 is calculated differently
than for bends where > 90. See the Pro/ENGINEER Wildfire 5.0 help files for
more information on formulas as well as another feature called a Conversion.
You can use one of three tables supplied with Pro/ENGINEER Wildfire or you can
create and name your own. The three tables supplied have developed lengths
based on values for soft, medium, and very hard materials. The y-factor and
developed lengths they contain are listed below and are based on values found
in Machinerys Handbook, 25th Edition.
Table
Name
Materials
yfactor
k-factor
TABLE1
0.55
0.35
TABLE2
0.64
0.41
TABLE3
0.71
0.45
Best Practices
If you create your own library of bend tables, point to the appropriate
folder with the configuration option
pro_sheet_met_directory_<pathname>. You can find bend tables that are
specified by name in your projects current directory and in the folder
specified by the configuration option.
Bend tables are only applicable for constant-radius bends. Bends with a
varying radius, as in a cone or cylinder, calculate the developed length
using the y-factor. Bend tables are applied to a geometry with flange walls
based on the arc profiles.
1.
bend_table.prt
1.
Task 2. Drive the developed length of all of the bends in the model with
the system supplied table for hard materials (TABLE3).
1. Click Edit > Setup > Bend Allow > Bend Table > Set > Confirm >
From File > table3.
2. Click Done/Return > Done/Return > Done/Return.
3. From the model tree, right-click the FIRST WALL feature and select Edit.
Note that the developed length for this feature is now 3.85 mm. If you
inspect the bend allowances for the Flat 1 and Flange 1 features you
will also find that they have developed lengths of 3.85 mm as well.
This is based on a y-factor value of .71 from the TABLE3 system
1.
Task 3. Drive the developed length of the bend in the Flat 1 feature using
a user-defined bend table (new.bnd).
1. In the model tree, right-click the Flat 1 feature and select Edit
Definition.
2. From the dashboard, click Bend Allowance and select the A Feature
Specific Set Up check box.
3. Click By Bend Table > Browse.
4. Select the NEW.BND table and click Open.
5. Click Complete Feature
6. In the model tree, right-click the Flat 1 feature and select Edit.
Note that the developed length of the bend in this feature is now
calculated as 3.69 mm.
Fixed Geometry
You can specify a default reference for the fixed surface for
unbend and bend back features.
You do not have to select the fixed side
after setting default fixed geometry.
Applies to:
Unbend features
FixedGeom
1.
Task 1. Define the default fixed wall for all bend back and unbend
operations.
1. Click Edit > Setup > Fixed Geom.
2. Click Select and select the wall surface to remain fixed, as shown.
3. Click Done/Return > Done/Return.
Click Unbend
Flat States
A flat state is a completely unbent copy of your part.
Formed Model
Family Table
Flat State
Flat States
A flat state is a completely unbent copy of your part. It streamlines the creation
of flat patterns needed in manufacturing because you can create any number of
flat states, at any time in your design process, whether your part is fully formed
or fully flat.
You use family tables to control flat states. You can:
Use the Update command to transfer features you added to a flat state
from the flat state to the generic part, except for features you specifically
suppressed. You can then delete or suppress desired features which are
then deleted or suppressed in any other flat state in that part's family
table.
Use the Show command to list the flat state instances related to the
generic part. You select the instances from the list, and they will open in a
new window.
You can edit individual flat state instances to make any necessary modifications.
Any new features you add to a flat state are enabled in that specific flat state
instance but suppressed in the generic part. Any features you delete from a flat
state are suppressed in the specific flat state instance but still enabled in the
generic part. Keep in mind that any features you add to the generic part, after
you create the flat state, are added to all flat state instances.
When you create a flat state instance, the unbend operation or the flat state is
automatically added to the end of the generic part's model tree. Any
modifications made to the generic do not affect the flat state. Therefore, in the
generic, a flat state works exactly like a flat pattern. Any features added to the
generic part are automatically reordered to always be inserted before the
unbend.
