Introduction to Sheet Metal Features

SolidWorks 2009
Table of Contents

Introduction to Sheet Metal Features

Base Flange Method – Magazine File …………………………………………………………….. 3

Envelopment & Development of Surfaces …………………………………………………………….. 14

Development of Transition Pieces …………………………………………………………….. 23

Conversion to Sheet Metal …………………………………………………………….. 33

Introduction to Sheet Metal Features

Published by:
The National Centre for Technology in Education

National Centre for Technology in Education

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

MAGAZINE FILE.

Sheet Metal The sheet metal feature within SolidWorks enables the user to build a sheet metal
model, using a variety of sheet metal features. The development of the model can
be created by flattening the model as a whole or by flattening individual bends.

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Prerequisite knowledge To complete this model you should have a working knowledge of Solidworks
2006/2009.

Focus of lesson This lesson focuses on using the base flange approach to sheet metal. Commands
used include Base Flange, Edge Flange, Corners and Extruded Cut.

Getting started.
New File Create a new part file.

Save File Save the file to a chosen location as Magazine File.

Getting Started In order to begin working with Sheet Metal you must first activate the sheet
metal tab on the command manager.

To activate this tab,

right click on the
command manager.
Choose Sheet Metal
from the drop-down list.

The Sheet Metal tab is now active on the command manager.

Note: The Sheet Metal commands are also available from the drop down menu by
selecting “Insert” and “Sheet Metal”…

Creating a sketch: How do we start to model the magazine file as a sheet metal part?

We will begin by creating a sketch to generate the base of the file.

What plane will this sketch be created on?

Because the file sits on the horizontal plane we will create

a sketch on the Top Plane.

Sketch: Create a rectangular sketch on the top plane placing

the top left hand corner coincident with the origin.

Smart dimension the rectangle as shown.

Height – 400mm & Width – 100mm

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Sheet Metal Feature: To create a sheet metal feature, click the Sheet Metal tab on the
Command Manager and choose Base Flange

Enter a value of 1.50mm for thickness in the

Base Flange options dialog box

Click Ok

About Base Flange When a base flange feature is created SolidWorks

immediately recognises this part as a sheet metal part.

Only one base flange feature may be inserted for

each sheet metal part document.

When a base flange feature is cretaed a number of items

are added to the feature manager design tree.

Sheet-Metal1: is automatically added above the

Base flange feature. It holds the default sheet metal
settings such as sheet metal thickness, radius etc.

Sheet-Metal1 will remain at the top of the feature manager design tree

Sheet-Metal 1 Right click on Sheet-Metal 1 and choose

Edit Feature

The sheet metal settings may be changed here.

Choose OK

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Flat-Pattern Feature This is added below the base flange feature. It has a couple of special properties
that are not found with other features.

Unlike other features, flat-pattern will remain at the bottom of the tree. Other
sheet metal features, when added, will appear overhead even though they are
added after its creation. Secondly, the feature is suppressed when added to the
design tree.

We will look further at this feature as we work through this exercise.

Adding the vertical faces We will create the vertical faces using Edge Flange

Edge Flange Edge flange is used to create a 90° bend to a selected edge, in the direction and
distance specified, using the thickness of the part. The shape of the flange by
default is rectangular. This may be edited to a custom profile also.

Adding an Edge Flange Select Edge Flange from the sheet metal toolbar.

Choose the back edge of the base flange as the edge on

which you wish to create the edge flange.

Drag the edge upwards and left click to indicate direction

and an initial value for length.

The default radius of 1mm is used. The gap distance is greyed out as there is
only one selection.

The flange angle is set to 90°.

Enter a value of 400mm for Flange Length

Choosing material inside will ensure that the face

of the edge flange, when bent, will be flush with
the original edge of the base flange, as indicated opposite.

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

A preview of the proposed flange is displayed.

We wish to add further selections to the feature.

Adding further edges. Choose the edges indicated to create further edge
flanges, using the same parameters.

Enter a Gap Distance of 0.01mm. Gap distance refers to the distance between
adjacent edge flanges and must be greater than 0mm.

