The SOLIDWORKS Convert to Sheet Metal tool efficiently generates Sheet Metal shapes even without expertise in Sheet Metal functions.
Transforming a solid or surface body into a sheet metal design that can be flattened supports manufacturing processes. Flattened parts can be exported in DXF or DWG formats for cutting software.
Developing the outer shape as a standard model might be simpler than beginning with sheet metal. The transformation of a bulldozer blade depicted in the image illustrates this process.
How to Access the Convert to Sheet Metal Command
The Convert to Sheet Metal function is found in the CommandManager under the Sheet Metal Tab. Access it through the Sheet Metal drop-down menu under Insert > Sheet Metal > Convert To Sheet Metal…
Once the command is selected, designate the fixed face and thickness in the PropertyManager. The fixed face should be the most substantial face for bending, as all bends will originate from that face.
Choose to select all bends or only specific ones. Automatically identify corners that require separation. The ripping function is automated.
Convert To Sheet Metal Command Options
Make sure to turn off Keep Body to prevent duplicating the original body. Opt for Reverse thickness to include an extra wall thickness outside the model. Select appropriate Corner Types and Auto Reliefs.
Following the conversion, new features such as Sheet-Metal, Convert-Solid1, and Flat-Pattern will appear. Right-click on Convert-Solid1 to access the Edit Feature option.
Limitations
Collect All Bends might not capture all edges in the part. Thin Extrudes are more effective. Utilize the Convert to Sheet Metal feature multiple times for superior outcomes.
Conclusion
Utilize the sheet metal conversion tool to accelerate design and manufacturing processes.
SOLIDWORKS Sheet Metal is a robust tool for creating bent components. Sheet metal components are initially designed folded and can be effortlessly flattened for drawings or laser cutting.
Three primary methods include: sheet metal features, bending thin-walled parts, and converting to sheet metal.
Turning on the SolidWorks Sheet Metal Tab
To access sheet metal features, activate the sheet metal tab. Right-click on any tab and select Sheet Metal to unveil the tab.
Base Flange Method
The base flange technique commences with a 2D sketch. Enclosed sketches produce sheet metal without bends, while open sketches incorporate bends automatically.
Base flanges are typically used to create the initial structure of a sheet metal part. They form the foundation from which additional features can be added, such as flanges, tabs, or cutouts.
When creating a base flange, it is important to consider the material thickness and bend radius, as these factors will affect the overall design and manufacturability of the part. Additionally, accurate measurements and calculations are crucial to ensure the final part meets the desired specifications.
Insert Bends Method
Insert Bends integrates bends into existing geometry. Ensure to shell the shape before using insert bends.
Define the fixed face and apply rips for corners. Rips introduce gaps between flanges.
Inserting bends is a useful technique for creating complex shapes with bends and curves. When inserting bends, it is important to consider the material thickness and the bend radius to ensure the desired result. By defining the fixed face and applying rips for corners, you can control the placement and alignment of the bends in your geometry.
Convert to Sheet Metal Method
Convert to Sheet Metal is a feature in sheet metal design software that is similar to the Insert Bends command. The main difference is that Convert to Sheet Metal allows you to specify the sheet metal thickness directly within the feature itself.
To use the Convert to Sheet Metal method, first select a primary base flange and the edges that you want to bend to create your sheet metal part.
Material
The choice of material is crucial in sheet metal design as different materials have varying properties such as strength, flexibility, and corrosion resistance.
Flange length
The length of the flange determines the size and shape of the final sheet metal part. Longer flanges allow for more complex geometries but may require additional support to prevent warping during bending.
Coefficient of friction
The coefficient of friction between the sheet metal and bending tools affects the amount of force required to bend the material. This value should be carefully considered to ensure accurate and consistent bending results.
Tooling considerations
When designing sheet metal parts, it is important to take into account the capabilities of the bending tools available. Factors such as tooling radius, opening width, and material compatibility can impact the final design and manufacturing process.