When you create a flat state instance it is automatically added to the generic
part's family table. If you in turn add or remove features from a flat state
instance, the system records those changes in the generic part's family table.
1.
FLAT_STATE.PRT
The system displays the Regular Type dialog box, so that you can
define the unbend operation.
1.
1.
3. Click Flat State > Create and press ENTER to accept the default name.
4. Click Tools > Family Table to display the instances.
5. Click OK.
1.
The family table is updated to include a new column for the cut feature
that was just deleted. The generic and first flat state instance will
regenerate the cut, and the new flat state will not.
6. Click OK.
This completes the procedure.
Objectives
After successfully completing this module, you will be able to:
Text
HTML
Radii Report Detailed information about the bend radii in the part.
You can access the text reports, with info_output_format set to text, by
clicking Info > Sheetmetalfrom the main menu. This opens the Sheetmetal
Info dialog box.
Used K and Y Factors by Part Lists all values of the K-factors and Yfactors that are used by the part or features.
Bend Tables Associated with Part Detailed information about bend
tables used in the part.
Bends Containing Feature Bend Table Lists the assigned bend tables
used by the features.
Bends Allowance Information about bends assigned to a feature with or
without a 90 degree bend angle.
Bend Radii Detailed information about the bend radii of features.
Design Rules - Violations Check Detailed report on your model's
compliance with any design rules that have been defined.
You can access the HTML reports, with info_output_format set to html, by
clicking Info > Model.
Note that the HTML reports are more interactive than the text reports. For
example, in the Bend Tables section of the HTML report, you can click the Get
Table Contents
icon to access another HTML report that lists the entire
bend table.
Reports
1.
REPORTS.PRT
3. Scroll to the Bend Tables section and use the report to view the table
contents.
5. Click Back
in the browser.
The equations and dimensions used for each bend are listed.
The bend radii and radius type (inside or outside) for each bend are
listed.
1.
Task 2. Set the configuration option for text reports, and review the Bend
Report.
1. Click Tools > Options.
2. Type info_output_format in the Option text box and text in the Value
text box.
3. Click Info > Sheetmetal to display the Sheetmetal Info dialog box.
Click OK.
Design Rules
Design rules are geometric standards for your design.
A Rule table contains the design
standards.
MIN_DIST_BTWN_CUTS
MIN_CUT_TO_BOUND
MIN_CUT_TO_BEND
MIN_WALL_HEIGHT
MIN_SLOT_TAB_WIDTH
MIN_SLOT_TAB_LENGTH
MIN_LASER_DIM
MIN_CUT_TO_BEND
Design Rules
MIN_CUT_TO_BOUND
Design rules are geometric standards for your design. You can establish the
design rules that fit your materials and the manufacturing processes you use.
For example, in the upper-right image, the dimension 5 represents the
MIN_CUT_TO_BEND option. This is the minimum distance a cut can be placed
relative to a bend. Any distance greater than or equal to the
MIN_CUT_TO_BEND parameter is an acceptable value.
The second image is an example of MIN_CUT_TO_BOUND. In this case, the
parameter (a value of 2 in the image) represents the smallest allowable value
between any boundary and the edge of any cut.
Note that the Design Rules do not stop the model from regenerating when there
is a rule violation, but the violations can be displayed in a report.
The standard rule table contains the following default sheetmetal design rules.
In the table, T is the stock thickness and R is the bend radius.
Parameter
Description
MIN_DIST_BTWN_CUTS
MIN_CUT_TO_BOUND
MIN_CUT_TO_BEND
MIN_WALL_HEIGHT
MIN_SLOT_TAB_WIDTH
MIN_SLOT_TAB_LENGT
H
MIN_LASER_DIM
You specify design standards in a rule table and assign the table to your part.
You can develop as many tables as you need and you can edit the table at any
time.
Note that you cannot directly add additional rules beyond those found in the
table, but through the use of relations you can customize them.