Gap Distance

Click OK.

Creating cut edge: In order to complete the shape of the magazine file we must cut a section from the
rectangular prism which we have created.

Extruded Cut Extruded cut within Sheet Metal is used in a similar manner to the way we use it
in dealing with solid models.

We will begin by creating a sketch of

the profile used to create the cut on the
right face of the box.

Note: the enlarged detail of the sketch shows

a horizontal line coincident with the edge of
the front face and the endpoint of the inclined
line on the right face

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Select Extrude Cut from the Sheet Metal tab.

The line sketch is automatically

selected. From the options list
deselect the Direction 2 box.

In the direction 1 box select

the Through All end condition.

Select “Flip side to cut”, if

Necessary, to remove what is
above the plane and keep what
is underneath.

Choose OK

Corners Zoom into the lower right hand corner.

You will notice that the corner is open.

The faces may be extended to close the corner using

the Corners feature on the Sheet Metal toolbar.

Choose Corners, Closed Corner.

Select the face indicated.

Choose a gap distance of 0.5mm

Select Overlap as corner type

An overlap ratio of 1 will ensure

that the two faces overlap completely.

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

A preview will be displayed as shown opposite.

Note: The gap distance of 0.5mm

can be seen clearly at this stage.

Selecting further faces Rotate the model and choose the face as
indicated below.

Rotate the model and choose the corresponding

faces on the opposite side.

In total you should now have 4 faces selected.

Choose OK. The corners now appear as shown

below.

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Adding tabs To complete the part tabs must be added to vertical edges of the side pieces.

We will use Edge Flange to add these tabs.

Choose Edge Flange and select the internal

corner of the vertical side.

Drag the corner in the direction shown and left

left click to assign an initial distance.

Input the following;

Angle - 90°

Flange Length – 20mm

Flange Position –
Material Inside

Edit Flange Profile Choose Front View.

Select Edit Flange Profile from the Flange Parameters

The sketch used to create the flange appears along with

the profile sketch dialog box shown.

We must edit this sketch in order to edit the shape

of the flange.

We are going to edit the sketch so that the top

is chamfered at 45°, as shown.

How will we achieve this?

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Editing the sketch. We must first remove the automatic relations from the
line.

To delete the relation; right click on the relation icon,

displayed in green when highlighted, and select delete
from the dropdown list. Alternatively choose delete
from the keyboard.

Removing the relations allows us to add angular

dimensions to the line.

Smart Dimension Smart dimension the angle as shown. Add the length of
the flange, 20mm.

The profile sketch dialog box will indicate whether the

sketch may be used to create the flange or not.

Choose Finish

A preview of the customised tab is displayed.

Choose Isometric View.

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Selecting other edges We want to add a similar tab to the other

3 internal corners.

Using rotate and zoom commands select the

remaining corners, as indicated opposite.

Unfortunately, each of the sketches defining the

Individual flange profiles must be edited separately.

Choose Edge 2 and select Edit Flange Profile

Edit the profile as before.

Repeat the procedure for edges 3 & 4.

Choose OK.

Flat-pattern Remember the Flat-pattern1 feature discussed earlier?

It is added to the bottom of the feature manager design tree when we create a
sheet metal part. As sheet metal features are added to the part it remains at the
bottom. You will also notice that it is greyed out or suppressed.

Lets see what happens when we unsuppress it!

Unsuppress Flat-pattern Right click on the feature and choose unsuppress from the pop-up toolbar

The sheet metal model flattens

out into the surface development
used to create it.

All of the bend lines are displayed.

Select the top face and choose Normal To

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Introduction to Sheet Metal Features
Base Flange Method - Magazine File

Complete surface development

Suppress Left click on Flat-Pattern1 and choose

Suppress to return to the sheet metal

Add appearance: Add an appropriate appearance to the model.

Choose Yellow Low Gloss Plastic

Save the completed part

Lesson Complete!

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

Prerequisite knowledge: Exercise 1 - Magazine File should be completed in advance of this exercise..

