creating a sheetmetal forming tool

[dj4244]

"drafted rectangular emboss .06h x 1.5 x 3.02: The part's thickness may not be compatible with this form tool. The thickness must be less than the minimum radius of curvature for the form tool." That's the message I get when I try to insert an emboss i created to go into .060 material and make the raised (or lowered) area .06. What may I be doing wrong?

David A. Johnson
Thunder Systems Inc.
Corona, CA

 

[MadMango]

It sounds like you either need a radius on your tool, or the radius you have is too small/large.

Ray Reynolds
"There is no reason anyone would want a computer in their home."
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Have you read faq731-376 to make the best use of Eng-Tips Forums?

 

[dj4244]

Radius on tool is .050. walls are 45 degrees.

David A. Johnson
Thunder Systems Inc.
Corona, CA

 

[JNR]

Well, there ya go.... your thickness (.060) is GREATER than your minmum radius (.050).

Where is the excess material going to go? This is a sheetmetal forming process, not forging. SW can't do plastic deformations as forming operations. Very complex - like stretch forming

I was - and he did. So at least I didn't get coal.....

 

[dj4244]

JNR - Are you saying that I can't form a raised area the same thickness as the material. What if I needed it less than the material, say .30 high. I don't see where there is room for a radius of .060 plus! But I know a smaller radius can be formed in sheetmetal, I'm looking at one.

David A. Johnson
Thunder Systems Inc.
Corona, CA

 

[JNR]

No, not at all. What you can't do is have the tool radius less than the material thickness. (We're talking about the fillet rads on the corners of the tool ie. the "bend rads".) It has nothing to do with the forming offset distance.

I was - and he did. So at least I didn't get coal.....

 

[CorBlimeyLimey]

dj4244
You may be looking at an actual part which has a sharp or sharper radius, but what JNR is saying is correct. SW cannot handle Plastic Deformation....Yet.
It uses consistent thickness in its approach to forming.


CorBlimeyLimey
Barrie, Ontario
faq559-863

 

[JNR]

Exactly, CorBlimey! dj244, ping us if we are not explaining this adequately.

I was - and he did. So at least I didn't get coal.....
OK, OK, It's a reference to my holiday sig. "Be naughty - Save Santa a trip..."