Your design can be tested against the design table using the Info > Model html
report or the Info > Sheetmetal > Design Check text report.
1.
RULES.PRT
1.
1.
Click Regenerate
2. Click Refresh
3. Scroll to the bottom of the report, and notice now that by moving the cut
down, the MIN_CUT_TO_BEND rule is violated.
Moving the cut down has now caused the bottom edge to get too close
to the bend. The allowable value is 1.6250 but the current value is
1.3750. Therefore, you have to change the height of the cut by 0.25.
4. Edit the dimensions to move the cut feature away from the bend.
Click Regenerate
5. Click Refresh
6. Scroll to the bottom of the report, and notice that there are no longer any
violations.
Sheetmetal Parameters
Defaults and Parameters
You can set common values and define common feature geometry to streamline
the design process. This can be accomplished using the Sheet Metal Defaults
and Parameters file. The defaults and parameters file is stored in tabular
format, and uses the .smd extension.
You can:
of menu picks required during the design process. A parameter, on the other
hand, holds a numeric value.
The slide displays a typical Sheetmetal Parameters table. The highlighted
entities function as both defaults and parameters. The following items are found
in the table.
1.
DEFAULTS.PRT
Task 1. Open the Sheetmetal Parameters dialog box and check for nondefault parameter values.
1. Click Edit > Setup > Parameters to open the Sheetmetal Parameters
dialog box.
2. Notice that the SMT_THICKNESS parameter is set to 0.25 which is not the
default value. Edit the Value cell to 1.00 and press ENTER.
3. Click OK > Yes to apply the new value and regenerate the model.
1.
Task 2. Open the Sheetmetal Parameters dialog box and set several
defaults.
1. Click Parameters from the menu manager.
2. Set the default bend radius, and enable it to apply automatically:
Task 3. Create a bend feature to see the impact of setting the defaults.
1. Click Bend
Notice that the dialog box is automatically completed, and you were
not prompted to provide the Bend Angle and Radius elements. These
were predefined in the defaults and parameters table.
Edge Rips
Rip Connects
Point Reliefs
Corner Reliefs
Original Model
Flattened Model
Define a point break that divides an existing edge into two separate edges
that can be partially ripped and partially bent.
Define the end of a rip connection.
You create point relief by placing datum points on edges (selected or created on
the fly).
Edge Rips
You can make a rip along the edge.
Rip Connects
You can connect rips with planar, straight-line rips. The rip connects are
sketched with point-to-point connections, which require you to define rip
endpoints. The rip endpoints can be datum points or vertices and must either be
at the end of a rip or on the part border. The rip connects cannot be collinear
with existing edges.
Corner Reliefs
You can place relief in selected corners.
1.
CONVERSION.PRT
Task 1. Apply the Create Conversion tool, and add point relief.
1. From the feature toolbar, click Conversion
Conversion dialog box.
2. In the SMT Conversion dialog box, click Point Reliefs > Define.
3. Click Point Display
from the main toolbar to display points and press
CTRL + D to orient to the Standard Orientation.
4. Create a datum point to locate the relief.
5. Click OK > Done. Do not complete the SMT Conversion dialog box.
1.
1.
1.
1.
Objectives
After successfully completing this module, you will be able to:
Add the flat and formed views to a drawing using multi-model drawings
and flat states.
Apply dimensions using the Auto Ordinate tool.
Define the bend order sequence and create the bend order table.
Formed Model
Flat State
The Drawing
Flat States
A flat state is a completely unbent copy of your part. It streamlines the creation
of flat patterns needed in manufacturing because you can create any number of
flat states, at any time in your design process, whether your part is fully formed
or fully flat.
You use family tables to control flat states. You can:
Use the Update command to transfer features you added to a flat state
from the flat state to the generic part, except for features you
suppressed. You can then delete or suppress desired features which are
then deleted or suppressed in any other flat state in that part's family
table.