Focus of lesson: To further explore the tools available within sheet metal and investigate how
these tools may be used to enhance the teaching of geometry.

Commands Used: This lesson includes Sketching, Base Flange, Flatten, Extruded Cut, Fold and
Unfold.

Problem: A worksheet is presented based on a hexagonal prism and irregular shaped

opening.
The hexagonal prism, shown overleaf, is to be produced complete with the given
window removed. The solution requires us to generate the hexagonal prism,
unfold it, add the true shape of the cut out to the development and then refold the
model. The orthographic views will be generated from this model.

We will omit the top and bottom surfaces of the prism from the model as the
problem does not require them.

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

We will explore the use of SolidWorks in completing the problem, focusing on

sheet metal features

How will we create the solution?

To complete the solution to this problem we must first create the development
of the hexagonal prism.

Getting started: We will begin by creating the model of the prism and then derive the
development from it. To start we will draw the base profile of the prism, a
hexagon.
Create a new SolidWorks part document and save it as Hexagonal Prism.

What Plane will we sketch on?

As the hexagonal prism sits on the horizontal plane we will begin sketching on
the Top Plane.

Sketch: Create a hexagonal sketch on the top plane, placing

the centre of the hexagon coincident with the origin.

Add Relation Add a horizontal relation to one of its sides,

and a side length of 75mm.

These three pieces of information are needed to

fully define the sketch

Base Flange If a base flange is created using this closed sketch

it will not allow us to create the thin walled sheet
metal hexagonal prism we require.

Instead it will generate a solid prism as shown.

In order for SolidWorks to create the sheet metal

container, a joint edge, or break, must be placed in it.

This joint will be the position from which the

prism will later be developed.

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

Breaking the sketch How will we create a break in the sketch?

We will use the trim command to create the break

in the sketch.

Centreline Select Centreline and draw a line from the

origin to the midpoint of the top edge of the hexagon.

Offset Offset this line 0.1mm.

Choose Bi directional. This will offset the line at both

sides of the original

For Construction These lines are for construction purposes only and will not form part of the
feature afterwards. For this reason they must be marked as construction lines.

Zoom in, select the offset lines and choose

For Construction from the Line properties dialog box.
These lines will now change to a chain line type.

Trim In order to trim the sketch we will need to zoom in.

Select the Zoom to area icon

Trim (Contd.) Choose Trim Entities Select Trim to closest

Select the portion of the hexagonal sketch

which lies between the two offset lines.

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

SolidWorks warning SolidWorks gives us a warning because the original centreline has a midpoint
relation with the line we are trying to trim. Trimming the line will delete the
relation.

Choose Yes when the SolidWorks dialog box appears.

Choose OK. Exit the sketch

Create feature: What will we use to create the feature from the hexagonal sketch?

Base Flange: Select Base flange from the

sheet metal toolbar.

Direction 1: 150mm

Thickness: 1.5mm

Bend radius: 1mm

Adding Window feature In order to create the sketch for the window feature we need to flatten the prism.
In the previous exercise we unsuppressed the flat pattern feature to develop the
model.

Unsuppressing the flat-pattern feature is not suitable in this instance. Why?

If we create a sketch on the surface of the unsuppressed flat-pattern feature and

then extrude cut that sketch, the feature created will be added to the feature
manager tree below the flat pattern feature.

Because the new feature is created below the flat-pattern feature it will not be
displayed when the model is suppressed.

About Unfold/Fold Unfold can be used to flatten a model, allowing you to create sheet metal features
which cross bend lines eg a hole. Fold takes the unfolded model in the flattened
state and refolds it.

Any feature created in the unfolded state will appear above the flat-pattern feature
in the featuremanager design tree and hence will appear when the flat-pattern
feature is suppressed.

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

Unfold Select Unfold from the sheet metal toolbar or

choose Insert, Sheet metal, Unfold…

Choose the following options;

Fixed face: This will be the only surface which remains

stationary. Choose the front face as shown

Bends to Unfold: These may be selected individually

from the graphics area or choose all bends.
In this case we wish to unfold all the bends so we
select Collect All Bends.

