Sheetmetal Funda

- For University Use Only -
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PTC Global Services
Fundamentals of
Sheetmetal
Release 2000i2
T869-310-03
Copyright
Fundamentals of Sheetmetal
COPYRIGHT © 1989-2000 PARAMETRIC TECHNOLOGY CORPORATION. ALL RIGHTS

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PRINTING HISTORY
Document No. Date Description
T869-310-03 09/22/00 Initial Printing of Fundamentals of Sheetmetal for Release 2000i2
Order Number DT-869-310-EN

Printed in U.S.A
Training Agenda
Day 1
8:30-8:45 Welcome and Introduction
8:45-9:15 Module 1 – Introduction to Sheetmetal Design
9:15-9:30 Module 2 – Primary Walls
9:30-10:00 Exercise
10:00-10:30 Module 3 – Secondary and Unattached Walls
10:30-10:45 Break
10:45-11:15 Exercise
11:15-11:30 Module 4 – Unbend, Bend Back, and Cuts
12:00-1:00 Lunch
1:00-1:30 Module 5 – Notches and Punches
1:30-2:00 Exercise
2:00-2:15 Break
2:15-2:45 Module 6 – Sheetmetal Forms
2:45-3:30 Exercise
3:30-4:00 Module 7 – Bend Features
4:00-4:30 Exercise
Day 2
8:30-9:00 Review
9:00-9:30 Module 8 – Unbending Sheetmetal Geometry
9:30-10:15 Exercise
10:15-10:30 Break
10:30-11:00 Module 9 – Converting Solid Parts
11:30-12:00 Module 10 – Sheetmetal Drawings with Flat States and Bend Order Tables
12:00-1:00 Lunch
1:00-1:45 Exercise
1:45-2:15 Module 11 – Additional Features
2:15-2:45 Exercise
2:45-3:00 Break
3:00-3:30 Module 12 – Setting Up for Design
3:30-4:00 Exercise
4:00-4:30 Module 13 – Interrogating the Sheetmetal Part
4:30-5:00 Exercise
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Table of Contents
INTRODUCTION TO SHEETMETAL DESIGN 1-1

THE SHEETMETAL DESIGN ENVIRONMENT............................................................1-3
SHEETMETAL PARTS.....................................................................................................1-3
Features .............................................................................................................................. 1-3
Sheetmetal Part Display ..................................................................................................... 1-4
Orienting the Sheetmetal Part ............................................................................................ 1-4
Developed Length .............................................................................................................. 1-5
DESIGN APPROACH .......................................................................................................1-5
MODULE SUMMARY......................................................................................................1-9
PRIMARY WALLS 2-1

WALL TYPES....................................................................................................................2-3
CREATING THE FIRST WALL .......................................................................................2-3
Wall Feature Options ......................................................................................................... 2-3
Sketching Technique.......................................................................................................... 2-5
LABORATORY PRACTICAL ..........................................................................................2-7
EXERCISE 1: Creating the Cable Box Base ..................................................................... 2-7
MODULE SUMMARY....................................................................................................2-13
SECONDARY AND UNATTACHED WALLS 3-1

TYPES OF SECONDARY WALLS ..................................................................................3-3
Resulting Geometry ........................................................................................................... 3-6
Creating Other Walls ......................................................................................................... 3-7
CREATING UNATTACHED WALLS .............................................................................3-9
Merging Unattached Walls .............................................................................................. 3-10
SECONDARY WALLS WITH RELIEF .........................................................................3-10
LABORATORY PRACTICAL ........................................................................................3-13
EXERCISE 1: Adding Walls to the Cable Box Base....................................................... 3-13
EXERCISE 2: Adding Walls to the Tuner Cover ............................................................ 3-17
EXERCISE 3: Creating the Box ...................................................................................... 3-26
EXERCISE 4: Creating an Unattached Wall ................................................................... 3-35
MODULE SUMMARY....................................................................................................3-41
UNBEND, BEND BACK, AND CUTS 4-1
THE UNBEND, REGULAR FEATURE........................................................................... 4-3
THE BEND BACK FEATURE ......................................................................................... 4-4
CREATING SHEETMETAL CUTS ................................................................................. 4-5
Dimensioning Scheme........................................................................................................4-6
LABORATORY PRACTICAL ......................................................................................... 4-7
EXERCISE 1: Unbend and Bend Back ..............................................................................4-7
MODULE SUMMARY ................................................................................................... 4-13
NOTCHES AND PUNCHES 5-1

INCREASING YOUR EFFICIENCY WITH SHEETMETAL NOTCHES AND
PUNCHES.......................................................................................................................... 5-3
Creating a Punch or Notch UDF.........................................................................................5-3
Placing a Punch or Notch Feature ......................................................................................5-5
EXERCISE 1: Creating Notches in the Flat State of the Model.........................................5-7
MODULE SUMMARY ................................................................................................... 5-15
SHEETMETAL FORMS 6-1

CREATING FORM FEATURES ...................................................................................... 6-3
CREATING FORM PARTS.............................................................................................. 6-3
Creating Rips in the Geometry ...........................................................................................6-5
Using Multiple Forms on a Single Die Model....................................................................6-5
Using Multiple Forms on a Single Punch Model ...............................................................6-6
PLACING FORM FEATURES ......................................................................................... 6-7
Placing By Reference .........................................................................................................6-7
Copying the Geometry .......................................................................................................6-8
RETURNING THE MODEL TO THE FLAT................................................................... 6-8
EXERCISE 1: Forms for the Cover ...................................................................................6-9
EXERCISE 2: Placing a Die Form...................................................................................6-18
MODULE SUMMARY ................................................................................................... 6-21
BEND FEATURES 7-1

BEND FEATURES............................................................................................................ 7-3
Angle ..................................................................................................................................7-3
Roll .....................................................................................................................................7-3
Regular ...............................................................................................................................7-4
W/Transit (With Transition)...............................................................................................7-4
Planar Bends ...................................................................................................................... 7-4
BEND LINES .....................................................................................................................7-5
Bend Line Adjustment ....................................................................................................... 7-7
EXERCISE 1: Creating a Model in the Flat ...................................................................... 7-9
MODULE SUMMARY....................................................................................................7-21
UNBENDING SHEETMETAL GEOMETRY 8-1

UNBENDING GEOMETRY AFTER DEFINING THE MODEL ....................................8-3
Unbending Ruled Geometry: the Regular Unbend ............................................................ 8-3
Unbending Nonruled Geometry: the Cross Section Driven Unbend ................................. 8-3
Adding Tears to the Geometry: Ripping ............................................................................ 8-4
DEFORMATION AREAS .................................................................................................8-6
EXERCISE 1: Creating a Regular Unbend Feature........................................................... 8-9
EXERCISE 2: Cross Sectional Unbend ........................................................................... 8-11
EXERCISE 3: Creating a Deformation Area ................................................................... 8-16
MODULE SUMMARY....................................................................................................8-21
CONVERTING SOLID PARTS 9-1

CREATING SHEETMETAL PARTS FROM SOLID PARTS .........................................9-3
CREATING A DEVELOPABLE PART............................................................................9-4
EXERCISE 1: Converting a Sheetmetal Part..................................................................... 9-7
EXERCISE 2: Using the Sheetmetal Conversion Feature ............................................... 9-10
MODULE SUMMARY....................................................................................................9-15
SHEETMETAL DRAWINGS WITH FLAT STATES AND BEND ORDER

TABLES 10-1
FLAT STATES.................................................................................................................10-3
Retrieving Instances......................................................................................................... 10-3
CREATING MULTI-MODEL DRAWINGS...................................................................10-4
DOCUMENTING THE BEND ORDER..........................................................................10-5
LABORATORY PRACTICAL ........................................................................................10-7
EXERCISE 1: Documenting the Model........................................................................... 10-7
MODULE SUMMARY..................................................................................................10-17
ADDITIONAL FEATURES 11-1

FLAT PATTERN .............................................................................................................11-3
SOLID FEATURES......................................................................................................... 11-3
EDGE TREATMENTS....................................................................................................11-3
Using Projected Datum Curves ........................................................................................ 11-4
LABORATORY PRACTICAL ....................................................................................... 11-7
EXERCISE 1: Using a Projected Datum Curve to Create a Cut ......................................11-7
MODULE SUMMARY ................................................................................................. 11-13
SETTING UP FOR DESIGN 12-1

CALCULATING DEVELOPED LENGTH .................................................................... 12-3
SETTING UP A DEFAULT RADIUS ............................................................................ 12-7
SETTING DEFAULT FIXED GEOMETRY .................................................................. 12-7
EXERCISE 1: Calculating the Length of a Sheetmetal Part ............................................12-9
EXERCISE 2: Setting Up for Sheetmetal ......................................................................12-12
MODULE SUMMARY ................................................................................................. 12-19
INTERROGATING THE SHEETMETAL MODEL 13-1

SHEETMETAL INFORMATION................................................................................... 13-3
Measurement ....................................................................................................................13-3
Surface Analysis...............................................................................................................13-3
Sheetmetal Bend Reports .................................................................................................13-4
Sheetmetal Radii Reports .................................................................................................13-5
DESIGN RULES.............................................................................................................. 13-6
Establishing a Design Rule Table.....................................................................................13-6
EXERCISE 1: Using Sheetmetal Information Tools........................................................13-9
MODULE SUMMARY ................................................................................................. 13-13
ADDITIONAL EXERCISES A-1

EXERCISE 1: Creating a Blended Primary Wall..............................................................A-3
EXERCISE 2: Creating a Flat Primary Wall.....................................................................A-6
EXERCISE 3: Creating a Swept Secondary Wall .............................................................A-8
EXERCISE 4: Creating a Twisted Secondary Wall ........................................................A-10
EXERCISE 5: Bend Line Adjustment.............................................................................A-13
EXERCISE 6: Creating an Edge Bend and a Rip............................................................A-18
SKETCHER BASICS B-1

