Wire/Rod Bending

[badgerdave]

Hi Everybody!

I've got a tricky problem, I have to make a handle out of wire that gets bent and need the initial length. I've read that this can be accomplished by using a sheet metal part and adding fillets to get it almost round (0.0001 flats on 4 sides)

Unfortunately this only allows bends in one plane.

I came up with a two part process that works, but I'm wondering if there's a better way. (and if it is the best way, to put the record of it on here since I get help here all the time!)

I've attached a quick sketch of what I'm trying to do in MSPaint.
Here goes..
First I started by making a sheet metal part that was as thick as I'd need for my rod. I bent it twice and then cut out the middle so that it would look like a horseshoe (and be a square bar. I added the fillets to make it nearly round as well.(I suppose this could also be accomplished by making an "L" shape and mirroring)

Once I have the horseshoe shape dimensions, I made another sheet metal part using edge flanges to control the outside dimensions. This unfolded pretty easily.

Finally I put views from both models into one drawing.

Is this the best way? is there a way to make the two part files linked so that they automatically update?

Thanks!!

 

[MadMango]

I would use a Sketch (maybe 3D even) and Sweep a closed Profile. Then measure the segments of the Sketch path for total length.

"Art without engineering is dreaming; Engineering without art is calculating."


Have you read faq731-376 to make the best use of these Forums?

 

[Updraft]

Sheet metal seems like a difficult route. With sheet metal you have bend deductions that yield an accurate flat pattern. This is specialized for sheet metal because the neutral axis is rarely in the center of the thickness.

Your drawing doesn't help me understand the detail of your handle, but the test of your OP would lead one to make a 3D sketch of path and then attach a profile sketch to the end to make a sweep feature. If the neutral axis is centered in the profile for its entire path then the length of your wire is just the length of the 3D sketched path. If this is not the case, i.e., the neutral axis is not always in the center, such as in a bend with a radius < 3 wire diameters, then a piecewise sheet metal part might be the way to go. However, unless you have accurate bend deduction or K-factor information then even the sheet metal approach will yield a false number.

You might be best off figuring out your own bend deduction information by taking a piece of the wire, measuring its straight length, and then making representative bends in it. Measure the finished result and compare that to the length in the model of each straight and curved segment (measured at its centerline) and the difference should be the amount of material change due to the bends.

- - -Updraft

 

[CorBlimeyLimey]

badgerdave,

Try using the Weldment function. The Cut List will give the centreline length, and depepnding on the wire size and bend radii, that may be close enough.