SolidWorks will automatically select all bends from

the model. Choose OK

The model is now unfolded. Notice how similar unfolding

is to flattening, however unfolding allows us to add sheet metal features and
include them in the flat-pattern feature. Flattening does not allow us to do this.

Hide Sketch The sketch used to create the base-flange may

be hidden by clicking on it and choosing hide.

Sketch: Create the following sketch on the front face of the

unfolded sheet metal part.

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

Mirror Choose Mirror . Mirror the sketch across the centreline

Choose OK. Exit the sketch

Cut Extrude To remove the material from the development we will create an Extruded Cut
feature.

Choose Extruded cut from the sheet metal toolbar.

Choose the sketched window

Select the Through All end condition

Click OK.

Refold To refold the prism select Fold from the sheet metal toolbar or
Choose Insert, Sheet metal, Fold from the drop-down menu

Now that the window has been added to the model,

we can refold the model.

Folding the hexagonal prism follows a similar procedure

to unfolding it.

We must indicate which surface is to remain stationary

and which bends are to be folded.

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

Fixed Face By default SolidWorks chooses the same fixed face

as was used to unfold the model. A different face may
be chosen if you wish

Bends to fold Choose Collect All Bends

The model will fold along the bend lines and the
folded model will include the cut-out.

Flatten the model Right click on the flat-pattern feature and

choose unsuppress

or choose flatten from the sheet metal toolbar.

Note: This tool will both flatten and unflatten the model

Edit Appearance: Choose Blue Medium Gloss Plastic

Save the completed part

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

Creating a drawing: As with any Solidworks part, a drawing may be produced by selecting File,
Create drawing from Part/Assembly or

Choose from the standard toolbar

When a drawing is created from a sheet metal part, in addition to the standard
views, the opportunity exists to create a view which displays the development
of that part.

Create Drawing: With the part file open select File, Create drawing from
part/assembly.

Select DCG A3L as the drawing template you wish to use.

Standard Views All of the standard drawing views are displayed in the
Task Pane

Any of these views may be dragged and dropped onto

the drawing sheet.

Flat pattern Flat Pattern is included in these views.

Dragging this icon into the sheet will generate a view

displaying the development of the prism.

Creating the view layout To generate the solution we want to create 3 orthographic views and add the
surface development of the cut hexagonal prism

Drag the Front View onto the sheet and project an End view and Plan view
from the parent view. Use an appropriate scale

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Introduction to Sheet Metal Features
Envelopment & Development of Surfaces

Adding the surface To add the surface development, select Model View from
development: the View Layout toolbar.

Model View Choose the hexagonal prism from the Open

documents list in the Model View options
dialog box.

Select next to proceed

Flat Pattern Select the Flat Pattern option

Position the flat pattern view on the drawing sheet.

Choose OK.

Positioning the views Drag the views to position them on the sheet.

Note: The text may be removed from the surface

development by selecting it and choosing Hide

Save all SolidWorks Documents. Lesson Complete!

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Introduction to Sheet Metal Features
Development of Transition Pieces

Extractor Hood - Transition piece development

Prerequisite knowledge: Exercise 1 – “Magazine File” and Exercise 2 “Easter Egg Box” should be
completed before attempting this exercise..

Focus of lesson: To further explore the tools available within sheet metal, through the completion
of a transition piece exercise.

Commands Used: This lesson includes Sketching and Lofted Bend, Fold and Unfold. It works
through the creation and development of a transition piece.

Development of transition part

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Introduction to Sheet Metal Features
Development of Transition Pieces

Getting started.
New File Create a new part file.

Save File Save the file to a chosen location as Extractor Hood.

Creating a sketch: How will we create the transition piece? (Extractor Hood)
The extractor hood is created in a similar way to the way that pyramids are
created as Solidworks parts, as a loft.
Loft is also available in Sheet metal and is called Lofted Bend

What is required to create a loft?