Use the Show command to list the flat state instances related to the
generic part. You select the instances from the list, and they will open in a
new window.
You can make any necessary modifications to individual flat state instances. Any
new features you add to a flat state are enabled in that specific flat state
instance but suppressed in the generic part. Any features you delete from a flat
state are suppressed in the specific flat state instance but still enabled in the
generic part. Keep in mind that any features you add to the generic part, after
you create the flat state, are added to all flat state instances.
When you create a flat state instance, the unbend or the flat state is
automatically added to the end of the generic part's model tree. Any
modifications made to the generic do not affect the flat state. Therefore, in the
generic, a flat state works exactly as a flat pattern. Any features added to the
generic are automatically reordered to always be inserted before the unbend.
When you create a flat state instance it is automatically added to the generic
part's family table. If you in turn add or remove features from a flat state
instance, the system records those changes in the generic part's family table.
1.
CREATE NEW
1.
5. Select No Hidden as the Display Style from the drop-down list and
click Apply.
6. Select Scale from the Categories list. Select the Custom Scale option
and type 2 as the scale value.
7. Click OK to complete the view definition.
8. Right click and select Lock View Movement option, to disable it.
9. Move the view to the desired location.
10. Click anywhere on the drawing to de-select the view.
Selected Surfaces
Ordinate Dimensions
1.
AUTOORDINATE.DRW
Task 1. Create auto ordinate dimensions for the tabs on the top of the flat
state view.
1. Select the Annotate tab in the Drawing ribbon.
2. Click Auto Ordinate Dimension
3. Press CTRL and select the two surfaces shown in the image.
1.
5. Select the 0 baseline dimension and drag its witness line endpoint to an
appropriate location.
Bend Type
Bend Direction
Bend Angle
o Measured as deflection from the flat.
Bend Notes
The bend line notes are automatically created for each bend in your design. The notes are
parametric and aligned with the bend, so they enable you to easily provide drawing dimensions
and bend annotations. This information enables manufacturers to program their bending
machines, locate punch positions, and create dimension inspection documents.
You can customize the display order by changing the smt_bend_notes_order configuration
option. You can also customize the bend line note symbol by modifying the symbol source files.
The following is an example bend line note.
Default
Symbol
Bend Type
Formed
Inside bend radius is equal to or smaller than ten times the sheetmetal
thickness.
(Inside Bend Radius =< Thickness * 10)
Rolled
Inside bend radius is greater than ten times the sheetmetal thickness.
(Inside Bend Radius > Thickness * 10)
Bend Direction
Up
Inside radius is on the sheetmetal's driving surface.
Down
Inside radius in on the sheetmetal's offset surface.
Bend Angle
45
Pro/ENGINEER measures the angle of the bend as the angle of
deflection from the flat. The bend angle displays according to the
format set in the ang_units configuration option.
BendNotes
1.
Task 1. Display the bend lines and bend notes in the drawing.
1. Select the Annotate tab in the Drawing ribbon.
2. Select the flat view.
3. Click Show Annotations
4. Click Datums Tab
6. Click OK.
Bent Part
Sequence 1 and 2
Sequence 3 and 4
The bend order table is used to document the bend order for manufacturing.
When creating the bend order table, you start with the model completely
unbent.
You use bend order tables to document the dimensioning and the order of the
bend features in your sheetmetal design. You can display bend order tables in
sheetmetal drawings to better illustrate the bending process for manufacturing.
You can also store and edit the tables with a text editor, in a file named
PARTNAME.BOT.
You create bend order tables by fully unbending your part and then recording
the bend back process. You select the bend or groups of bends in the sequence
that matches your manufacturing process. You cannot create or edit a bend
order table on a completely unbent part, so a flat state is used.
The table can also provide you with information concerning bends that are not
90 degrees. This can be very helpful when you use bend tables or a bend
formula that does not consider the bend angle in its calculation.