THE SKETCHER ENVIRONMENT ............................................................................... B-2
The Sketcher Interface....................................................................................................... B-2
Intent Manager .................................................................................................................. B-3
Pop-Up Menus .................................................................................................................. B-4
SKETCHER MODE FUNCTIONALITY.........................................................................B-4
Sketcher Menus................................................................................................................. B-4
Specifying References....................................................................................................... B-5
Creating Geometry............................................................................................................ B-6
Dimensioning.................................................................................................................... B-7
Constraining.................................................................................................................... B-10
Additional Sketcher Tools .............................................................................................. B-11
SETTING SKETCHER PREFERENCES ...................................................................... B-14
SKETCHER PHILOSOPHY ...........................................................................................B-17
Rules of Thumb............................................................................................................... B-17
LABORATORY PRACTICAL .......................................................................................B-19
EXERCISE 1: Sketching Basics ..................................................................................... B-19
EXERCISE 2: Sketching in Steps................................................................................... B-25
EXERCISE 3: Sketching a Hexagon .............................................................................. B-30
MODULE SUMMARY...................................................................................................B-33
USING PTC.HELP C-1

PTC HELP OVERVIEW...................................................................................................C-2
PTC HELP FEATURES....................................................................................................C-2
USING THE PRO/ENGINEER HELP SYSTEM .............................................................C-2
Getting Help While Performing a Task..............................................................................C-2
GETTING HELP THROUGH THE PTC HELP SIDEBAR.............................................C-3
PTC HELP MODULE LIST..............................................................................................C-4
PTC GLOBAL SERVICES: TECHNICAL SUPPORT D-1

FINDING THE TECHNICAL SUPPORT PAGE.............................................................D-2
OPENING A TECHNICAL SUPPORT CALL ................................................................D-2
Opening a call via email: .................................................................................................. D-2
Opening a Call via Telephone:.......................................................................................... D-3
Opening calls on the PTC Web Site:................................................................................. D-3
Sending Data To Technical Support ................................................................................. D-3
CALL / SPR FLOW CHART AND PRIORITIES............................................................D-4
REGISTERING FOR ON-LINE SUPPORT.....................................................................D-5
ONLINE SERVICES.........................................................................................................D-6
FINDING SOLUTIONS IN THE KNOWLEDGE BASE ................................................D-6
GETTING UP-TO-DATE INFORMATION ....................................................................D-8
CONTACT INFORMATION............................................................................................D-8
Internet .............................................................................................................................. D-8
Telephone ..........................................................................................................................D-9
ELECTRONIC SERVICES ............................................................................................ D-13

For University Use Only - Commercial Use Prohibited
Module
Introduction to Sheetmetal Design

Using the functionality available with the Pro/SHEETMETAL
module, you can capture your design intent by bending flat material
into its final formed shape, as well as create a flat form for
manufacturers to use to develop the actual model.
Objectives
After completing this module, you will be able to:
• List benefits of designing sheetmetal components using

Pro/SHEETMETAL
• List specialized sheetmetal feature types
• Describe the display of a sheetmetal part
• Describe how to orient a sheetmetal part
• Describe the design approach for a sheetmetal part
Page 1-1
NOTES
THE SHEETMETAL DESIGN ENVIRONMENT

Using Pro/SHEETMETAL to generate sheetmetal components enables
you to do the following:
• Design a sheetmetal part that defines the supporting structures in an

assembly
• Add sheetmetal-specific features such as walls, bends, cuts, punches,
notches, and forms to a model in either the formed or flat condition
• Control the developed length of the bends when creating a flat instance
of the model
• Create flat patterns and flat states of the model geometry to reflect the
manufacturing and design models
• Create bend order tables that define the bend order, bend radius, and
bend angle used in the manufacturing process
• Document the design by generating production drawings of the flat
model and design model, as well as bend order tables
SHEETMETAL PARTS
Features
Sheetmetal parts are created in Sheetmetal mode, Assembly mode as
sheetmetal components, or from a regular Pro/ENGINEER part. When you
create a new file, you can use a default template or choose one from a list
of standard or user customizable templates. When you use a template that
contains designated parameters, you are able to enter parameter values as
you create the model. Templates also include default datum planes and a
coordinate system, saved views, and default layers.
Pro/ENGINEER offers specialized feature types for the sheetmetal design

environment. They include the following:
• sheetmetal cuts
• notches
• punches
• bends
• unbends
Introducti on to Sh eetm etal D esig n Pag e 1- 3

NOTES
• bend backs
• forms
• walls
Note:
Create features in an order that captures your design intent, not
in the order in which you would manufacture the geometry.
Sheetmetal Part Display

A sheetmetal part appears with green and white surfaces with side surfaces
in between to define depth. This enables you to visualize the part and
geometry selection, since sheetmetal parts tend to be comparatively thin.
Sheetmetal parts always have a constant thickness. Pro/ENGINEER
creates the white surface by offsetting it from the green surface by the
amount of the material thickness. The side (depth) surfaces do not appear
until the part has been successfully regenerated.
Orienting the Sheetmetal Part

When orienting a sheetmetal part, the first selection must be a planar
surface or a datum plane and the second selection may be an edge. (This
way of viewing is available in all modes of Pro/ENGINEER.) You may
also use the thin edge surfaces of the sheetmetal part for orienting. Using
Query Select is the suggested method of selecting these thin surfaces.
Figure 1: Orienting a Sheetmetal Part
Pag e 1- 4 Fundament als of Sh e etme t al

NOTES
Developed Length
Pro/ENGINEER automatically compensates for stretching that occurs in
the area of a bend by taking into account the thickness of the sheetmetal,
the radius of the bend, the bend angle, and other material properties. This
enables you to capture your design intent through the creation of the
formed sheetmetal model, but also enables you to create a flat form of the
model for manufacturers to use to develop the actual model.
Figure 2: The Developed Length
DESIGN APPROACH
You can generate sheetmetal models at either the sheetmetal level or the
assembly level, but the assembly level enables you to use the top-down
design approach.
The following is a typical design approach for creating sheetmetal parts at

the assembly level:
1. Create the assembly by assembling all major components relative

to each other. You can include simple supporting structures, or
sheetmetal parts that are not completely defined at this time.

NOTES
Figure 3: Assembly of Sheetmetal Components
2. Create or modify sheetmetal parts in Assembly mode using the

internal components as references. This process will aid in creating
support walls, form features for stiffening panels, and punches and
notches for fastening the components.

NOTES
Cover created in Additional

assembly features added to
referencing complete cover
internal in Sheetmetal
components mode
Figure 4: Modify Sheetmetal Parts in Assembly Mode
3. After the cabinet and supporting structures are defined relative to

the internal components and each other, add any remaining
components or features.
4. Create or select a bend table to provide material allowances when

unbending the part. The bend table data will be used to ensure
accurate flat pattern geometry of the sheetmetal part.
5. In Sheetmetal mode, create a bend order table to define the

bending sequences for each part.
6. Add a Flat Pattern feature. This will create the flat pattern for
manufacturing. Another option is to create a Flat State.
7. Create a family table for each sheetmetal part that includes at least
two instances: the unbent flat pattern instance and the “as

NOTES
designed” instance. These instances are automatically created

using the Flat State option.
8. Document the parts by creating drawings. You can include both

instances (that is, with a multi-model drawing). Show the
dimensions for the “as designed” part and show/create dimensions
for the flat pattern part. Add the bend order table as a note.
Figure 5: Drawing of Sheetmetal Part

NOTES
MODULE SUMMARY
In this module, you have learned about:
• The benefits of using Sheetmetal mode to design sheetmetal parts

• Display and orientation characteristics specific to sheetmetal parts
• A design approach for creating sheetmetal parts at the assembly level

Module
Primary Walls
In this module, you will learn how to create primary walls. The first
sheetmetal feature must be a wall.
Objectives
• Create the primary wall in a sheetmetal model

• Use sketching techniques to create the section for a primary wall
Page 2-1
NOTES
WALL TYPES
Pro/SHEETMETAL gives you the ability to create two types of walls:
primary and secondary. Primary walls do not need another wall in order to
exist. They can stand alone. A secondary wall, however, must be attached
to another wall because it cannot exist independently; thus, it is always a
child of another wall.
CREATING THE FIRST WALL

Wall Feature Options
To create any model in Pro/ENGINEER, you should start with three
default datum planes. If you use one of the sheetmetal templates, the part
will automatically include these. When creating sheetmetal geometry, you
must add a wall as the next feature.
The following options are available for creating walls:
• Extrude – Sketches the side section of the wall and extrudes it to a

specified depth, as shown in Figure 1.
Figure 1: Extruding to a Specified Depth
• Revolve – Sketches the side section of the wall and revolves it about a
centerline, as shown in Figure 2.
P rim a ry Wa lls Pag e 2- 3

NOTES
Figure 2: Revolving about a Centerline
• Blend – Uses parallel, rotational, or general blend feature forms to

create a wall, as shown in Figure 3. For more information on blends,
see “Creating a Blend” in PTC Help.
Figure 3: Using Blend Feature Forms
• Flat– Sketches the boundaries of the wall in the Sketcher plane, as

shown in Figure 4.
Figure 4: Sketching in a Plane

NOTES
• Offset – Offsets from an existing surface, as shown in Figure 5. For

more information on offset surfaces, see “Creating Surfaces by
Offsetting” in PTC Help.
Figure 5: Offsetting from an Existing Surface
• Advanced – Creates a wall by using datum curves, multiple

trajectories, and so on.
Sketching Technique
When creating an extruded wall, you can insert bends to represent inside
and outside radii. Usually, you dimension all bends in sheetmetal parts to
the inside. To do this, you may need to use the Thicken option to thicken
the material and dimension the offset edges, as shown in Figure 6.