Previously, when we used lofts to create pyramids, we created two sketches; a
sketch of the base profile and one of the top profile. We then used these two
sketches to create a feature. The procedure is the same in sheet metal.

What sketches do we need to represent the profile of the

base and top of the extractor hood?

What shape is the Base profile?

What shape is the Top profile?

Base: Rectangular in shape

Top: Circular in shape.

Creating Base Sketch: What Plane will we create the Sketch on?

Because the hood sits on the Horizontal plane we will sketch the profile on the
top plane.

Create the sketch shown on the top plane

Width: 600mm

Depth: 450mm

Note: A Centre rectangle was used to create the

rectangle. This will allow us to use the origin to
reference both sketches, ensuring they are correctly
aligned. It will also allow us to use the origin when
creating breaks in the sketches.

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Introduction to Sheet Metal Features
Development of Transition Pieces

Sketch Fillet: In sheet metal the lofted bend command can only create a feature from
sketches which have rounded edges. Although the hood has a rectangular base
sketch, we will have to create a fillet at each corner to create the sheet metal part
in SolidWorks. We will use a 2mm radius for the purposes of the sketch fillet.
Select sketch fillet and add the 2 mm radius to each corner.

Sheet metal sketches: As this sketch will be used to create a sheet metal feature a break must be added.
This break in the sketch will later allow Solidworks to develop the completed
model.

Break the sketch Where is the best place to create a break in the sketch?
In real life the joint or break in the hood would be kept out of view of the user
and would be at the back of the hood. For the same reasons we will create the
break in the sketch at the back.

To create the break in the sketch first draw a

centre line from the origin to the midpoint of
the back line of the sketch.

Offset Offset 2 lines 1mm either side of the centreline.

These lines will be used to trim the sketch.

Select offset, enter a value of 1mm and check the

Bi – directional option.

The lines that we have just drawn will allow us to break

or trim our initial sketch. They are not part of the finished
sketch and must be converted to construction lines.

To do this left click on the lines and check

“For Construction” from the options box.

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Introduction to Sheet Metal Features
Development of Transition Pieces

Trim Sketch: Zoom into the area between the lines we have just created, and use Power Trim
to remove the material.

Base profile sketch complete!

Exit Sketch Exit the sketch. Rename the sketch base profile

Creating Top Profile: The top profile is positioned a height of 275mm above the
base profile.

How will we create the profile 275mm above

the base profile?
In order to create this sketch we must first
create a plane on which to draw the sketch.
This new plane will be a height of 275mm
above the top plane.

From Features select Reference geometry

and Plane.

Create a plane 275mm above the Top plane.

Creating the Sketch: Note: Earlier we mentioned that the top profile was circular in shape.
However if we use the circle command to create the top profile, the finished
feature will develop without fold lines. In order to create triangulation in the
development the top profile must have an equal number of curved and straight
sections as the bottom profile.

Circular profile with four flat sections. Flat Section of curve (Highlighted)

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Introduction to Sheet Metal Features
Development of Transition Pieces

Creating the circular section with the flat sections included as shown.
We could use the circle command and cut sections from it – rejoining these
sections with straight lines. Would this be the best way to produce the profile?

Alternatively

Creating top profile We begin by drawing a square, in this case 250mm side length. Create a sketch
fillet, of 123mm, on the four corners. This will leave 4 flat sections of 1mm on
the four sides.

Create Sketch: On the new plane create a

centre rectangle sketch.

Adding Relations The sketch may be fully defined

by smart dimensioning one side
and adding appropriate relations.

Note the relations added

Sketch Fillet Add a sketch fillet of 123mm to each

of the corners.

Should the SolidWorks warning shown

below appear; Choose Yes

Break the sketch Just as in the base profile, a break must be added to the sketch profile.

The same procedure may be adopted as used previously or alternatively you may
take the approach outlined overleaf.

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Introduction to Sheet Metal Features
Development of Transition Pieces

Alternatively: We can use the break lines from the first sketch
to create a break in this sketch using the
convert entities sketch command.