Bend order tables are shown on a production drawing by creating a note and
reading it in the .bot file. If you change the table in Sheetmetal mode, the note
on the drawing automatically updates; however, you must manually add any
new bends to the table.
In order to create or work with bend order tables, you need your sheetmetal
part to be in a bent condition.
The standard bend order table contains:
Bend direction.
Bend angle.
Bend radius.
Bend length.
1.
BENDORDER.DRW
Task 1. Open the RIGHT_PANEL.PRT model and create the bend order
sequence for the main bends.
1. Select RIGHT_PANEL.PRT in the model tree, right-click, and click Open.
2. Click Open.
3. Create the first bend in the sequence.
4. Click Add Bend, zoom in to the model, press CTRL and select the two
bend surfaces, as shown.
Edit the selection type to Surface from the object selection drop-down
list to select the bend surfaces.
5. Click OK > Next and select the wall surface to remain fixed, as shown.
6. Click Add Bend, zoom in and select the bend surface, as shown.
7. Click OK > Next and select the same surface to remain fixed as you
selected in Step 5.
8. Click Add Bend, zoom in and select the bend surface, as shown.
9. Click OK > Next and select the same surface to remain fixed as you
selected in Step 5.
10. Click Add Bend, zoom in and select the bend surface, as shown.
11. Click OK > Next and select the same surface to remain fixed as you
selected in Step 5.
12. Click Done > Done/Return > Done/Return to save the bend order
table.
1.
You can place more views in the drawing while showing feature details
and dimensions. The dimensions and notes can be arranged in the
drawing as desired. If you are interested in learning more about
creating drawing for parts, you can request information for the course
Detailing with Pro/ENGINEER Wildfire 5.0.
Design Project
Module Overview
This module contains an advanced, self-paced project. The purpose of this
project is to provide you with an opportunity to practice the skills you have
learned in the class without relying on step-by-step instructions. In this project,
you create some of the main components of a stapler. These components are
manufactured using sheetmetal.
Objectives
After successfully completing this module, you will be able to:
Apply the skills you learned in this course to real-world design projects.
Designing a Stapler
Project Designing a Stapler
Stapler Components
Designing a Stapler
In this project, you will design four parts of a stapler that are made of sheetmetal. These parts are
shown with the corresponding numbers in the top figure.
1.
2.
3.
4.
Handle
Plunger
Base
Magazine
Design Aspects
Several aspects of the design that you will encounter are detailed below.
Layout
Model Tree
Skeleton Model
Scenario
Seals, a company that manufactures staplers, is planning to introduce a new
hand stapler. The stapler has sheetmetal mechanical parts and plastic covers.
The design team of your company has created the product structure and based
it on the top-level assembly structure created in Pro/ENGINEER Wildfire 5.0. You
are assigned with the task of designing the four major components - Handle,
Magazine, Plunger and the Base. You will design these parts and review the
assembly components with the top-down design approach in mind.
In this exercise, you will examine the existing HAND_STAPLER.ASM and some of
its top-down design components before creating the necessary geometry in
BASE.PRT.
1.
hand_stapler_skel.prt
Notice the datum planes defined with dimensions for the four
components of the stapler assembly, which are the Base, Handle,
Magazine, and Plunger. Also, notice the Pin axis and the Staple Center
defined with an axis and a plane, respectively.
2. 1. Scroll down in the model tree to see the published geometry features
for each of the stapler assembly components.
3. 2. Click File > Declare > List Decl. Review the list of declared items in
the skeleton model.
You can capture all the necessary design dimensions for creating the
components and assembling them in the skeleton model. The skeleton
model can be driven by a layout to externally control some
dimensions.
4.
5. 3. Click Open
7. 5. Click File > Close Window > File > Close Window from the main
menu to close both of the windows.
8.
1.
Step 2. Retrieve the stapler assembly model and review its structure.
