Chapter 10

Sheet Metal Design

 Chapter 10 - Objectives
• After completing this chapter, you will be able
to perform the following:
– Start the Autodesk Inventor sheet metal environment
– Modify settings for sheet metal design
– Create sheet metal parts
– Modify sheet metal parts to match design
requirements
– Create sheet metal flat patterns
– Create drawing views of sheet metal parts
 Sheet Metal Fabrication
• Sheet Metal Examples
– Enclosures
– Brackets
– Structures or Frames
 Sheet Metal Fabrication
• Bend Tables
• L=A+B-x Construction
• L Unfolded Length
• A Length of folded face 1
• B Length of folded face 2
• x Adjustment from bend table

• Measurements A and B are to the intersection of the

extended outer faces on either side of the bend.
This intersection is used when the angle of the bend
is less than or equal to 90 degrees.
 Sheet Metal Fabrication
• Bend Tables
– L=A+B-x Construction
• L Unfolded Length
• A Length of folded face 1
• B Length of folded face 2
• x Adjustment from bend table

• Use these measurements when the bend angle is greater

than 90 degrees. The measurements are parallel to the
face, and tangent to the outer surface of the bend. The
same formula is used to determine the unfolded length of
the part.
 Sheet Metal Parts
• Sheet Metal Design
Methods
– Folded State
– Flat State
– Disjointed Solids
– Shelled Parts
 Sheet Metal Parts
• Sheet Metal Part Template(s)
• Convert part to Sheet Metal part
– Model tab
– or Environment tab
 Sheet Metal Tools
• Sheet Metal Rules
– Click the Sheet Metal tab > Setup panel
– Sheet metal specific parameters driven by rules
 Sheet Metal Tools
• Sheet Metal Styles
– Bend Tab
 Sheet Metal Tools
• Sheet Metal Styles
– Bend Transitions
– Controls the intersection of edges across a
bend in the flattened sheet.
 Sheet Metal Tools
• Sheet Metal Styles
– Corner Tab
– Relief Shape
– Jacobi Corner
 Sheet Metal Tools
• Sheet Metal Unfold Method
– Linear – KFactor Value
– Bend Table
 Custom Equation Method
• Additional control to unfold model
– Bend Compensation
– Bend Allowance
– Bend Deduction
– KFactor
 Sheet Metal Tools
• Sheet Metal Defaults
– After you define sheet metal rules
– Use the Sheet Metal Defaults tool to select the rule
that is active for the sheet metal part
 Sheet Metal Tools
• Sheet Metal Face
– Extrudes a closed profile a distance equal to the
sheet metal thickness
• Unfold Options
• Relief Options
 Sheet Metal Tools
• Contour Flange
– Created from an open sketch profile
• Bends are added at sharp intersections
 Sheet Metal Tools
• Flange
– Creates a sheet metal face and bend to an
existing face
– Extends the full length of the selected edge
– Corner Edits – click glyph in corner
 Exercise 10-1

• Creating Sheet Metal Parts

 Contour Roll
• Create from an open sketch profile
• No radius required between sketch lines
• First or secondary feature
• Unfolded
• Flat pattern
 Lofted Flange
• Create transitions from one shape to another
• Two sketches
• Output
– Die form
– Press break
 Rip
• Open a closed sheet metal part
– Rip options
• One sketch point
• Two sketch points
• End points
• Work point
• Midpoint of an edge
 Exercise 10-2

• Lofted Flanges, Contour Roll, and Rips

 Sheet Metal Tools
• Hem
– Eliminate sharp edges
– Strengthen an open edge of a face
– Material is folded back over a face with a small gap
 Exercise 10-3

• Hems
 Sheet Metal Tools
• Fold
– Turns a flat pattern into a folded model
– Add folds at sketched lines
 Sheet Metal Tools
• Bend
– Child objects of other features
• When two faced connect
– Connect disjointed face
 Exercise 10-4

• Modifying Sheet Metal Parts

 Sheet Metal Tools
• Cut
– Sheet Metal tab > Modify panel > Cut
• Distance of the cut is equal to the Thickness
parameter
– Project Flat Pattern
• Cut Across Bend
• Define Distance
 Sheet Metal Tools
• Unfold/Refold
– Unfold selected or all bends
– Add feature
– Refold selected or all bends
 Exercise 10-5
• Cut Across Bend
 Sheet Metal Tools
• Corner Seam
– Created when three faces meet
– Create mitered gaps between coplanar faces
 Sheet Metal Tools
• Corner Round
– Sheet Metal specific Fillet tool
• Corner Chamfer
– Sheet Metal specific Chamfer tool
 Sheet Metal Tools
• Create Punch
– iFeature
• Center Point
• Parameters
• Punch ID
• Custom Depth
• Simplified Sketch
 Sheet Metal Tools
• Punch Tool
– Center Point required
– Creates Cuts and 3D
Deformations
• Dimples
• Louvers
– Set Punch Folder
• Applications Options > iFeature tab
– Flat Pattern
• Representation
 Exercise 10-6

• Punch Tool
 Sheet Metal Tools
• Flat Pattern
– Represents the starting point for sheet metal
part manufacturing
– Creates a 3D model of the unfolded part
• Displayed in a 2D drawing view
• Flat Pattern – Browser
• Flat Pattern – Extents, area
 Sheet Metal Tools
• Flat Pattern
– Extents, area
– Edit Definition
• Punch Representation
– Flat Patten Features
• Effect Flat Pattern Only
 Sheet Metal Tools
• Common Tools – Sheet Metal tab
– Holes
– Work Features
– Feature Patterns
– Mirror
– Parameters
 Detailing Sheet Metal Designs
• Detailing Sheet Metal Designs
– 3D Model and Flat Patterns
 Exercise 10-7
• Documenting Sheet Metal Designs
 Applying Your Skills
• Skill Exercise 10-1
 Checking Your Skills
1. The base feature of a sheet metal part is most often a:
a. Revolve
b. Face
c. Extrude
d. Flange
2. What is the correct procedure to change the edges connected by a bend feature?
a. Suppress the existing bend, and add a new bend.
b. Delete the existing bend, and add a new bend.
c. Edit the bend, and select the new edges.
d. Create a corner seam between the desired faces.
3. Which command would you use to create a full-length rectangular face off of an
existing face edge?
a. Flange
b. Extrude
c. Face
d. Bend
4. What action is required to update a flat pattern model?
a. Right-click on the flat pattern in the browser, and select Update.
b. Erase the existing flat pattern, and recreate it.
c. Create a new flat pattern drawing view.
d. The flat pattern is updated automatically.
Continued….
 Checking Your Skills - continued
5. True__ False__ Sheet metal parts can contain features created with Autodesk
Inventor modeling tools.
6. True__ False__ Sheet Metal Style settings cannot be overridden; a new style must be
created for different settings.
7. True__ False__ During the creation of a sheet metal face, the face can extend to
meet another face and connect to it with a bend.
8. True__ False__ A sheet metal cut that used the Distance extents option must be
created equal to the Thickness parameter.
9. What is a common term for a three-bend intersection?
10. True__ False__ When creating a sheet metal punch, you can select an alternate 2D
representation to display in flat patterns and drawing views.