SOLIDWORKS

Sheet Metal

Dassault Systèmes SolidWorks Corporation

175 Wyman Street
Waltham, Massachusetts 02451 USA
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Document Number: PMT1906-ENG

 Contents

Introduction
About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Design Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conventions Used in this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About the Training Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Training Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Windows® 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Use of Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Graphics and Graphics Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Color Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
More SOLIDWORKS Training Resources. . . . . . . . . . . . . . . . . . . . . . 6
Local User Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Contents SOLIDWORKS

Lesson 1:
Basic Flange Features
What are Sheet Metal Parts? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sheet Metal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unique Sheet Metal Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flange Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Base Flange/Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sheet Metal Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
What is Bend Allowance?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Using Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Editing Sheet Metal Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sheet Metal Bend Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Flat-Pattern Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Flatten and Exit Flatten. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Toggle Flat Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Additional Flange Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Edge Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Edge Flange Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Editing the Flange Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Flange Profile Relations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Edge Flanges on Curved Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Miter Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Miter Flange Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hem Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hem Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cuts in Sheet Metal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Summary of Flange Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Exercise 1: Sheet Metal Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Exercise 2: Flange Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Exercise 3: Edit Flange Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Exercise 4: Sheet Metal Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Exercise 5: Assorted Framing Hangers . . . . . . . . . . . . . . . . . . . . . . . 57
Lesson 2:
Working with the Flat Pattern
Working with the Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Flat Pattern Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Features for Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Corner-Trim Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Corner-Trim Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Corners in the Formed State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Closed Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Closed Corner Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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SOLIDWORKS Contents

Corner Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Break Corner/Corner Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Producing the Flat Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Sheet Metal Cut List Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Accessing Cut List Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Flat Pattern Drawing Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Flat Pattern View Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Drawing Document Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Sheet Metal Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cut List Properties as a Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Exporting the Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Exercise 6: Flat Pattern Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Exercise 7: Working with Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Lesson 3:
Additional Sheet Metal Techniques
Additional Sheet Metal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Designing from the Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Sketched Bend Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Jog Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Adding Features in an Unfolded State . . . . . . . . . . . . . . . . . . . . . . . 105
Unfold and Fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Creating Cuts in the Flat Pattern. . . . . . . . . . . . . . . . . . . . . . . . . 108
Swept Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Swept Flange Flat Pattern Options . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Lofted Bends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Bent Lofted Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Bent Bend Region Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Formed Lofted Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Formed Bend Region Options . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Lofted Bends in the Design Library . . . . . . . . . . . . . . . . . . . . . . . . . 120
Exercise 8: Sheet Metal from Flat . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Exercise 9: Jogs and Hems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Exercise 10: Fold & Unfold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Exercise 11: Conical Swept Flange . . . . . . . . . . . . . . . . . . . . . . . . . 132
Exercise 12: Lofted Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Exercise 13: Using Symmetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Manual Relief Cut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Sheet Metal Library Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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Contents SOLIDWORKS

Lesson 4:
Converting to Sheet Metal
Sheet Metal Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Insert Bends Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Imported Geometry to Sheet Metal . . . . . . . . . . . . . . . . . . . . . . . . . 146
Adding Rips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Insert Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Associated Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Switching Between States. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Making Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Welded Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Converting Cones and Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Convert to Sheet Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Convert to Sheet Metal Settings . . . . . . . . . . . . . . . . . . . . . . . . . 163
Using Rip Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Exercise 14: Importing and Converting . . . . . . . . . . . . . . . . . . . . . . 169
Exercise 15: Unrolling a Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Exercise 16: Convert to Sheet Metal Practice . . . . . . . . . . . . . . . . . 176
Exercise 17: Convert with Rips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Exercise 18: Sheet Metal Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Lesson 5:
Multibody Sheet Metal Parts
Multibody Sheet Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Tools to Create Multibody Sheet Metal Parts. . . . . . . . . . . . . . . 183
Multibodies with Base Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Sheet Metal Parameters for Multibodies . . . . . . . . . . . . . . . . . . . . . 185
Solid Body Feature History . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Cut List Item Properties for Multibodies . . . . . . . . . . . . . . . . . . . . . 186
Flat Pattern Drawing Views for Multibodies . . . . . . . . . . . . . . . . . . 187
Cut List Balloon Annotations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Exporting to DXF/DWGs with Multibodies. . . . . . . . . . . . . . . . . . . 192
Convert with Multibodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Hiding and Showing Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Hide and Show . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Hide/Show Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Isolate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
The Display Pane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Using Split with Sheet Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Patterning for Multibodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Using Edge Flanges to Merge Bodies. . . . . . . . . . . . . . . . . . . . . . . . 201
Interfering Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Combining Sheet Metal with Other Bodies . . . . . . . . . . . . . . . . . . . 204
Assigning Materials to Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Exercise 19: Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Exercise 20: Mirroring and Merging Bodies . . . . . . . . . . . . . . . . . . 217
Exercise 21: Sheet Metal Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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SOLIDWORKS Contents

Lesson 6:
Forming Tools and Gussets
Sheet Metal Forming Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
How They Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Types of Forming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Standard Forming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
The Forming Tools Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Using a Standard Forming Tool . . . . . . . . . . . . . . . . . . . . . . . . . 237
Form Tool Feature Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Form Tool Features in the Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Part Document Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Custom Forming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Split Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Forming Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Form Tools in Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Punch Tables and Punch ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Sheet Metal Gusset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Exercise 22: Forming Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Exercise 23: Sheet Metal Gusset . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Lesson 7:
Additional Sheet Metal Functions
Additional Sheet Metal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Cross-Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Cross Break Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Vent Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Mirror Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Tab and Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Process Plans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Sheet Metal Costing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Appendix A:
Sheet Metal Tables
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
The Sample Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Templates and Other Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Customizing Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
K-Factor Ratio Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282