NOTES
Figure 6: Thickening the Material
It is common practice to dimension sheetmetal walls to the mold line (the

intersection of the flat wall extensions). To create this dimensioning
scheme, you must add Sketcher centerlines and points while creating the
wall section. You can then dimension to the Sketcher points, instead of the
tangent points on the arc, as shown in Figure 7.
Figure 7: Defining a Mold Line

NOTES
LABORATORY PRACTICAL
Goal
The goal of this exercise is to create the primary wall of a sheetmetal part
as an extruded wall.
Method
In this exercise, you begin developing the lower housing of a cable box.
The section of the extruded wall will be thickened and the inside radii
dimensioned.
EXERCISE 1: Creating the Cable Box Base
Figure 8: First Wall of Cable Box
Task 1. Start the definition of a sheetmetal model.
1. Create a new part file and select Sheetmetal as the sub-type in the
NEW dialog box, as shown in Figure 9. The Use default template
option is selected so that the part uses the default sheetmetal
template.
2. Type [CABLE_BOX_BASE] as the name and click OK .

NOTES
Sub-type
selection
Figure 9: NEW Dialog Box
Task 2. Create an extruded wall on both sides of the FRONT datum

plane.
1. Click Feature > Create > Wall > Extruded > Done > Both Sides
> Done .
2. Select datum plane FRONT as the sketching plane and datum plane
TOP as the top reference.
3. Sketch the section as shown in Figure 10.

NOTES
Figure 10: The Dimensioning Scheme
Task 3. Change the dimensioning scheme so that the system dimensions

the inside radius by thickening the geometry.
1. Click Sketch > Feature Tools > Thicken .
2. Click Flip or Okay to add material inside the sketched section.
3. Type [0.08] as the thickness.
4. Delete the existing radius dimension.
5. Add a radius dimension to the thicken line, as shown in Figure 11.

This results in an inside radius.
Tips:
Make sure that you pick the thicken arc, not the solid arc. Use
Query Sel to make it easier.

NOTES
Dimension
the thicken
arc
Figure 11: Dimensioning the Thicken Line
6. Modify the radius dimension to [.13] and exit from Sketcher.
7. Extrude to a blind depth of [12]. The completed wall feature

appears as shown in Figure 12.

NOTES
Figure 12: The Finished Base
8. Save the model and erase it from memory.

NOTES
MODULE SUMMARY
In this module, you have learned that:
• The first sheetmetal feature must be a wall.

• The section of a wall can be thickened so that inside radii are
dimensioned.
• Centerlines can be used in the section of a wall to dimension to the
mold line.

Module
Secondary and Unattached Walls

After you create the base wall for a sheetmetal model, you can attach
secondary walls to its edges. You can also create unattached walls
and later merge the geometry.
Objectives
• Create an attached secondary wall along the complete length of the

primary wall edge
• Create an attached secondary wall partially along the primary wall
edge
• Create relief for secondary walls
• Create unattached walls and merge the geometry
Page 3-1
NOTES
TYPES OF SECONDARY WALLS

You can create several different types of secondary walls by sketching the
bend in the wall or automatically creating a bend along the attachment
edge. Using the No Radius and Use Radius options, you can create flat,
extruded, partial, and swept secondary walls.
• Flat, No Radius – Sketch the boundaries of the wall attached to the

selected edge. The new wall is automatically created parallel to the
adjacent wall, as shown in Figure 1 and Figure 2.
Figure 1: Flat, No Radius
Figure 2: A Wall Partially Along the Edge
• Extruded, No Radius – Sketch the side section of the wall that will be
extruded along the attachment edge. You determine if the bend is
created when sketching the section, as shown in Figure 3.
Figure 3: Extruded, No Radius
Se conda ry and Un atta ched Wall s Pag e 3- 3

NOTES
If you sketch an arc to define the bend, you must sketch it tangent to the
attachment edge and adjacent to the green or white surface, as shown in
Figure 4.
Figure 4: Ensuring Tangency
You can also partially extrude the wall along the selected edge using the
blind depth option and by defining a sketching plane partially along the
edge.
• Swept, No Radius – You can attach the wall to a nonlinear edge, but
the edge must consist of all tangent entities, as shown in Figure 5. The
green or white surfaces of the attachment edge do not necessarily have
to be planar. For more information on sweeps, see “Creating a Sweep”
in PTC Help.
Figure 5: Swept, No Radius
• Flat, Use Radius – You can define the sketching plane at a specific
angle through a selected attachment edge and then define a radius for
the desired bend at the attachment edge, as shown in Figure 6.

NOTES
Figure 6: Flat, Use Radius
• Extruded, Use Radius – You can sketch the side profile of the wall
with a specified angle and then define the radius of the bend, as shown
in Figure 7. This bend deforms a portion of the existing attachment
wall.
Figure 7: Extruded, Use Radius
You can also partially extrude a wall along an edge using a blind depth
and relief, as shown in Figure 8.
Figure 8: Using Make Datum and Depth Option Blind

NOTES
• Swept, Use Radius – You can sketch the section for the wall, and
then specify the radius, as shown in Figure 9. With the Use Radius
option, you cannot enter a wall angle that is greater than 180° to the
adjacent green or white surface of the attachment edge.
Figure 9: Swept, Use Radius
Resulting Geometry
The Use Radius option produces different results, depending on the
attachment edge that you select, as shown in Figure 10 and Figure 11. If
you attach the geometry to an edge that is going to be the outside edge of
the wall, the length of the original wall does not change. However, if you
attach it to the inside edge, the wall extends a distance beyond the length
of the original wall that is equal to the thickness of the geometry.
Attached to inside edge
Attached to outside edge
Figure 10: Extruded Walls

NOTES
Figure 11: Flat Walls
When creating a flat wall, Pro/ENGINEER also enables you to

automatically miter a corner by sketching outside the attachment edge and
aligning to an existing wall, as shown in Figure 12. You must add rip
relief at the attachment edge.
Aligned to
inside edge
Figure 12: Mitered Corner
Part and Feature Bend Tables

When creating a wall with the Use Radius option, you must specify
whether you want to use a part bend table or a feature bend table. Bend
tables control the developed length of the bends. Using the Part Bend Tbl
option, you can use a single table to control all of the bends on the entire
model.
Creating Other Walls

A twist takes the form of an extension to a straight edge on an existing
planar wall. It can be rectangular or trapezoidal. It has an axis running
through it center, perpendicular to the attach edge and it can be twisted
around the axis by a specified amount, as shown in Figure 13. You cannot
use a radius with the twist wall type. You can unbend a twisted wall using

NOTES
the Unbend and Regular options. You can also add more walls to the end
of the wall.
To generate the twisted geometry, you must specify the following values:
• Point of attachment
• Width at the start
• Width at the end
• Length
• Twist angle
• Developed length
Figure 13: Twisted Wall
To create an extended wall, you can extend the existing green surface of a
wall up to an existing planar surface or to a specified distance. Using this
technique, you can close gaps between walls in the geometry by extending
up to the inside or outside surfaces of the wall, as shown in Figure 14. You
cannot use a radius with the extended wall type.

NOTES
Open corner
Extended to
the inside Extended to
surface outside surface
Figure 14: Closing Gaps between Walls by Extending
CREATING UNATTACHED WALLS

After you add the first wall of the model, you can create additional
unattached walls using the same methods. Figure 15 shows a primary wall
with an unattached wall. The Unattached option enables you to capture
the intent of the model with greater flexibility by enabling you to
concentrate in more than one area on the model. Once you have created
the walls, you can use an unattached or secondary wall to “bridge the gap”
and then merge the geometry.
Figure 15: Unattached Wall

NOTES
Merging Unattached Walls

To successfully merge an unattached wall with an unattached or secondary
wall, the wall geometry must be tangent to the wall with which you are
merging it.
Also, the corresponding green side of the unattached wall must be adjacent
to the green side of the adjacent wall. You can change this, if necessary,
by using the Swap Side element, as shown in Figure 16.
Figure 16: Matching the Side
SECONDARY WALLS WITH RELIEF

When creating walls or bends that require relief, the system provides an
automatic relief function. The choices are as follows:
• No Relief – Attach the wall without reliefs.

• StrtchRelief – Use material stretching to provide bend relief at the
wall attachment points, as shown in Figure 17. The system prompts for
the width and angle of the stretch relief.
Figure 17: Stretch Relief

NOTES
• Rip relief– At the wall attachment points, rip the existing material
normal to the edge and back to the tangent line as shown in Figure 18.
Figure 18: Rip Relief
• RecRelief – At the wall attachment points, apply a rectangular cut by

defining its width and depth, as shown in Figure 19.
Figure 19: Rectangular Relief
• ObrndRelief - At the wall attachment points, apply an obround cut by

defining its width and depth, as shown in Figure 20.
Figure 20: Obround Relief

NOTES
Goal
The goal of this exercise is to create secondary walls with relief, when
necessary and create unattached walls that are eventually merged with
existing geometry.
Method
In the first exercise, you will create secondary walls using different types
of automatic relief. In the second exercise, you will create secondary walls
and create additional extruded and extended walls to close gaps in the
geometry. In the third exercise, you will create a new part using several
different techniques to construct the walls. In the fourth exercise, you will
create two unattached walls in a part and merge them to complete the
geometry.
EXERCISE 1: Adding Walls to the Cable Box Base
Figure 21: Cable Box Base
Task 1. Create a Flat, Use Radius wall with obround relief on one end
of the cable box base.
1. Open CABLE_BOX_BASE.PRT. If you did not complete the base of

the cable box, open SECONDARY_CABLE_BASE.PRT.
2. Click Feature > Create > Wall > Flat > Use Radius > Done .

