Tolerance Setting or Adjustment to Recognize a Sheet Metal Punch Outline for Auto-Tooling

[Ecyganik]

First of all, I apolgize if this is the wrong place to post this message. If it is, please advise otherwise. I am a mechanical designer by trade but I have been forced into solving this particular problem.

I have a SolidWorks (2012) sheet metal part (doulble break panel) that has several sets of numbers on it for panel identification. The numbers are created as features and as sketches using a font that I created. Basically, the font is nothing more than rectangles arranged vertically and horizontally to represent numbers. Once a part is complete, a DXF is generated of the flat pattern, for manufacturing. Up to this point, everything is okay.

The problem occurs after importing the DXF file where the rectangles are supposed to auto-tool in the CAM software. Manufacturing uses an old Amada Press with AP100 (US) Software (Version 7.0 MetalSoft Corp.) The "auto-tool" process works on some of the rectangles but fails on others. The difference between success and failure to auto-tool is a descrepancy of tens of thousands of an inch (.00014).

Example:
Rectangle tool; .375 x .063. DXF imports some rectangles as .37511 x .06357 and others as .37528 x .06372 because of the difference in numbers, only some of the rectangles auto-tool.

Is there a solution to this problem?

Any help would be greatly appreciated,

Best regards,
Eddie

 

[berkshire]

I think you need to edit the toolpath in metalsoft after it has imported the DXF file. DXF sometimes has a hard time with dimensions from exported parametric modelling files. Importing 3 digit decimals as 5 digit decimals is just one of them. If you are using Solidworks, try exporting the file to a file folder as a DXF. then re-import it and look at what was saved. Then edit it as an autocad file in solidworks and resave it.
B.E.

 

[Ecyganik]

berkshire,

I know I can edit the file but the whole purpose of auto-tooling is to eliminate un-necessary steps and streamline the process.
Thanks for te response.
Regards,
Eddie

 

[mcgyvr]

Are the rectangles being "scaled" by Solidworks during dxf output?
Are the rectangles being "scaled" by Metalsoft during dxf input?
Figure out which one and contact that company to discuss why and what your options are.

 

[Ecyganik]

The original font files are 801 pts in length but the font is input in SolidWorks at a height of ".846" in order to acheive an eventual length of ".375". The discrepancy in size noted above (.00014) is realized immediately by creating a DXF from SolidWorks and then importing it as a drawing.

 

[mcgyvr]

Sounds to me like you need to fix your "user created" font.
NO idea why you have a font entered at .846" to get .375"??

If the actual font height is incorrect in solidworks its going to be incorrect in the dxf file..
I'd suspect if you adjust the number of units your measure tool in swx shows you might see the problem right there..
I'd suspect you need to go to more than 3 digits when inserting your font so its "more accurate" to start with.