1. Click Open
2. In the File Open dialog box, select HAND_STAPLER.ASM and click Open.
3. Review the skeleton models and the components placed in the assembly.
In the model tree menu, click Settings
and then click Tree Filters. .
If necessary, enable the Features check box and click OK.
4. Expand the parts in the model tree and review the defined features.
The skeleton models are created to control the dimension and location
of each of the assembly components. The published geometry from
the main skeleton model is placed as copied geometry in the
component skeleton models. The parts are created in the assembly as
empty parts and placed at default locations or with reference to the
relevant skeleton model.
1.
, Axis Display
, Point Display
, and Csys
4. Right-click and select Define Internal Sketch from the pop-up menu.
5. Select datum plane TOP as the sketching plane and orient the datum
plane RIGHT to face right. Click Sketch to start the sketch.
6. Click Sketch > Data from File > File System... from the main menu.
Select BASE_FLAT.SEC and click Open.
10. Type 1 as the scale and 90 as the rotation angle in the Move & Resize
dialog box.
11. Click and hold the location handle, and drag the sketch, as shown. Click
to place the sketch.
12. Click Accept Changes
If you select the top (upper) edge, the wall will point downwards. If this
is the case, cancel the creation of the feature and start over using the
bottom (lower) edge.
19. Press SHIFT and select the tangent edge chain for the flange wall.
20. Select the Shape tab on the dashboard. Edit the width of flange wall
to 16.
21. Click Change Thickness Side
on the dashboard.
22. Select the Relief tab on the dashboard. Select the Define each side
separately check box.
23. Edit the relief for side 1 to No Relief and side 2 to Stretch.
24. Click Complete Feature
25. Copy the flange wall to the other side. With the previously created flange
wall still selected, click Copy
26. Click Paste
27. Press SHIFT and select the tangent edge chain for the flange wall.
28. Select the Relief tab. Edit the relief for side 2 to No Relief and side 1
to Stretch.
29. Click Complete Feature
Scenario
In this exercise, you will build geometry in the HANDLE.PRT.
Stapler
1.
hand_stapler.asm
11.
13.
20.
21.17. Create a sheetmetal cut. Click Extrude Tool
toolbar.
22.18. Right-click anywhere in the graphics area and select Define Internal
Sketch.
23.Select datum plane FRONT as the sketching plane and select the datum
plane TOP as the reference to face the top. ClickSketch to start the
sketch.
24.Click Sketch > Data from File > File System from the main menu.
Select HANDLE_CUT.SEC and click Open.
25.Select anywhere in the graphics area to initially place the sketch.
26.Right-click and hold the location handle, and drag it to the point in the
sketch. Click to place the location handle, as shown.
27.
28.19. Drag the sketch using the location handle to the intersection of the
references, as shown. Ensure that the scale value is 1 in the Scale Rotate
dialog box.
29.20. Click Accept Changes
30.21. Add additional constraints and edit the dimensions of the sketch, as
shown.
Be sure to align the right edge of the sketch to the end of the
extruded sheetmetal wall.
Be sure to align the top edge of the sketch to the top of the
extruded sheetmetal wall.
Be sure to create the 2.50 dimension between the vertical sketched
edge and the vertical reference (the RIGHT datum plane).
24. Click Options from the dashboard. In the Side 1 field, click Through
All
.
25. In the Side 2 field, click Through All
26. Click Complete Feature
27. Create a hole for the pin. Click Insert > Hole from the main menu.
28. Click Datum Axis Tool , press CTRL and select datum
planes RIGHT and TOP from the model tree. Click OK.
29. Click Resume Feature
on the dashboard.
30. Press CTRL and select datum plane FRONT from the model tree.
31. Right-click the depth handle, and click To Selected
outer wall surface.
32. Select the Shape tab and click To Selected
33. Select the front outer wall surface.
35. Create another hole for the top grip on the handle. Click Insert >
Hole from the main menu.
36. Click Datum Point Tool
wall.
on the dashboard.
as the depth.