NOTES
3. Click Part Bend Tbl > Done/Return > Inside Rad >
Done/Return .
4. Pick the lower green edge to attach the wall as shown in Figure 22.
Attach to the green

lower edge
Figure 22: Attaching the Wall to the Lower Edge
5. Click Done to use the default bend angle of 90 degrees.
6. Click Okay to accept the viewing direction.
7. Sketch the section as an open section consisting of three lines as

shown in Figure 23.
Align the endpoint

to the edge
Figure 23: Sketching an Open Section
8. Exit Sketcher when the section is complete and orient to the

default view.
9. Click w/Relief > Done . A point on the attachment edge highlights

at the end of the new wall.
10. Click ObrndRelief > Done for the first end of the wall.

NOTES
11. Click Enter Value and type [0.20] for the relief’s width.
12. Click Tan To Bend .
13. Define the same relief for the other end of the wall.
14. Type [0.13] for the bend radius value. Click OK in the dialog
box. The part should appear as shown in Figure 24.
Figure 24: Flat Wall with Obround Relief
Task 2. Create another wall on the other end of the part.
1. Create a similar flat wall on the opposite end of the cable box. Use
obround relief on both ends of the wall. Make this wall reference
the first flat wall (that is, no dimensions are required for the second
flat wall). The part should appear as shown in Figure 25.

NOTES
Figure 25: Completed Cable Box Base

NOTES
EXERCISE 2: Adding Walls to the Tuner Cover
Figure 26: Secondary Walls Added to Tuner Cover
Task 1. Create a flat wall on one end of the part that does not extend
past the existing wall.
1. Open TUNER_COVER.PRT.
2. Click Feature > Create > Wall > Flat > Use Radius > Done .
Done/Return .
4. Pick the edge indicated in Figure 27.
Pick the upper

white edge
Figure 27: Attachment Edge for Flat Wall

NOTES
5. Click 90.000 > Done .
6. Click Okay for the direction of viewing the sketching plane.
7. Sketch an open section in which the endpoints pass through the

Sketcher points provided by the system. Align the horizontal edge
to the lower surface of the existing side wall, as shown in Figure
28.
Section sketched
to Sketcher points
Align to bottom
surface of wall
Figure 28: Open Section for Flat Wall
8. When finished sketching, exit from Sketcher.
9. Use rip relief at both ends of the wall.
10. Type [.05] as the bending radius value.
11. Click OK . The model should appear as shown in Figure 29.
Task 2. Create an extruded wall on the other end of the model.
1. Click Create > Wall > Extruded > Use Radius > Done .
Done/Return .
3. Click One Side > Done .
4. Pick the edge to attach the wall, as shown in Figure 29.

NOTES
Pick here on
the white edge
Figure 29: Selection Edge for Extruded Wall
5. Click Default > Flip to define the sketching plane and viewing
direction.
6. Sketch the section as shown in Figure 30. Make sure that the
endpoint passes through the Sketcher point provided by the system.
Align the other end to the edge of the existing wall.
Align endpoint to
edge
Sketched line
Figure 30: Section for Extruded Wall

NOTES
7. Finish the wall definition using rip relief on both ends and type
[.05] as the bending radius value. The part should appear as
shown in Figure 31. The walls that you just created look identical.
Figure 31: Flat and Extruded Walls
Task 3. Extend the flat wall to the outside of the side walls.
1. Click Create > Wall > Extend > Done .
2. Pick the edge shown in Figure 32 as the edge to extend.
3. Click Query Sel to pick the hidden inside surface of the side wall
to define the extension distance.

NOTES
Pick hidden
inside surface
Pick this
edge
Figure 32: Defining the Geometry to Extend
4. Click OK . The part should appear as shown in Figure 33.
Figure 33: Completed Extension
5. Create another wall extension on the other end of the flat wall
using the references shown in Figure 34.

NOTES
Extend the
wall to this
surface
Pick this
edge
Figure 34: Defining the Second Wall Extension
Task 4. Use Extruded walls to create tabs on the back wall of the model
to close the gap.
1. Click Create > Wall > Extruded > No Radius > Done .
2. Use a part bend table to drive the bend geometry and extrude one
side of the sketching plane.
3. Pick the attachment edge as shown in Figure 35.
Pick this
hidden edge
for
attachment
(inside edge)
Figure 35: Specifying the Attachment Edge

NOTES
4. Click Default > Okay to define the sketching plane and viewing
direction.
5. Sketch a section consisting of a line and a tangent arc, as shown in

Figure 36. Use the dimensioning scheme shown.
Tangent arc
Line
Figure 36: Section for Extruded Wall
6. Finish the definition of the wall. It should appear as shown in

Figure 37 (as viewed from the underside of the part).
Figure 37: Tab Created as an Extruded Wall

NOTES
7. Add another extruded No Radius wall to the other side of the wall
to fully close up the cover. The completed part should appear as
shown in Figure 38.
Figure 38: Completed Part
Task 5. Determine if any of the walls that you created overlap in the
unbent state of the model.
1. Click Create > Unbend > Regular > Done and pick the top
surface of the cover to remain fixed.
2. Click Unbend All > Done .
3. Click OK to complete the feature. The unbent state of the model

should appear as shown in Figure 39. If any of the walls overlap,
they are highlighted in red.

NOTES
Surface to
remain fixed
Figure 39: Unbent State
4. Save the part and erase it from memory.

NOTES
EXERCISE 3: Creating the Box
Figure 40: Completed Model
Task 1. Create a new sheetmetal part.
1. Create a new sheetmetal part called BOX.
2. For the first sheetmetal feature, create an extruded wall using the
section shown in Figure 41, sketched on the TOP datum plane.

NOTES
Figure 41: Section for Base Wall
3. Click Thicken on the pop-up menu to thicken the sketch. Type

[0.12] as the inside wall value to maintain the proper
dimensioning scheme. Make sure that the 0.35 dimension belongs
to the inside (thickened) portion.
4. Extrude the wall to a blind depth of [10.00].
Task 2. Create three flat secondary walls attached to the base wall.
1. Create a flat wall using the Use Radius , Part Bend Tbl , and
Inside Rad options.
2. Pick the green edge indicated in Figure 42 to attach the wall.

NOTES
Attach wall to
the green edge
Figure 42: Attaching the Wall
3. Use the default bend angle of 90 degrees.
4. Sketch the wall as shown in Figure 43. After finishing the sketch,
click No Relief and type [0.10] as the bend radius.
Figure 43: First Secondary Wall

NOTES
5. Create another flat wall so that it closes off the end of the box and
Pro/ENGINEER miters the corner automatically. Use the Use
Radius , Part Bend Tbl , and Inside Rad options. Use the default
bend angle of 90 degrees. Pick the edge shown in Figure 44.
Attachment edge
(white edge)
Figure 44: Creating Another Flat Wall
6. Sketch the section for the wall, as shown in Figure 45. You do not
need to add dimensions, but add the appropriate references. Notice
that the side of the sketch crossing the bend is beyond the Sketcher
point. Pro/ENGINEER, therefore, miters both walls at this corner.

NOTES
Right vertex
of edge
Figure 45: Sketching Second Wall to Create a Miter
7. After finishing the sketch, click W/Relief and use the Rip relief
option for the right vertex, as shown in Figure 45. Type [0.35] as
a bend radius.
8. Create another flat wall for the other end of BOX.PRT. Use the
default bend angle of 90 degrees. Pick the white edge indicated in
Figure 46.
Attachment edge
(white edge)
Figure 46: Creating a Flat Wall for the Other End of BOX.PRT

NOTES
9. Sketch the wall using the section shown in Figure 47. After
finishing the sketch, click No Relief and type [0.10] as the bend
radius.
Figure 47: Sketching the Flat Wall
Task 3. Create a secondary wall that is partially extruded along the base
wall.
1. Create an extruded wall using the Use Radius , Part Bend Tbl ,
and Inside Rad options.
2. Click One Side > Done .
3. Pick the green edge as shown in Figure 48.

NOTES
Pick this green

edge to attach
wall
Offset the datum

plane from datum
plane RIGHT
Figure 48: Offsetting Datum Point
4. Click Make Datum and create a datum plane Offset from datum
plane RIGHT by [2.0].
5. Flip the viewing direction. Keep in mind that the direction of

viewing for the wall is also the direction of feature creation.
6. Click Default on the SKET VIEW menu to define the orientation.

NOTES
Figure 49: Sketching the Partial Wall
8. After completing the sketch, click W/Relief and use the Rip Relief
option on each end of the wall.
9. Type [0.10] as the bend radius value. Do not click OK yet.
10. Click the optional Depth element in the dialog box, then click
Define .
11. Type a Blind depth of [1.5].
12. Click OK to complete the feature. The wall should appear as shown
in Figure 50.

NOTES
Figure 50: Partial Wall Feature with Rip Relief
Task 4. Redefine the wall to change the relief from rip to stretch.
1. Redefine the last wall and click Relief in the dialog box.
2. Click w/Relief > Done > StrtchRelief > Done .
3. Type [0.25] as a stretch relief value and [45] as an angle for

both ends. Notice the changes that occur where the partial wall
meets the base feature wall, as shown in Figure 51.
Figure 51: Partial Wall Feature with a Stretch Relief

NOTES
EXERCISE 4: Creating an Unattached Wall
Figure 52: Custom Shield
Task 1. Open the part and use the surface geometry to create two walls.
1. Open CUSTOM_SHIELD.PRT.
2. Click Feature > Create > Sheet Metal > Wall > Offset > Done .
3. Pick the surface on the right-hand side, as shown in Figure 53.

