Modeling failure in ASM 1

[nitrocad]

I am modeling a vertical 6" diameter pipe support which is approx 7' long and intersects a 7' diameter 45 degree duct. the centerline of the pipe support is tangent to the outside of the duct it supports, so the top of the pipe has a weird cutout which i've created by using a subtractive sweep the size and shape of the 7'diameter duct. I need the flat pattern in order to fab the pipe supports. However when I go to create the flat pattern, it fails and gives me this error message.

PIPE.ipt: Errors occurred during update
PIPE.ipt (Flat Pattern): Errors occurred during update
Definition1: Could not build this ASMFlatPattern
Modeling failure in ASM. Redefine inputs.

Does anyone know of a solution? I have attached the Inventor part file.

 

[rollupswx]

I have attached the Inventor part file.

Did you verify the attachment?

 

[nitrocad]

Sorry the attachment didn't seem to take. Here is the part file for the modeling flat pattern error (hopefully) I looked all over to figure out how to edit my thread but couldn't find it so geuss i'll just reply.

 

[EngAddict]

It has a problem with the faces that are created by the cut across the part.

Try this. Delete all faces except the outside face. Thicken the resulting surface inwards at distance of 't'. Now it will flatten and you will have square edges for the cut out (as per real laser cutting).

Note: you can also set your sheet metal style to use 't' for thickness. Means everything will be driven from parameters.