Secondary Features
Add supplementary features like flanges, hems, jogs, etc., to sheet metal components based on complexity. Secondary features inherit properties from the main feature, but some properties can be altered, like adjusting the bend radius for specific bends.
Flatten
During the design phase, view the flattened version of a sheet metal part by clicking the flatten button. SolidWorks sheet metal only supports features that can be flattened; errors will arise if non-flattenable features are added. The flattened version can be detailed in a 2D drawing.
Discover tips and techniques for designing sheet metal parts in SolidWorks, covering fundamentals and features. Explore the introductory video and blog for beginners on SolidWorks Sheet Metal.
Pick the best profile
Selecting the optimal profile is key in SolidWorks for sheet metal design. Different strategies can be employed using the base flange method, open profile sketches for initial bends, and closed profile sketches for detailed features.
Edit Flange Profile
The edge flange tool introduces bends to sheet metal bodies, enabling modifications to flange geometry via ‘Edit Flange Profile’. Adjustments like position, offset, additional material, and holes can be made within the sketch.
When using the ‘Edit Flange Profile’ feature, users can easily customize the shape and size of the flange to fit their specific design requirements. This tool allows for flexibility in creating intricate flange designs, ensuring that the final product meets the desired specifications.
Normal Cut
Sheet metal parts are profiled using laser or plasma cutters before bending to ensure cut faces are at 90 degrees. Design SOLIDWORKS models in alignment with manufacturing methods for compatibility.
Additionally, it is important to consider the tooling requirements for the cutting process. Laser cutting is ideal for intricate designs and tighter tolerances, while plasma cutting is better suited for thicker materials. Understanding the capabilities of each method will help optimize the manufacturing process and ensure high-quality results.
Unfold/Fold
Cuts across bends can be added while folded or unfolded in SolidWorks for enhanced control. Unfolding a part allows the addition of cut features before folding back to maintain history in the feature manager.
Link to Thickness
Adding cuts with the ‘link to thickness’ option in sheet metal parts ensures depth adjustments with sheet thickness changes. This method simplifies cut depth modifications without manual input.
Right click to export to DXF/DWG
To send sheet metal parts to a laser cutter without a 2D drawing, export to DXF directly from the 3D model in SolidWorks. Customize export settings such as hidden lines, bend lines, and sketches for manufacturing.
Precision is critical in sheet metal bending due to material stretch during bending. It’s essential to position bend lines accurately to counteract material stretch, which varies for each material type, thickness, and bend angle.
How to Create Sheet Metal Bends in SolidWorks
Sheet metal design in SolidWorks is made simpler with user-friendly features. Steps include creating a base flange/tab, dimensioning the part, setting base flange parameters like K-factor, adding flanges, exporting as DXF, and configuring bend lines for manufacturing.
Calculating Sheet Metal Parameters
SolidWorks calculates sheet metal flat pattern sizes based on bend allowance calculations. Refer to our Bend Allowance article for manual calculation guidance. Employ parameters like K-factor or bend table in SolidWorks.
Visit our website to access a bending calculator for SolidWorks sheet metal work verification. Watch a video guide on using the calculator.
Use the bending calculator to determine parameters for sheet metal parts: Base Length: 8.125”, Outer Flange Length: 1”, Material: 5052 Aluminum (0.063” thickness).
The calculator provides details on bend lines, total length, K-factor, bend radius, and thickness.
In SolidWorks, create a sheet metal tab, sketch as usual to match SendCutSend bending calculator, specify sheet metal properties, add bends.
Export DXF by right-clicking on the 3D model face, selecting “Export to DXF/DWG,” then choosing “Sheet Metal,” “Geometry,” “Bend Lines,” and saving.
Verify and save the DXF file for quoting, order via SendCutSend, ensuring the base length aligns with 8.125″ due to calculator adjustments.
SolidWorks sheet metal design feature complements the SendCutSend calculator. Adhere to bending guidelines for successful outcomes.
Upload the DXF file to our app, indicate material and quantity, define bends and angles for an instant parts quote.