Flattening a curved surface

[chimps12]

Hello,

1st time poster long time reader. I was wondering if there was a way to flatten a curved surface such as the one attached with this posting. I am trying to create a pretty acurate flat pattern of this part so it can be exported as a .dxf to be laser cut. I have tried the indent, deform, and flex commands in solidworks with no such luck. Also have tried a 3rd part software such as blankworks, but the problem with this software is that instead of creating a continuous curve of the exterior of the flatten part I get a serious of lines which do not seem to be too acurate where there is radius. So at this point I am out of ideas. I would appricaite any other suggestions.

Thanks,

Rich

 

[JMirisola]

I don't know that there's anything workable that you can do. Because it's a compound curve, SolidWorks, in the end, won't be able to flatten it.

Jeff Mirisola, CSWP, Certified DriveWorks AE
CAD Administrator, Ultimate Survival Technologies
My Blog

 

[CorBlimeyLimey]

Start with Sheet Metal (similar to attached), Unfold (not Flatten), create the profile, then Fold.

 

[chimps12]

CorBlimeyLimey,

Thanks for getting back to me so quick. Unfortunatly my company has not yet made the upgrade to 09 so I am not able to open your file. Is there anyway you can upload the file in 08 or attach a picture to further illustrate what you are recommending?

 

[CorBlimeyLimey]

Create the flat D-shaped portion first, then use the Edge Flange tool to create a shallow radial bend on the curved portion of the D.

 

[JMirisola]

CBL, were you able to get it to work with the radii? I wasn't, and jumped to the conclusion that it was too complex.

Jeff Mirisola, CSWP, Certified DriveWorks AE
CAD Administrator, Ultimate Survival Technologies
My Blog

 

[CorBlimeyLimey]

Jeff ... I didn't create an exact copy, just a flat D-shape and then an angled Edge Flange off the curved portion with whatever default radius. I jumped to the conclusion that chimps12 could adapt the geometry to suit. I will try a more accurate rendition later tonight.

 

[CorBlimeyLimey]

Yep ... it worked great.

 

[chimps12]

Hey Guys,

Ok so here is what I have so far. I created the flat d portion and an angled flange off of the rounded side of the d. I cannot make the final bend for the small curled pieces that come of of the large curve. I have attached a picture for reference. The part in the grey is the sheetmetal.

 

[JMirisola]

Ah, ok CBL. If you apply the radii in the sketch it does work great.

chimps12 - As CBL said, create the 'D' shape. Instead of creating an extrude, use the sheet metal tools to create a base flange. Then create an edge flange on the arc, setting the angle and bend radius. Once you have that, use the 'Unfold' command not the 'Flatten' command. Create the profile sketch for the cut, then cut it. Now 'Fold' it back.

If you have FeatureWorks, one of us can post a file for you. You can then run FW on it, being sure to select 'Sheet Metal', and see how the part was created.

Jeff Mirisola, CSWP, Certified DriveWorks AE
CAD Administrator, Ultimate Survival Technologies
My Blog

 

[chimps12]

JMirsola,

I have featureworks so if you can send the file along it would be much appriciated. I think I am with you on what you are describing, but am still stuck on the part as described above. I belive the part would need to be bent twice. Once along the curved side of the flat D and again where the top and bottom cornerns curl up.

 

[rstupplebeen]

You might get more accurate results (depending on your end goal) quicker by performing FEA on the part assuming you have above the base Cosmos or another package. Make a rigid floor and apply a suction pressure to the part until it is flat. This will only be as accurate as your estimate of Poisson's ratio. I hope this helps.

Rob Stupplebeen

 

[JMirisola]

chimps12,
I'm going to have to go back to my first statement. A singular edge flange will work on a curve, but I can't see a way to add the needed bends on the corners.

Jeff Mirisola, CSWP, Certified DriveWorks AE
CAD Administrator, Ultimate Survival Technologies
My Blog

 

[chimps12]

JMirisola,

Can you post the file you had created anyway. i would be interested in taking a look at it.

Thanks,

 

[chimps12]

JMirisola & CMB,

How are you able to get the part to flatten? When I try and flatten the flange attached to the curved section on the D I get an error stating that Solidworks cannot flatten a toridal bend.

Thanks,

 

[JMirisola]

Here's a quick and dirty part. I saved it as a parasolid.

Jeff Mirisola, CSWP, Certified DriveWorks AE
CAD Administrator, Ultimate Survival Technologies
My Blog