Scenario
In this exercise, you will add to the geometry that already exists in the
MAGAZINE.PRT by creating flat walls.
Stapler
1.
hand_stapler.asm
3.
4. 2. Create a flat wall on one side. Click Flat
5. 3. Select the edge of the wall, as shown.
6.
7. 4. Select the Shape tab on the dashboard to edit the dimensions of wall.
8. Edit the width of the wall to 3 and the offset value to -6, as shown.
9.
10.5. Select the Relief tab on the dashboard.
11.6. Select the Define each side separately check box.
12.7. Edit the relief for side 1 to No Relief and side 2 to Rectangular.
13.8. Click Change Thickness Side
16.
17.11. Create a flat wall on the other side. With the previous wall selected,
click Edit > Mirror.
18.12. Select datum plane FRONT and click Complete Feature
19.
21.14. Click File > Close Window from the main menu.
22.15. Review the assembly created so far. Click File > Close Window from
the main menu.
23.16. Click File > Erase > Not Displayed to clear all models from
memory.
This completes the exercise.
Scenario
You continue to design the stapler. Out of the four components, you have
partially completed the Handle, Magazine, and Base parts.
Stapler
1.
hand_stapler.asm
in the main
6. Select datum plane FRONT from the model tree as the placement
reference. Notice that the axis is created normal to the plane by default.
10. Right-click anywhere in the graphics area and select Define Internal
Sketch.
11. Select datum plane FRONT from the model tree as the sketching plane.
12. Verify that the RIGHT datum plane is set to a right orientation and
click Sketch.
13. Add the axis created in the previous step as an additional reference by
clicking Sketch > References from the main tool bar and selecting the
axis.
14. Click Close in the References dialog box.
16. Click Sketch > Data from File > File System from the main menu.
Select the section BASE_CUT.SEC and click Open.
17. Click anywhere in the graphics area to make an initial placement of the
section.
18. Right-click the location handle and drag it to the point, as shown. Click
to locate the location handle.
19. Edit the scale value in the Move & Resize dialog box to 1 and press
ENTER. Click the location handle and drag the section to snap to the axis
reference, as shown. Click to locate the section.
21. Click Sketch > Constrain > Coincident. Select the right end of the
section and the right end of the BASE.PRT. Delete the 86.00 dimension
that appears in the Resolve Sketch dialog box.
22. Select the bottom horizontal line of the section and the horizontal
Sketcher reference of the BASE.PRT. Right click and selectCoincident.
23. Create and edit the dimensions and constraints, as shown.
Click Options from the dashboard. In the Side 1 field, click Through All
In the Side 2 field, click Through All
Click Complete Feature
1.
Preview of Hole
Step 3. Create a flat wall to create the lip at the rear of stapler base.
1. Click Named View List
the TOP view.
3. Click the bend angle drop-down list on the dashboard and select Flat as
the angle value.
4. In the Shape tab, click Sketch.
5. Click No hidden
9. Click Shading
1.
9. Select references for the sketch. Click Sketch > References from the
main toolbar.
10. Select the existing references and delete them. Select the two vertices
as references and click Close, as shown.
11. Create the sketch and complete the bend. Click Line
line, as shown.
and sketch a
14. If necessary, click Flip to set the side to remain fixed, as shown.
15. Click Okay to accept the fixed side, as shown.
18. Click Thickness as the radius value and click OK to complete the bend
feature.
19. Click Shading
from the main toolbar. Press CTRL + D to orient to
the Standard Orientation.
1.
from the
to start
Select the datum plane FRONT in both the models to define the
Align constraint.
Select the datum plane STAPLE from the base model and datum
plane RIGHT from the reference model to define the Align constraint.
Accept the default offset value, if necessary. Change the Offset value
to Coincident.
Click New Constraint and select the surfaces from the two models
(the bottom hidden surface from the BASE.PRT model and the top visible
surface from the PIN_BEND_FORM.PRT, to define a Mate constraint, as
shown.