Pick this surface
from which to
offset
Figure 53: Pick Right-Hand Surface
4. Type [0] as the offset value.
5. If necessary, flip the arrow outward (to the right), as shown in

Figure 54. Click Okay.

NOTES
Figure 54: Offset Direction
6. Type [.05] as the thickness and click OK .
7. Create an unattached offset wall on the other side. Notice that the
Unattached option is automatically selected when you click
Offset . Type [0] as the offset value and add the thickness to the
outside (to the left), as shown in Figure 55.
Figure 55: Direction of Offset
8. Blank the SURFACES layer.
Task 2. Create an unattached flat wall that spans the gap between the
two offset walls.
1. Click Create > Wall > Flat > Unattached > Done .
2. Pick the FRONT datum plane as the sketching reference. Flip the
arrow outward as shown in Figure 56.
3. Pick the TOP datum plane as the top reference.

NOTES
Figure 56: Sketch Viewing Direction
Note:
Keep in mind that the direction of viewing is also the direction
in which Pro/ENGINEER adds the material thickness.
4. Pick the top datum planes and the two vertical surfaces as
references for the section, as shown in Figure 57.
Pick these
surfaces as
references
Figure 57: Section References
5. Sketch a horizontal centerline along the TOP datum plane.
6. Sketch a rectangle, symmetric about the centerline, where the

vertical edges lie on the referenced surfaces, as shown in Figure
58. Complete the feature when finished sketching.

NOTES
Figure 58: Section for Flat Wall
Task 3. Merge the three walls.
1. Click Create > Wall > Merge > Done .
2. Pick the bend surface on the first wall and click Done Sel > Done
Refs .
3. Pick the front flat surface and click Done Sel > Done Refs again.
4. Click OK in the dialog box.
Pick these surfaces to

merge
Figure 59: Merging the Flat Wall with the First Offset Wall
5. Create another merge feature for the other offset wall on the left
side (Figure 60).

NOTES
Figure 60: Finished Model

NOTES
MODULE SUMMARY
• When creating some secondary wall types, you have the option of
having the system automatically apply a radius at the attachment edge.
• The Use Radius option produces different results depending on the
attachment edge selection.
• You can extrude secondary walls partially along an attachment edge
by using the optional Depth element.
• Unattached walls enable you to concentrate on more than one area of
the model.
• Automatic relief can be added to walls when necessary.

Module
Unbend, Bend Back, and Cuts

It is easier to create sheetmetal parts in a completely bent condition;
however, some features must be created in a flat state. Combinations
of unbend and bend back features enable these features to be created
effectively.
Objectives
• Create unbend features

• Create bend back features
• Create sheetmetal cut features
Page 4-1
NOTES
THE UNBEND, REGULAR FEATURE

The unbend, regular feature will unbend the curved surfaces of the part
created by walls and bend features. If all bends are selected, a flat pattern
of the part is automatically generated. You are prompted to pick a plane or
edge to remain fixed while the part is being unbent. It is good practice to
always pick the same plane or edge each time an unbend or bend back
feature is created. This will keep the part in a consistent orientation.
Original model Unbend selected
Unbend all
Figure 1: Unbend Sheetmetal Geometry
Unbend , Bend B ack , and Cu ts Pag e 4- 3

NOTES
THE BEND BACK FEATURE

The bend back feature may be used to return an unbent feature to its
original condition. When you create a bend back feature, you can specify
contours to remain fixed (that is, unbent) by picking on the edge of that
contour.
Figure 2: The Bend Back Feature
Notes:
When a sheetmetal wall overlaps and intersects in the unbent
position, the system highlights it and issues a warning.

NOTES
CREATING SHEETMETAL CUTS

A sheetmetal cut feature enables you to create Thru All and Thru Next
cuts. The techniques for creating the cuts are the same as in Part mode.
Unlike the solid cut, the sheetmetal cut always removes material normal to
the green or white side of the model in order to emulate most sheetmetal
manufacturing processes. The solid cut removes material normal to the
sketching plane.
Solid cut
Sheetmetal cut projected on the white side
Sheetmetal cut projected on green side
Figure 3: Removing Material Using a Sheetmetal Cut

NOTES
Dimensioning Scheme
Features may be added to the sheetmetal part while the part is in any
design condition (that is, completely bent, completely unbent in its flat
condition, or at any stage in-between). It is easiest to design sheetmetal
parts in the completely bent condition. When creating features in the
unbent stages, care must be taken when picking sketcher references. See
the example in Figure 4.
Cut created before bend Cut created after bend

and unbend features
When bend is created,

new surfaces result. Cut
section stays in old
surface location. When bent back, cut section
stays with cut feature. The
cut could have been created
in the bent state.
Figure 4: Creating a Cut in the Flat Condition

NOTES
Goal
The goal of this lab is to create sheetmetal cuts across bent geometry that
result in flat contours.
Method
In this exercise, you create a wall with two bends. An unbend feature is
created followed by two sheetmetal cuts. A bend back feature is then
created, but with two contours remaining flat.
Figure 5: Sheetmetal Cuts with Flat Contours
EXERCISE 1: Unbend and Bend Back

Task 1. Create a new sheetmetal part.
1. Create a new part called BEND_BACK using the default template.
2. Create an extruded wall using the dimension scheme shown in

Figure 6 (use an equal length constraint for the horizontal
segments). Create the wall on both sides of the datum plane. Type
a blind depth of [6.0].

NOTES
Figure 6: Extruded Wall
Task 2. Create an unbend feature.
1. Click Feature > Create > Sheet Metal > Unbend > Regular >
Done .
2. Pick the surface shown in Figure 7 as the one to remain fixed while
unbending.
Pick this surface to

remain fixed
Figure 7: Surface to Remain Fixed during Unbend
3. Click Unbend All > Done and click OK in the dialog box.

NOTES
Task 3. Create a Thru Next, Thin Cut on the part.
1. Click Feature > Create > Sheet Metal > Cut > Extrude > Thin >
Done .
2. Sketch on the large top face of the part as shown in Figure 8.
Pick this surface as the

sketching plane
Figure 8: Sketching Plane for Cut
3. Sketch the cut as shown in Figure 9.
Figure 9: Section for Cut
4. Add the thickness to the outside of the cut. Type a thickness value
of [0.3].
5. Click Thru Next for the depth of the cut. The completed feature
should appear as shown in Figure 10.

NOTES
Figure 10: First Cut Feature
6. Create a similar cut through the bend on the other side of the part
as shown in Figure 11.
Figure 11: Second Cut Feature
Task 4. Create a Bend Back feature.
1. Click Feature > Create > Sheet Metal > Bend Back .
2. Pick the surface shown in Figure 12 to remain fixed.

remain fixed
Figure 12: Surface to Remain Fixed during Bend Back
3. Click BendBack Sel > Done .
4. Pick the two surfaces shown in Figure 13.

NOTES
Pick these two surfaces for the

Bend Back feature
Figure 13: Select References for Bend Back
5. After picking the two surfaces, click Done Sel > Done Refs .
6. Type [yes] at the prompt for the contour to remain flat.
7. Type [yes] for the second contour. The part should appear as
shown in Figure 14.

NOTES
MODULE SUMMARY
In this module, you have learned:
• Selected curved surfaces created by wall and bend features can be

unbent.
• An unbent surface can be returned to the bent condition using an bend
back feature.
• Sheetmetal cuts can be created Thru All or Thru Next.
• Sheetmetal cuts always remove material normal to the green or white
surface of the model.
• If a contour partially intersects a bend that is being bent back, the
system prompts you as to whether you want this contour to remain flat

Module
Notches and Punches

Notches are used to relieve material that interferes with bending in
places such as the corners of flanges. Punches are templated
cutouts. Punches and notches are manufacturing operations. In
Pro/ENGINEER they are created using cuts and user-defined
features (UDF); in manufacturing, each punch or notch has a
specific tool that defines its shape. Punches and notches can be used
to create cuts and capture manufacturing information such as the
tool name.
Objectives
• Create user-defined features

• Create notch and punch features using user-defined features
Page 5-1
NOTES
INCREASING YOUR EFFICIENCY WITH

SHEETMETAL NOTCHES AND PUNCHES
Figure 1 shows examples of notches and a punch that can be defined with
user-defined features (UDF). A UDF consists of selected features, all their
associated dimensions, any relations between the selected features, and a
list of references for placing the UDF on a part. For more information on
UDFs, see “creating a UDF” in PTC Help.
Notches
Punch
Figure 1: Sheetmetal Notches and Punch
To create a notch or punch UDF, you use the following parameters that are
specific to sheetmetal design and manufacturing:
• A coordinate system to locate tooling for automated punch and notch

operations
• A specific tool ID to specify the proper tool for the manufacturing
operation
• A single sheetmetal cut feature, as shown in Figure 2.
The cut remains
normal to
surfaces in the
bend
Figure 2: Using a Notch UDF
Creating a Punch or Notch UDF

Use the following steps to create a notch or punch UDF:
1. Create a simple sheetmetal part to serve as a reference part.
No tch es, Punche s, and UD Fs Pag e 5- 3

NOTES
2. Create a cut feature. Sketch the desired section for Punch or Notch.
Be sure to include the coordinate system. When you are aligning
and dimensioning, keep in mind the convenience of eventual
placement of the UDF.
Notes:
If a notch is intended to relieve material in bend areas, create a
bend and unbend it. When sketching the cut, align its sides to
the bend edges.
If you can set up relations for the feature (for example, the
overall cut height is always 1.2 of the side height), do so; it
reduces the number of variable dimensions you have to type
every time when placing the punch/notch.
3. Click Feature > UDF Library. The UDF menu appears.
4. Click Create , then type the name of the UDF. The UDF OPTIONS
menu appears.
5. Click Stand Alone > Done . (Punch and notch UDFs can only be
Stand Alone.)
6. The system prompts you to indicate whether you want to include

the reference part. If the part is simple, type [Y]; otherwise, type
[N]. The UDF:<UDFNAME>, STANDALONE dialog box appears.
7. The UDF FEATS menu appears with Add pre-selected. This, in

turn, brings up the SELECT FEAT menu. Pick the cut feature, then
click Done > Done/Return .
8. Type [Y] when the system prompts you to indicate whether you
are defining this UDF for a punch or a notch feature.
Note:
If a coordinate system is not included in the feature, the UDF
creation is aborted at this point.
9. In response to the system prompt, type the tool name.
10. The SYMMETRY menu appears to define the symmetry of the tool
relative to the feature coordinate system. Click one of the options.