Convert Entities This command allows elements from previous

sketches or model edges to be converted into
sketch entities. In this case it uses the
break lines from the base profile sketch to create
sketch segments in the current sketch.

Note: When using the Convert Entities command, you must pre select the
elements of the sketch you wish to convert before selecting convert entities

Also

Using this command means that any changes made to the distance between the
break lines in the base profile automatically updates in the top profile

Select sketch elements: What elements of the base profile sketch do we wish to convert for use in the
top profile sketch?

The break lines from

the base profile.

Multiple Selections Select the break lines - To select more

than one line from the sketch you must
hold down the Ctrl button while selecting
the lines.

Convert Entities With the break lines and the top profile
Selected, choose Convert Entities

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Introduction to Sheet Metal Features
Development of Transition Pieces

This will now convert the break

lines into sketch lines within
the top profile sketch.

Construction Geometry Note: these new lines must now be

changed into construction lines, and
then the area between them must be trimmed
in the same way as we did in the first sketch.

Exit the sketch and rename top profile

Completed Sketches The completed sketches of the top and base profiles.

Creating the Feature: Note: In order to create a lofted bend feature

we must have exited both sketches, as both
will be used to create the feature.

Lofted Bend Select Lofted bend from the sheet metal toolbar

Profiles Select the sketch profiles to create the loft

Sketch1 - Base Profile
Sketch2 - Top Profile

Note: When choosing the two sketches pick

corresponding parts of both sketches to avoid
forming a warped surface.

Thickness Enter a Thickness of 0.5mm

Bend Lines The number of bend lines used to create the

transition piece may be controlled here.

Choose 4 bend lines.

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Introduction to Sheet Metal Features
Development of Transition Pieces

Click OK to confirm

Hiding the Plane: Left click on plane1 in the feature manager tree and select Hide

Flatten Choose Flatten

The transition piece development is

displayed.

Note: 4 bend lines at each transition.

Creating a drawing: As with any Solidworks part, a drawing may be produced by selecting
File, Create drawing from Part/Assembly or

Choose from the standard toolbar

When a drawing is created from a sheet metal part, in addition to the standard
views, the opportunity exists to create a view which displays the development of
that part.

Create Drawing: With the part file open select File, Create drawing from
part/assembly.

Select DCG A3L as the drawing template you wish to use.

Standard Views All of the standard drawing views are displayed in the Task Pane

Any of these views may be dragged and dropped onto the drawing sheet.

Flat pattern Flat Pattern is included in these views.

Dragging this icon into the sheet will generate a view

displaying the development of the prism.

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Introduction to Sheet Metal Features
Development of Transition Pieces

Creating the view layout To generate the solution we want to create 3 orthographic views and add the
surface development of the transition piece

Drag the Front View onto the sheet and project a Plan view from the parent view.
Use a scale of 1:5

Adding the surface To add the surface development, select Model View from
development: the View Layout toolbar.

Model View Choose Extractor Hood from the Open

documents list in the Model View options
dialog box.

Select next to proceed

Flat Pattern Select the Flat Pattern option

Position the flat pattern view on the drawing sheet.

Choose OK.

Positioning the views Drag the views to position them on the sheet.

Note: The text may be removed from the surface

development by right clicking on it and choosing
Hide.

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Introduction to Sheet Metal Features
Development of Transition Pieces

Save & Close Save all SolidWorks Documents. Lesson Complete!

Introduction to Sheet Metal features Design & Communication Graphics 32

Introduction to Sheet Metalwork
Convert to Sheet Metal

Golf Ball Package - Convert to Sheet Metal

Prerequisite knowledge: Sheet metal exercises 1, 2, and 3, should be completed in advance of this
exercise.

Focus of lesson: To convert solid features to sheet metal and to use sheet metal to create a surface
development.

Commands Used: This lesson includes Sketching, Lofted Bend, Flatten, Extruded Cut and Convert
to Sheet Metal.

Problem: The development of the Golf ball package is to be created using SolidWorks. The
box is based on a square based pyramid. The window is created with a cut
generated by a cylinder. Generate the pyramid, removing the cut material for the
window. Retrieve the development of the box using sheet metal features.