1.
5. Select the Placement tab in the dashboard. Edit the offset dimensions
from datum FRONT to 0 and from the front surface to15.35.
Edit the hole diameter value to 3 on the dashboard.
Edit the depth option to Through All
Feature
.
7. Click Save
from the main toolbar, and click OK. From the main menu,
click File > Close Window.
This completes the exercise.
Scenario
In this exercise you will complete the MAGAZINE.PRT.
Stapler
1.
hand_stapler.asm
Step 1. Retrieve the Stapler Magazine and create a spring holder detail.
1. Activate the Stapler Assembly window.
2. Right-click the MAGAZINE.PRT part in the model tree and select Open.
Select datum plane FRONT in both the models to define the Align
constraint.
5. Select the Placement tab and click New Constraint and select the
surfaces as references, to create a mate constraint, as shown.
6. Accept the default offset value, if necessary. Edit the offset value
to Coincident.
7. Click the yellow punch direction arrow upwards if necessary. The punch
direction should follow the same direction the punch model is protruding
into the part.
8. Right-click and select Excluded Surfaces.
9. Press CTRL and select the two side surfaces from the punch, as shown.
1.
9. Create another flat wall on the other side of the magazine. With the
previously created wall still selected, click Copy
1.
Step 3. Create bends on the flat walls created to define the pin guides.
1. Start creating the first bend. Click Bend
9. Click Sketch > References from the main toolbar. Select the existing
references and click Delete.
10. Select the two vertices as references, as shown, and click Close.
13. Complete the bend feature. Click Flip > Okay > Flip > Okay to create
the bend feature toward the fixed side, as shown.
19. Using the method described in the previous steps, create the bend on
the other flat wall.
1.
1.
4. Click OK.
5. Review the flat state. In the Flat State menu, click Show.
6. Select MAGAZINE_FLAT1.
7. Click Window > Close.
8. Click Save
from the main toolbar, and click OK. From the main menu,
click File > Close Window.
1.
4. Click Save
1.
from the
3. If necessary, edit the Look For option to Axis. Edit the Look In option to
PIN.PRT. Click Find Now.
4. Select PIN_AXIS and click Add Item
. Click Close.
5. Click Find
6. Edit the Look For option to Axis. Change the Look In option to
HAND_STAPLER_SKEL.PRT. Click Find Now.
7. Select PIN_AXIS and click Add Item
. Click Close.
8. Using Find
, add another constraint to Align the datum
plane FRONT from PIN.PRT with datum MID_PLANE from
HAND_STAPLER_SKEL.PRT.
9. Click Complete Component
Scenario
In this exercise you will create a drawing for the PLUNGER.PRT. You will also add
a bend order table to the drawing and show the PLUNGER.PRT in both the bent
and unbent states.
Stapler
1.
hand_stapler.asm
4. Add the first bend to the bend order. Click Add Bend and select the bend
surface, as shown.
5. Click OK > Next.
7. Add the second bend to the bend order table. Select the bend surface as
the second bend, as shown.
8. Click OK > Next.
10. Add the third bend to the bend order table. Select the bend surface as
the third bend, as shown.
11. Click OK > Next.
13. Add the fourth bend to the bend order table. Click Add Bend and select
the bend surface as the fourth bend, as shown.
14. Click OK > Next.
1.
1.
Click New
Clear the Use Default Template check box and click OK.
2. Select The generic instance as the model to be used for creating views.
Click Open.
3. Place the view in the top-right corner of the drawing, as shown:
5. Place the TOP view of the flat instance at the center of the drawing, as
shown:
1.
To move views, dimensions, and notes, utilize a click and release then
click and drag workflow. To move a note, select the note, then click
and hold the note while moving. To stop note movement and place the
note, release the mouse button.
6. Click Save
7. From the main menu, click Window > Close for all open models.
8. Click File > Erase > Not Displayed > OK to erase all models in session.
This completes the exercise.