403 - Getting the Most Out of Sheet Metal Modeling

Transcription

1 4 th Generation VLC courtesy of Edison Getting the Most Out of Sheet Metal Modeling Jeff Walker, Product Planning Manager, #SEU13

2 Agenda: Getting the Most Out of Sheet Metal Modeling Who am I? What you will learn Solid Edge capabilities nstrations Benefits of this topic How to learn more 4 th Generation VLC courtesy of Edison2 Page 2

3 About: Jeff Walker Jeff Walker Product Planning Manager Jeff has a bachelor s degree in Mechanical Engineering from Auburn University. Prior to his role in the Solid Edge Planning organization he was a stress analyst for the US Army Missile Command using FEA tools to conduct studies of missile systems and related equipment. Jeff has over 25 years of experience in the mechanical CAD and CAE software industry. Page 3

4 What you will learn This session will show the fundamentals of sheet metal modeling in Solid Edge and how to take your designs a step further with new capabilities in Solid Edge ST6. Attendees will learn the common concepts from basic sheet metal modeling to flat pattern creation. Techniques and workflows will be shown for creating sheet metal designs in part documents, part features in sheet metal documents, and how to get comfortable with designing sheet metal models using synchronous technology. Page 4

5 Topics Solid Edge Sheetmetal - Introduction Sheet Metal Features Defining Gage Defining Bend Properties Defining Neutral Factor Overriding Sheet Metal Properties Sheet Metal Parts Straight Brake & Rolled Sheet Metal Features on Part Models ST6 Quick Enhancements ST6 Flatten Enhancements ST6 Transform to Sheet Metal Breaking into Sync Sheet Metal More. Questions? Page 5

6 Solid Edge Sheet Metal - Introduction Dedicated document type (.psm) Dedicated environments Modelling (Synchronous & Ordered) Creation of Sheetmetal model with dedicated Sheetmetal commands Flatten Create flat patterns for drawings with bend centerlines Simplify Simplify Sheetmetal models for large assemblies Page 6

7 Sheet Metal Features Basic features Tab Flange Advanced features Contour Flange Lofted Flange Hem Deform features Dimples Louver Drawn cutouts Beads Gusset X-Brake Etch Emboss ST6 Supporting features Insert Bend Unbend Re-bend Jog Detailing features Holes Slots (ST5) Cuts Normal Cuts Break Corner Corners 2 bend corners 3 bend corners Page 7

8 Defining Gage Material Application->Properties->Material Table->Material Tab Gage Application- >Properties->Material Table->Gage Tab Associate with Material moved from Material page drop down to Gage tab ST6 Page 8

9 Defining Bend Properties Bend Radius Application- >Properties->Material Table->Bend Radius Tools->Variables->BendRadius Bend Relief Application- >Properties->Material Table->Relief<Width/Depth> Tools->Variables-> Relief<Width/Depth> Page 9

10 Defining Neutral Factor Neutral Factor Application- >Properties->Material Table->Gage Tab Use Excel File Users can use Gagetable.xls to define their own materials, bend radii, bend reliefs and also neutral factors for various bend radii and bend angles. Bend Equation group Users can define their own neutral factor through a VB program Tools->Variables->Neutral Factor Neutral factor can also be defined for each individual bend in Sync or per feature in Ordered Page 10

11 Overriding Sheet Metal Properties In Ordered bend parameters (Radius, Bend relief & NF) can be overridden at the feature level Feature->Options In Sync bend parameters (Radius, Bend relief & NF) can be overridden by selecting the bend and using the bend handle Bend->Bend Handle->Options Page 11

12 Sheet Metal Parts Straight Brake & Rolled Sheet Metal parts can be created in multiple ways Start with the Sheet Metal template for a dedicated document Create a Sheet Metal part in a Part document Typical usage Change in design intent i.e., starts as regular part but it needs to be a Sheetmetal part now Translated parts Behaviour Document type is unchanged i.e., still a Part document Sheetmetal properties added to the Part document Sheetmetal environment activated Sheetmetal parts can be created and edited like in native Sheetmetal documents Remember SE can create rolled parts too Use contour flange as a starting point ST5 Page 12

13 ST6 Sheet Metal on Part Models ST6 offers capabilities to create SM features on thin portions of a regular part - only Ordered Think stamped parts Sheet Metal features supported Flanges, Contour Flanges Deform features on thin portions Page 13

14 ST6 Quick Enhancements Dimple and Drawn Cutout have been enhanced to support multiple profiles Already supported in Sync Only closed profiles Bead already supports multiple profiles Dynamic Preview during SM feature creation Most features now display a preview Add Flat_Pattern_Model_CutSize variables in templates Allows users to expose these through custom properties even if a flat patters does not exist Flatten Simplify b-splines option set to OFF Associate with Material moved from Material page drop down to Gage age Page 14

15 ST6 Flatten Enhancements Unbend, rebend and flat pattern have been enhanced to support features on cylindrical bends Flat features need to be created in ST6 Unbend, rebend & flat pattern Page 15

16 Transform to Sheet Metal Typical workflow Translated Parts Need to flatten or change thickness Change in requirements Starts as Part and needs to be Sheetmetal now Feature(s) Transform to Sync Sheetmetal (Ordered/Sync) Transform to Sheetmetal (Ordered) Automatically adds bends Option to rip the model Cut Users can custom rip the part ST5 Note Transform commands are enabled in Part documents from ST5 If in Part and want to work in Ordered, Transition to Ordered, Switch To Part and then run Transform to Sheetmetal command Page 16

17 Breaking into Sync Sheet Metal The When? Straight break bend parts Start with Tabs, Flanges and holes Graduate towards Contour Flanges, Patterns, Mirror Editing translated SM parts Thickness change, shape change, bend parameters etc Remember Integrated modelling The Why? Easy creation, easier edits Multiple flange creation Transforming translated SM parts to native SM parts Flange creation from Assembly Individual bend control Non-orthogonal plates/tabs And a lot more. Page 17

18 ST6 More.. The following ST6 enhancements will be covered in the Advanced Topic 503 tomorrow Emboss Flanges on linear edges Bends Contour Flanges Deform Features Contour flanges on contour flanges Features on Bends Dimples, beads, drawn cuts etc Flatten Enhancements Support deform features, part features and Emboss on bends When to use Sync/Ordered Integrated modelling Page 18

19 Questions? Ganapathy Kunda Page 19

20 A primer on bending Bending, flat length computation and neutral (k) factor Page 20 #SEU13

21 Bending Bending causes the inside surface to be compressed and outside to be stretched. In practice what this means is that using the bend arc length on either layer face for determining the flat length will be incorrect. Or using the plate lengths including the bends will also result in incorrect flat length -Use outer layer lengths Use inner layer lengths Use just plate lengths up to bends Or what happens when you create a bend on a flat? Page 21

22 Flat lengths Computation of flat correct lengths involves accounting for the material transition during the bending process. The constants are the tab lengths either to the inside of the bend or to the outside of the bend Flat length = A + B Bend Deduction Flat length = C + D + Bend Allowance Bend allowance (BA) PI * (inside bend radius + neutral factor * material thickness) * bend angle/180 Bend deduction (BD) = 2 * outside set back Bend Allowance Page 22

23 What is Neutral Factor (K-Factor)? Between the inside and the outside surfaces, there is a layer which is neither compressed nor stretched. This is known as the neutral layer. Neutral factor helps determine the location of the neutral layer. Neutral factor depends on bend radius, bend angle, ambient temperature, direction of material grain, bending methods etc. Neutral layer helps determine the correct length of bend. References: Wiki Article, look at the references section in the article for more details Page 23