New File Create a new part file.

Save File Save the file to a chosen location as Package development.

We will explore the use of SolidWorks in completing the problem, focusing on

sheet metal features.
Introduction to Sheet Metal features Design & Communication Graphics 33
Introduction to Sheet Metalwork
Convert to Sheet Metal

The approach The square based pyramid must first be modelled and the development of the
package created from it. As the pyramid is to be cut with a cylindrical feature, we
will create it as a solid. We will then convert it to a sheet metal component in
order to generate its development.

What geometric shapes are used?

The main body of the package is

created by modelling a square based pyramid.

The cut surface is generated by cutting the pyramid with a cylinder

to give a circular cut when viewed from the right or left.

Getting Started How will we create the pyramid?

In exercise three we created the transition piece using lofted bend. We will
use lofted bend again to create the pyramid.

What two sketch profiles must we create?

Base: Square

Top: Point

Creating Base Sketch: What Plane will we create the Sketch on?
Because the pyramid sits on the Horizontal
Plane, we will create our sketch on the top plane.

Create the sketch shown on the top plane.

Use only the dimension shown.
Add appropriate relations

Side: 100mm

Exit Sketch In order to create the second sketch we must

first exit this sketch

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Creating Top Profile: The top profile is positioned a height of 100mm above the
base profile.

How will we create the profile 100mm above

the base profile?
We must begin by creating a plane on which to sketch.

From Features select Reference geometry

and Plane.

Create a plane 100mm above the Top plane.

Creating sketch As the pyramid forms a point at the apex, we will

use point to create the top profile.

Note: by creating the base profile with the origin

as centre it allows us to use the origin to align
both profile sketches.

Select the new plane as the sketch plane. From the sketch toolbar select point
Position a point on the origin as shown. This will ensure that the point is
positioned directly over the centre of the rectangular base thus producing a right
pyramid.

Exit the Sketch Exit sketch.

Creating the Feature: Note: In order to create a lofted bend feature

we must have exited both sketches, as both
will be used to create the feature.

Loft Select Loft from the features toolbar

Profiles Select the sketch profiles to create the loft

Sketch1: Base Profile

Sketch2: Top Profile

Click OK to confirm

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Creating the Cut The pyramid is to be cut by a cylinder. In order to create this cut we will need to
sketch a circle to extrude cut through the pyramid.

The cylinder cuts through the pyramid therefore the

sketch is placed on the right plane which cuts the
pyramid symmetrically. A mid- plane extrusion
will be used to create the cut.

Due to the prudent location of the origin we can

use the Right plane on which to sketch.

Create Sketch Create the sketch shown on the

Right plane

Creating the feature Create an Extruded Cut feature using a Through All end condition in both
directions.

Click OK.

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Surface Development A cut pyramid has now been created but SolidWorks cannot create a development
from a solid model. We must convert the model to a sheet metal part in order to
retrieve the surface development.

Convert to sheet metal In Solidworks 2009 solid models can be converted to sheet metal. Using this
feature will allow us to create a development from this model.

Choose Convert to sheet metal from the sheet metal

toolbar.

When converting to sheet metal you will be required to choose;

 a fixed face, about which the development will be created

 corners which will become bends
 edges along which you wish to cut or rip the feature to flatten it out

Selecting a fixed face: Any face may be selected as the fixed face.

We will select one of the faces that are not

cut by the cylindrical hole.

Face 1 is entered as the selected face.

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Selecting Bend Edges: The bend edges must be selected.

Select each of the bends on the model.

As the bends are selected, SolidWorks

will automatically select the edges which
will be used as rip edges.

Further parameters The following parameters must be set;

Sheet thickness: 0.1mm

Bend radius: 0.1mm

Gap size: 0.25mm

Click OK.

The pyramid has now been converted to sheet metal

Design Tree Sheet Metal features have been added to the

Feature Manager Design Tree

Surface Development Right cick on Flat-pattern in the design tree

and choose Unsuppress.

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