NOTES
11. Continue with the process by responding to prompts for the

reference geometry, selecting variable dimensions, and so on.
12. Click OK in the dialog box. The system creates and stores the UDF.
13. Click Done/Return in the UDF menu.
Notes:
All punch/notch UDF feature attributes, including Tool Name
and Symmetry flags, can be redefined after the UDF has been
placed on the base part by clicking Feature > Redefine and
picking the UDF feature.
When you are creating a table-driven punch/notch group, you

can modify any instance Tool Name in the table.
Placing a Punch or Notch Feature

1. Click Notch or Punch from the SHEETMETAL menu.
2. Select the UDF from the OPEN dialog box.
3. Specify whether the reference part should be retrieved or not. The

GROUP ELEMENTS dialog box appears.
4. The SCALE menu appears. Click one of the first two options, then
click Done .
5. The DISP OPTION menu appears. Click one of the first three
options, then Done .
6. The SEL REF menu appears. Place the UDF by selecting placement
references.
Consider Design Intent When Using Notch Relief

When you actually create a sheetmetal part, you add the notch relief
before bending. However, you can capture your design intent more
accurately by creating the part in the formed state. Instead of adding relief
and then creating the wall, you should focus on dimensioning the walls to
preserve your design intent. Using this method, you can increase your
regeneration speed by suppressing the notches since the walls are not
children to those entities.

NOTES
Goal
The goal of this lab is to use UDFs to simplify the creation of multiple
notch features and to incorporate non-constant wall thickness into a
sheetmetal part.
Method
In the first exercise, you create a cut that is used to define a UDF. That
UDF is then used to define notch features in the flat state of another part.
In the second exercise, you show the varying thickness of a part by placing
a UDF.
EXERCISE 1: Creating Notches in the Flat State of

the Model
Task 1. Define the notch by creating a sheetmetal cut.
1. Open SQUARE_NOTCH_REF.PRT.
Surface to
remain fixed
Figure 3: SQUARE_NOTCH_REF.PRT
2. Create a Regular, Unbend All feature. Pick the top surface of the
part to remain fixed, as shown in Figure 3.
3. Create a sheetmetal cut using the top surface of the bend as the
sketching plane and the edge surface of the bend as the bottom
reference, as shown in Figure 4.

NOTES
Sketching plane
Bottom reference
plane
Figure 4: References for Sheetmetal Cut
4. Specify references as shown in Figure 5.
Specify this
vertical tangent
line as a
reference
Specify these
horizontal and
vertical bend
axes as
references
Figure 5: Sketching the Cut
5. Sketch horizontal and vertical centerlines along the bend axes.
6. Sketch a rectangle as shown in Figure 5. No other alignments are

required.

NOTES
7. Sketch a coordinate system at the intersection of the two

centerlines.
8. When finished sketching, exit from Sketcher. Remove the material

from the inside of the section, and create the feature using the Thru
All depth option.
9. Click OK . The part should appear as shown in Figure 6.
Figure 6: Completed Cut
Task 2. Define a UDF from the finished cut.
1. Click UDF Library > Create and type [square_notch].
2. Click Stand Alone > Done .
3. Type [yes] to include the reference part.
4. Pick the square cut that you just created.
5. Click Done Sel > Done > Done/Return .
6. Type [Y] to confirm that you are defining a UDF for a notch.
7. Type [square] as the tool name.
8. Click Both to have the tool symmetric about both axes.
9. Type prompts for the five references, as shown in Figure 7. Before

typing each prompt, make sure that the appropriate entity
highlights on the screen. When you have finished, click
Done/Return > OK .

NOTES
Vertical bend
axis Placement plane
Vertical bend
tangent edge
End surface
Horizontal bend
axis
Figure 7: Defining a UDF from the Cut
10. Save the model and close the window.
Task 3. Place the UDF on the tuner cover model to create notch relief at
the corners.
1. Open TUNER_COVER.PRT. If you did not complete the secondary

walls on the part, retrieve NOTCH_TUNER_COVER.PRT. The part
opens in the unbent state as shown in Figure 8.

NOTES
Figure 8: TUNER_COVER.PRT
2. Click Feature > Create > Notch .
3. Select the SQUARE_NOTCH.GPH file that you just created.

Retrieve reference part, if you wish.
4. Click Same Dims > Done > Normal > Done . This defines the
group to have the same dimensions as the UDF and displays them
so they may be modified.
5. Respond to the prompts by specifying the appropriate references,

as shown in Figure 9, for the lower, right-hand corner of the part.
Click Done to finish. The notch feature should appear as shown in
Figure 10.

NOTES
Vertical bend Vertical bend

tangent edge axis
Horizontal
tangent edge Placement plane
Perpendicular
end surface
Figure 9: Adding the Square Relief
Figure 10: Defining the Notch

NOTES
6. Add the notch relief to the other three corners on the part.
Add the other

three notches
Fixed surface for

bend back
Figure 11: Adding Notch Relief to Other Corners
Task 4. Now that you have added the relief, bend back the model to its
formed state.
1. Bend back the entire part. It should appear as shown in Figure 12.
Figure 12: The Completed Part

NOTES
MODULE SUMMARY
• Notches and punches are created by first defining a UDF.

• A simple sheetmetal part can be used to define the notch or punch
UDF.
• A coordinate system must be included in the UDF if it is to be used as
a notch or punch UDF.

Module
Sheetmetal Forms
In this module, you learn how to complete a forming operation to
plastically deform a sheetmetal model. Plastic deformation changes
the material properties of the metal as it flows under the force of the
forming operation.
Objectives
• Create form features

• Create form parts
• Place form features
• Use solid features to show edge treatments
• Create a flatten form feature
Page 6-1
NOTES
CREATING FORM FEATURES

To create a form feature, you use reference geometry. You can create two
types of sheetmetal forms: die and punch.
• A die form represents the forming geometry (convex or concave)

surrounded by a bounding plane. The surface that surrounds the
forming geometry—the base plane—must be planar, and the base
plane must completely surround the forming geometry. You can
reference multiple die forms from a single model.
• A punch form represents only forming geometry, using the entire
model to form the sheetmetal part.
Die form Punch form
Figure 1: Forms
CREATING FORM PARTS

The form model can be a solid part or another sheetmetal part, but you
should start the creation of both types of form models using default datum
planes. To make it easier to place the form, the datum planes should
intersect at the center of the form feature. If you use a sheetmetal model,
the sheetmetal to be formed should conform to the green side of the
sheetmetal component.
When creating a form model, keep in mind the following:
• Any convex surface must have a radius that is larger than the thickness
of the sheetmetal or equal to zero if the form is mated to the sheetmetal
geometry.
Sh e etmet al Fo rm s Pag e 6- 3
NOTES
Convex radius
greater than
thickness
Figure 2: Convex Surface
• Any concave surface must have a radius that is larger than the
thickness of the sheetmetal or equal to zero if the form is aligned to the
sheetmetal geometry.
Must have radius
greater than
thickness
Figure 3: Concave Surface
• The form can contain a combination of convex and concave geometry,

creating hollows. However, the hollows in the form must not drop
below the base plane or mating surface.
Hollow above
base plane
Figure 4: Hollows

NOTES
• The model can contain a coordinate system that you can reference to
determine where a forming die should strike the part in the
manufacturing process.
Creating Rips in the Geometry

Some forming operations consist of two tasks: plastically deforming the
sheetmetal and actually cutting the sheetmetal. Figure 5 shows an example
of a cooling fin that is cut through the side of the sheetmetal housing. You
can represent the shearing of the material by excluding surfaces from the
form when you place it on the sheetmetal model.
Excluded surface
Figure 5: Shearing Material
Using Multiple Forms on a Single Die Model

In some cases, it may be more convenient to store multiple forms on a
single form die model, as shown in Figure 6. For Pro/ENGINEER to
distinguish one set from another, however, you must specify a seed
surface to gather all surfaces that are surrounded by the base plane to
create the form geometry, as shown in Figure 7. You must select the seed
surface in all die forms, even if there is only one set of form geometry.
NOTES
Figure 6: Using Multiple Forms in a Single Die Model
Seed surface
Base plane
Figure 7: Specifying a Seed Surface
Using Multiple Forms on a Single Punch Model

To reduce the number of models stored for punch forms, you can create
the punch model with two sides, as shown in Figure 8. The system enables
you to select one side or the other, with respect to the mating surface that
you use in the punch model.

NOTES
Figure 8: Using Both Sides of a Punch Model
PLACING FORM FEATURES

When placing a form feature, you should consider the design intent,
particularly in terms of how the form feature references other features in
the model, as well as how it is referenced when you place it. The system
uses assembly type constraints to determine the location of the form
feature on the model. If you move a feature that the form references, the
system updates the form’s location parametrically.
Placing By Reference
You can place a form feature so that it references the original forming
model at all times. If the original form model changes, the geometry on
the sheetmetal part also changes. If the sheetmetal model cannot find the
referenced form model, the system freezes the geometry on the
component.
NOTES
Copying the Geometry

When you do not want to associate the geometry of the form to the
reference model, you can place the form model by copying all of the form
geometry into the sheetmetal model. This copy operation creates a
completely independent version of the form geometry; therefore, when
you make a change to the form, the system does not reflect it in the
component.
RETURNING THE MODEL TO THE FLAT

In some cases, you may have to return a sheetmetal model to its original
flat state after you have placed it. To do this, you can use the Flatten
Form option to flatten the form geometry in the model.
Figure 9: Flattening the Form
Note:
You should use the Flatten Form option as a tool to create
the flatten form feature, not to reduce regeneration time.

