Help creating corrugated/convoluted air duct part 2

[Isobar]

I am trying to create a non-circular bent corrugated air duct. I can easily create one of these things if it wasn't bent, but for the life of me I can't come up with an easier way to do this. The original part was done in I-deas, which we no longer use. Does anyone have any tricks that would help with this? All I have in the attached file is I cut a section through the existing part to get the base shape as an example, I need to create a brand new part and shape in general, but just for the example I wanted to use this.

My biggest problem is finding a way to bridge the upper and lower bends together to form the rounded sides like the dummy part has. My last resort is going to be creating a bunch of intermediate sections and doing a loft, but that is going to be very time consuming to make each of those sections, so any shortcuts would be very appreciated. I'm using NX 7.5.

 

[Isobar]

Oops forgot the attachment!

 

[JohnRBaker]

Attached is something similar that I did years ago. Perhaps it will give you some inspiration. Note that I suspect I could use a much simpler approach using the latest version of NX, but not NX 7.5.

John R. Baker, P.E.
Product 'Evangelist'
Product Engineering Software
Siemens PLM Software Inc.
Digital Factory
Cypress, CA
Siemens PLM:
UG/NX Museum:

To an Engineer, the glass is twice as big as it needs to be.

 

[mmauldin]

Another approach:

 

[mmauldin]

Just as i hit submit, I realized I could simplify that a bit more:

 

[Isobar]

One last quick question than, is there a way to do multiple instances of a datum plane offset say 5mm along a curve path at one time, or do I have to do each plane one at a time?

 

[Isobar]

Actually I figured out my last question, I was trying to do an array type, I found instance geometry had the option I was looking for. I'll take a look at your file Mmauldin, I was able to get pretty much what I wanted in about an hour with John's file, but I'm always up for learning more.

 

[mmauldin]

Ok, thought about it a little more:

 

[Isobar]

Thank you both, looks like your last idea would be the easiest way to get the drafted shape in there. John's method is great for a standard shape, but I found having to go in and try to draft each bellow was very frustrating. I like your last method of using the instanced geometry because it eliminates the dummy solid part that was hidden which always seems to cause problems with my suppliers and I have to export special files for them.