Twisted metal

[simonbrooke]

My company has a requirement to design a heatsink where the limbs are twisted 45 degrees to the main body - by way of example, consider a thin strip of metal twisted at the centre. I cannot see quite how to create this as a sheet metal part - what would its 'sharp' form be? I can see that perhaps a loft or quarter turn helical sweep could make the transition between main body and limb, but this would only look right and wouldn't flatten properly for a punching profile. Does anyone have any thoughts? I realise that I can bodge the issue by putting a note on the drawing to twist the limbs, but it's an interesting problem. I did think of using a form tool but on reflection I think I'd need a simultaneous 'up' and 'down' form which SolidWorks wouldn't like. A form tool wouldn't give the correct bend allowance either.

 

[TheTick]

From what you describe, I believe this may be beyond the capability of sheetmetal packages in nearly all CAD packages that I am aware of. You may need to develop your flat by other means.

I know there are other programs which can develop flats. Possible some useful info on this thread:
thread559-61213

Quasar Industries is a rapid-proto stamping house. I know they have capability. Perhaps they could lead you to some 3rd party who could develop the flat for you (if they won't). Talk to Ryan Assemany, tell him Roland from E.R. Wagner sent you. With any luck, he won't hang up on you.

http://www.quasar.com/

Good and evil: wrap them up and disguise it as people.

 

[rocheey]

Not sure if this is something like what you're looking for. but try the following, maybe with your own 'twist' on it <groan>

.. assuming units are inches...
Create a new Part. Create a sketched rectangle 6&quot; long * 1&quot; high.
Create a base flange, thickness=.062

Click on the face and open a new sketch. Draw a diagonal line from the top left to the bottom right of the base flange, dimensioning the endpoints of the line 1&quot; from each end of the base flange.

Close the sketch, click on the sketch and create angle=45 degrees, and the bend radius=1.0&quot;.

This should unflatten nicely.

 

[JNR]

I agree with TheTick, I don't think any CAD or sheetmetal package can do this stretching operation accurately. There's a whole lot of wierd plastic deformation going on in there and thickness changes, etc, etc. Very though analytical problem.

3/4 of all the Spam produced goes to Hawaii - shame that's not true of SPAM also.......