NOTES
Goal
The goal of this lab is to reference geometry in another model to create
form geometry in a sheetmetal part.
Method
In the first exercise, you are going to use two different form models to
create geometry in a sheetmetal part. The part will then be unbent and the
Flatten Form option will then be used to flatten the form geometry.
In the second exercise, you get additional practice by placing a die form
that represents louvers on a part for ventilation.
EXERCISE 1: Forms for the Cover
Figure 10: Form Geometry
Task 1. Create the formed feature for the recess on the cover part.
1. Open COVER.PRT.
2. Open FORM1.PRT. This part was created in Part mode and

represents the die that creates the recess. Close this window and
activate the COVER part window.
3. Click Feature > Create > Form . Accept the defaults of Die and
Reference in the OPTIONS menu.
NOTES
4. Select FORM1.PRT for the referencing geometry. The form part

opens in a second window along with a component placement
window.
5. Mate the front of the form and the green underside surface on the
cover part, as shown in Figure 11.
6. Align Offset DTM1 (yellow side) on the form part and the right
side wall of the cover, as shown in Figure 11. Type [-4.33] as
the offset value.
7. Mate Offset DTM2 (yellow side) on the form part and the bottom
end surface of the cover, as shown in Figure 11. Type a value of
[-6.33].
Mate front of form to

underside of cover
Mate Offset DTM2 and

end surface of cover by
-6.33
Align Offset DTM1

and right-hand side
of cover by -4.33
Figure 11: Assembling the Form to the Cover
8. The Message Window prompts, “Form feature can now be

placed”. Click Show Placement to preview the placement of the
form, then click Done to complete the placement.

NOTES
9. Pick the front surface of the form as the boundary plane, as shown
in Figure 12. Pick one of the rounds that touch the bounding plane
as the seed surface.
Boundary
Plane
Seed
Surface
Figure 12: Seed and Boundary Surfaces
10. Click Preview > OK to place the form. The part should appear as
shown in Figure 13.
Figure 13: Completed Form Feature
NOTES
Task 2. Create the rectangular cut.
1. Create the rectangular cut shown in Figure 14. Locate the cut from
the same end and side surfaces used to locate the form feature.
Figure 14: Section for Cut
Task 3. Create the knock-outs on the side of the box as a pattern of form
features.
1. Click Feature > Create > Form > Die > Reference > Done .
2. Select KNOCK_OUT_FORM.PRT as the reference part.
3. Place the form on the cover by using the assembly constraints as

shown in Figure 15 and Figure 16.

NOTES
Mate this surface

to the side surface
of the cover
Mate Offset
DTM3, yellow
side, 2.00 from
the back side
of cover
Mate Offset
DTM1, yellow
side, -1.25 from
the top of cover
Figure 15: Form Assembly References

Back
Side
Top
Surface
Side Surface
Figure 16: Form Placement Preview
NOTES
4. Pick the bounding plane and the seed surface as shown in Figure
17.
5. Select the optional Exclude Surf element in the FORM dialog box
and click Define .
6. Pick the six surfaces shown in Figure 17 to remove from the form
feature.
Boundary
Surface
Exclude
Surfaces Exclude
Surfaces
Seed
Surface
Figure 17: Boundary, Seed, and Exclude Surfaces
7. Click Ok . The part should appear as shown in Figure 18.

NOTES
Figure 18: Completed Form Feature
8. Click Pattern and pick the form feature.
9. Pick the 2.00 dimension as the dimension to increment in the first

direction.
10. Type an increment value of [2.50].
11. Click Done and type [4] as the total number of instances.
12. Click Done when asked for the second direction. The part should
appear as shown in Figure 19.
NOTES
Keep this
surface fixed
during the
unbend
Figure 19: Patterned Form Features
Task 4. Unbend the geometry.
1. Create an unbend feature with the surface shown in Figure 19

remaining fixed. As shown in Figure 20, the form geometry is not
flattened.
Figure 20: Unbent Geometry
2. Click Create > Flatten Form .

NOTES
3. Select the optional Form element in the dialog box and click
Define .
4. Pick the recess created with the FORM1.PRT part.
5. Click Done Sel > Done Refs .
6. Click Ok . The form feature is flattened.
7. Use the same method to flatten the first knock-out (the pattern
leader).
8. Create a reference pattern to flatten the remaining knock-outs. The

part should appear as shown in Figure 21.
Figure 21: Flattened Forms
NOTES
EXERCISE 2: Placing a Die Form
Figure 22: Ventilation Louvers
Task 1. Add the form model as a reference die form, pattern the form,
and mirror the part.
1. Open BOX.PRT. If you did not complete the secondary wall

exercise for the box, open FORM_BOX.PRT.
2. Add the FORM_LOUVER.PRT form model as a Die by Reference.

Locate the form as shown in Figure 23. Exclude the surface to
create a vent opening.

NOTES
Seed surface Boundary plane
Excluded surface
Align offset
DTM1, yellow Align offset the yellow
side from this side of DTM2 from this
surface of the box hidden surface of the
by –1.0 box by –2.5
Mate these
surfaces
Figure 23: Form References
3. Pattern the form to match the dimensioning scheme shown in

Figure 24.
NOTES
Figure 24: Patterning the Form
4. Use Mirror Geom to mirror the part. The part should appear as
shown in Figure 25.
Figure 25: Mirroring the Part

NOTES
MODULE SUMMARY
• You use a reference model to create a form feature.

• A form model can be a solid part or a sheetmetal part.
• You can represent rips or the shearing of the material by excluding
surfaces from the form when you place it on the sheetmetal model.
• The Flatten Form option is used to flatten form geometry in the
sheetmetal model.
Module
Bend Features
In this module, you learn how to develop a sheetmetal model from
the flat definition and then add bends and other geometry to reflect
the true manufacturing process.
Objectives
• Create Angle or Roll type bends on flat geometry

• Add bend line adjustment to obtain the desired location of the bend
feature
Page 7-1
NOTES
BEND FEATURES
A bend feature is used to add a bend to a flat section of the part. A bend
cannot be added where it crosses another bend feature. There are two
types of bend options.
Angle
An Angle type bend creates a bend with a specified radius and angle, as
shown in Figure 1. An angle appears along the axis of the radius to show
bend direction. The angle can be flipped to change the direction of
bending.
Figure 1: Bend Feature Using the Angle Option
Roll
A Roll type bend creates a bend with a specified radius, but the resulting
angle will be determined by the radius and the amount of material to bend,
Fixed Side
Bend Side
Figure 2: Bend Feature Using the Roll Option
For each Angle or Roll bend there are three options to choose from:
Regular , W/Transit , and Planar .
Bend Featu r es Pag e 7- 3

NOTES
Regular
A regular bend creates a bend with no transitional surfaces.
W/Transit (With Transition)

A bend with a transition deforms the surface between the bend and an area
that is to remain flat, as shown in Figure 3.
Bend line
Transition
lines
Surfaces
remain fixed
Figure 3: Bend with Transition
Planar Bends
A planar bend creates a bend feature around an axis that is perpendicular
to the green surface and sketching plane, as shown in Figure 4. The neutral
point for planar bends is placed according to the current y-factor and bend
tables will not be applicable.
Axis normal
to surface
Figure 4: Planar Bend
You can specify automatic bend reliefs to be created for a bend feature. If
w/Relief is selected, then after the bend entity is sketched you will be
prompted for each end in turn if you want it to be used for generating the
bend relief.

NOTES
It is possible to create a bend or unbend feature over a form feature, as

shown in Figure 5.
Figure 5: Bend over a Form Feature
BEND LINES
The bend line is used by the system as a reference point for developed
length calculation when creating bend geometry. The location of the
resulting wall depends on which side of the bend line you create the bend
as shown in Figure 6, Figure 7, and Figure 8.
Bend Side and

Fixed Portion
Figure 6: Bend Side Down

NOTES
Bend Side
Fixed Portion
Figure 7: Bend Side Up
Bend Side
(Both)
Fixed Portion
Figure 8: Both Sides

NOTES
Bend Line Adjustment

It is possible to control the location or placement of a bend feature by
adding bend line adjustment (BLA). The sketch of the bend line is
dimensioned to a reference and this dimension is the BLA. The BLA
dimension is modified to manipulate the placement of the bend. For the
two surfaces in Figure 9 to be coplanar, the developed length of the bend
(L) would have to be equal to the inside radius (R) plus the thickness (T).
Since the system gives both the radius of the bend and developed length of
the bend, a relation can be written to drive the BLA so that any change to
the model will always be reflected in the bend line placement, as shown in
Figure 10. For more information on relations, see “Relations” in PTC
Help.
These surfaces
are not coplanar
BS FS
L = developed length of bend

R = inside bend radius
T = material thickness
Figure 9: BLA of 0

NOTES
BLA = L - (R + T)
These surfaces are
coplanar
BS FS
Figure 10: Relationship for BLA

NOTES
Goal
The goal of this lab is to create a model in Sheetmetal mode entirely with
flat walls and bends.
Method
In this exercise, you create a part by creating flat walls and then bending
the geometry into shape using a combination of Angle and Roll bends.
EXERCISE 1: Creating a Model in the Flat
Figure 11: Final Geometry
Task 1. Create a new sheetmetal part called CLIP with a flat wall as the
base feature.
1. Create a new sheetmetal part called CLIP.
2. Create a flat wall as the first sheetmetal feature. In Sketcher,

change the number of dimension decimal places to [3] (click
Utilities > Sketcher Preferences > Parameters ). Sketch the

NOTES
section as shown in Figure 12, type a thickness of [0.01], and

complete the feature.
Figure 12: Sectioning the First Base Feature
Task 2. Create a roll bend with transition areas where the clip attaches
to the pencil.
1. Click Feature > Create > Sheet Metal > Bend > Roll > w/
Transition > Part Bend Tbl > Done/Return > Inside Rad >
Done/Return .
2. Pick the green side of the part, click Okay for the viewing
direction, and pick the lower edge of the ‘T’ to face the bottom.
3. Sketch the single vertical bend line as shown in Figure 13.

