Continued from Project 4: Stamped Depressions

Topic 5: Flanges for stamped sheet metals

What is a FLANGE?

A FLANGE is a structural sheet metal part which is used to either mate or stiffen panels precisely.

As there are two types one is used to mate and another is used to stiffen. So the shape is area of
interest which may be either simple or complex. Simple flanges have shape in one direction. Use a
simple offset or dragged section to define this type of flange. Due to its simple shape, the program
flange features are used to easily model. Complex flanges are those who have shapes in two
directions or consists of multiple shapes.

Questions to be answered when defining the face of flange?

1. Is it planar?
2. Is the shape is determined by geometry of mating component?

Can shape be defined by:

1. Padding of some curves that follow the flange profile?

2. Splitting a body with surface?
3. Removing or adding anybody?
4. Applying a draft to a face.
5. Rib curves along a guide.
6. CAD features?
7. Sheet metal features?

When you are determining the shape of flange trims ask the following questions?

1. Is it straight or curved?
2. Is the shape determined by mating part?
3. Can it be defined by splitting a solid?

Creation Methods

The face of a flange and the trim or cut line can be modeled using split planes/surfaces, bodies, and
or features, such as draft and/or fillets. Derive the flange face by removing material with a split
surface, by subtracting a body, or by adding material with a body. Use this method to model
complex shapes. This is a sophisticated way to create flange faces..

Using Rib to sweep a profile along a guide can also define a flange face. The input profile can be held
perpendicular to the guide. Multi-Section features allow multiple guide curves as input along with
multiple cross sections. Typical use will include two guide curves, a spine, and one cross section.

Most CAD systems have flange features that you can use for simple flanges. It's common to use
flange features after a part is shelled or thickened.
Project 1: Body in White Components: Flange Creation

Purpose: Add a flange for adjoining and stiffening to existing component

Approach: Create bodies to create a flange and remove a cut-out. Shell the part to complete the
main solid. Once complete carry out a design change.

Instructions:

1. Open Component stamped metal

Project Analysis
In this project, you learn to create a flange for fit and stiffening purposes. You use adjoining
geometry to form this flange. The project is partially complete so that you can concentrate
on just the flange creation. Notice that the chunky solid was created and you will need to
form it to fit the adjoining part.

The flange you create will be flush with the labeled flange on the adjoining part. You will need
to transition the part from a determined width of the flange. The flange itself will transition
from a stiffening flange to a mating flange. The flange you create will end about halfway across
the adjoining part but will have the same height. You will need to create the transition, the
flange, and the cutout.

When shelling the part, you will use an outside thickness. This means the flange you create
must be made flush to the adjoining face so it thickens away from the part.

2. You must create a new solid. Create a body Top flange and show the geometric set flange
development
 Create position sketch and create a sketch as shown above and coincide with flush plane.

3. Create a pad of above with 50 mm upward and 80 mm downward.

4. In the next few steps, you will split the top of the flange to match the existing flange and
create the transition from a stiffening flange to a mating flange.

Temporarily Hide Top Flange body and create an Isolated Plane flush with the top of the
adjoining flange within geometrical set Flange Development. Make top flange as work in
object and split the body. Keep lower portion.

5. Next a series of planes need to be created to split another portion of the Top Flange within
the Flange Development geometrical set. An angled transition will be created with this split.
Create a Plane using the Normal to curve top on the top angled edge and vertex.
 Within GSD create an Intersection between the new plane and top flush plane.
Create a 100deg angled plane rotating around the last intersection and plane created

6. Make Top Flange as work in object split the upper portion of the Top Flange Body and ADD
to part body.
7. Create a new body name it as CUTOUT and create a sketch on green colored plane.
 8. Pad the sketch upward 50 mm and downward 150 mm and remove cutoff from part body.

9. Make Flange Development as Work in object and create a offset plane of 94mm

10. Make part body as work in object and create a shell using outside thickness of 1mm.

Review: In this project, you only created one of the flanges on the part. You created the inside portion
of the model and used a outside thickness shell to create the outside shape. You did this because the
inside was the critical geometry. With the geometry you created, it became simple to edit the model.