Forming Tool Issue

[VELCROW]

I have a sheetmetal part, .120" thick, with a .120" bend radius. I created a forming tool to make a gusset in the bend. I looked at Tools>Check and the minimum radius on the forming tool is .180".

When I apply the tool, I get the message "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."

Last I checked, .120" (thickness) is less than .180" (minimum radius of the form tool).

If I drop the thickness to below .06", it works fine.

Any thoughts?

I'm using SW2011.

 

[CorBlimeyLimey]

Can you post the forming tool?

 

[VELCROW]

Here's the tool. I exaggerated the fillets just to make sure they were well above the part thickness.