NOTES
Figure 13: Sketching the Bend Line for the Roll
4. When the system prompts you to indicate the side on which to

create the feature, click Both to center the roll bend on the
sketched line, then click Okay to fix the area.
5. The system “grays out” the previous sketch, waiting for you to
sketch the transition areas. The first line that you sketch for a
transition area dictates the side that should remain bent. Sketch two
horizontal lines as shown in Figure 14.

NOTES
Figure 14: Sketching Transitional Areas
6. When the system prompts you to define another transition area,

type [no].
7. Click Enter Value and type [0.16] as the bend radius to

complete the feature. The part should appear as shown in Figure
15. Note that the bend starts its transition at the first sketched line
and is completely flat at the second.
Pick this edge to

remain fixed while
unbending
Figure 15: Roll Bend with Transition

NOTES
Task 3. Create an Unbend All feature, add two additional walls without
a radius, and bend back the geometry.
1. Create a regular unbend feature to unbend all geometry. Pick the

edge indicated in Figure 15 to remain fixed. Note that the bend
axis is now visible.
2. Create a flat wall attached to the lower edge (white or green).

Sketch the wall shown in Figure 16 with a centerline aligned to the
axis of the bend to make the sketch symmetric.
Figure 16: Sectioning the Additional Wall
3. Create another flat wall in the same fashion, as shown in Figure 17.

NOTES
Figure 17: Second Additional Wall Section
4. Create a bend back feature to bend back all of the geometry. Pick
the same edge that you used earlier to remain fixed. The part

NOTES
Figure 18: Clip after Creating the Two Additional Flat Walls
Task 4. Create a series of angular bends on the lower portion of the clip
to fold up the various walls.
1. Click Feature > Create > Sheet Metal > Bend > Angle, Regular
> Part Bend Tbl > Done/Return > Outside Rad > Done/Return .
2. Pick the green side of the wall that you just created as the
sketching plane.
3. Accept the default viewing direction and pick the lowest horizontal
line as the bottom reference.
4. Sketch the horizontal bend line as shown in Figure 19.

NOTES
Side to fix
Sketch this
line
Align to vertices
Side to create
bend feature
Figure 19: Creating a 90-Degree Bend
5. Create the bend feature below the sketched line, and fix the larger
portion of the clip. You do not need to add any relief for this bend
feature.
6. Rotate the model to clearly view the bend angle of 90 degrees, and
click Flip , if necessary.
7. Type [0.012] as the bend radius.

NOTES
Tip:
The most effective way to work with bend angles is to choose
a direction, preview the bend, and then flip, if necessary.
8. Create a vertical bend using the Outside Rad option as before.

Sketch the vertical bend line shown in Figure 20.
Sketch this line
Bend side
Fixed side
Align to
edges, not to
vertices
Figure 20: Creating Second and Third 90-Degree Bends
9. Create the bend on the left-hand side of the line toward the outside
of the model. No relief is required.
10. Type [90] as the bend angle.
11. Type [0.012] as the bend radius.

NOTES
12. Create the second vertical bend on the other side of the clip. The
part should appear as shown in Figure 21.
Top reference
plane
Sketching plane
(green side)
Figure 21: Specifying the Sketching Plane and Top Reference Plane
13. Create a 90° angular bend using the sketching and reference plane
indicated in Figure 21. Sketch the section shown in Figure 22.
Create the bend with no relief and a [0.012] bend radius.

NOTES
Bend side
Fixed side
Figure 22: Creating the Next 90-Degree Bend
14. Create the final bend using the approach that you used to create the
two previous bends (Figure 23).
Bend side
Sketch this
line
Fixed side
Figure 23: Creating the Last Bend

NOTES
Task 5. Create solid rounds on the sharp corners.
1. Click Feature > Create > Solid > Round > Simple > Done . Pick
the six edges indicated in Figure 24. Type [0.012] as the radius.
Pick these edges to

create the round
Figure 24: Specifying the Edges for the Round
2. Save the file and erase it from memory.

NOTES
MODULE SUMMARY
• An angle type bend creates a bend with a specified radius and angle.
• A roll type bend creates a bend with a specified radius, but the
resulting angle will be determined by the radius and the amount of
material to bend.
• A regular bend creates a bend with no translational surfaces.
• A bend with transition deforms the surface between the bend and an
area that is to remain flat.
• Planar bends create a bend feature around an axis that is perpendicular
to the green surface and sketching plane.
• You can specify automatic relief for a bend feature.
• You can control the location or placement of a bend feature by adding
bend line adjustment.

Module
Unbending Sheetmetal Geometry

It is often necessary to unbend deformed surfaces, such as wall
features consisting of complex curved surfaces. In order for the
system to unbend deformed material, the unbend must be reduced to
a simple unbend. The defining rule is that all surfaces to be unbent
must either have an outside edge or be adjacent to a deformed area
that has an outside edge.
Objectives
• Unbend ruled geometry

• Unbend nonruled geometry
• Add tears to geometry
• Create deformation areas
Page 8-1
NOTES
UNBENDING GEOMETRY AFTER DEFINING THE

MODEL
Depending on the complexity of the sheetmetal or the design task, you can
use various techniques to unbend the geometry:
• Create a regular unbend feature to unbend ruled geometry

• Use a cross section driven unbend feature to unbend nonruled
geometry
• Create tears in geometry by ripping
Unbending Ruled Geometry: the Regular Unbend

You can unbend ruled bends in the sheetmetal model using the regular
unbend feature. Although you can unbend both a wall and a bend, the
material must be unbendable or developable. You cannot unbend nonruled
surfaces using a regular unbend feature.
Unbending Nonruled Geometry: the Cross Section

Driven Unbend
To unbend nonruled sheetmetal geometry, you can create the cross section
driven unbend feature, as shown in Figure 1. The cross section term refers
to the curve that you use to influence the shape of the unbent wall. To
create a cross section driven unbend, you must do the following:
1. Select the cross section curve from existing geometry or sketch it

(it must be in the same plane as the fixed geometry).
2. Specify the geometry that should remain fixed in the model during
the unbend. The side that you fix must be planar.
3. Define the edges that should remain fixed since you cannot always
use the same edges to drive the shape of the cross section.
Unbend ing Sh eetmet al Geom et ry Pag e 8- 3

NOTES
Selected curve Sketched section
Figure 1: Cross Section Driven Unbend Feature
Note:
The system does not determine a developed length for a cross
sectional unbend.
Adding Tears to the Geometry: Ripping

Using the following methods, you can unbend sheetmetal geometry by
tearing it:
• Regular Rip - Cut the geometry by creating a sketched section to use

as the rip line, as shown in Figure 2.
• Edge Rip - Select existing edges to define references for a zero
volume cut, as shown in Figure 3.
• Surface Rip - Select a surface patch on the geometry and exclude the
entire surface from the model by creating a cut in the geometry, as
shown in Figure 4.

NOTES
Sketch
Rip created
Figure 2: Regular Rip
Figure 3: Edge Rip

NOTES
Corner
removed using
a surface rip
Edge rip added

along this edge
Figure 4: Surface Rip
DEFORMATION AREAS
When creating a regular unbend feature, Pro/ENGINEER highlights
geometry that it is going to deform as a result of the operation. If the
deformed surface does not extend to the edges of the model, you must
specify a surface to deform so that it does extend to its boundaries, as
shown in Figure 5.
Pick this surface
Figure 5: Selecting an Area to Deform

NOTES
If an appropriate surface does not exist on the model, you can break up a
surface into multiple patches by creating a deformation area, then specify
this area as the area to deform during the unbend operation. This gives you
the advantage of creating geometry that closely reflects the developed
part, as shown in Figure 6.
Developed
length
calculated
Deformation
only in these
areas
Figure 6: Deformation Areas
The developed lengths of the unbent geometry reflect the proper values.
Pro/ENGINEER approximates the geometry in the deformation area by
attaching the vertices with a line segment. The geometry does not become
thinner or thicker.
Pro/ENGINEER also enables you to sketch the deformed geometry since

the flat pattern is typically determined empirically. The part shown in
Figure 7 has a deform area defined and the default flat pattern is shown on
the right-hand side.

NOTES
Figure 7: Flat State with Automatic Deform Control
By redefining the Deform Control element in the FEATURE dialog box,

you can sketch the deform area's shape using the current sketcher
constraints. In Figure 8, a tangent arc has been sketched to change the
deformed geometry.
Figure 8: Flat State with Manual Deform Control
In addition to using the deform area feature to create a deformation area

during unbending, you can also use it to define edges for edge rips or to
split surfaces for bend line development.

NOTES
Goal
The goal of this lab is to teach you how to unbend both ruled and nonruled
geometry.
Method
In the first exercise, the geometry contains some walls with curvature in
two directions; you cannot automatically unbend it using the Regular
Unbend option. You deform some surfaces to unbend this part and then
extend the deformation to the outside of the model. In the second exercise
the cross section driven unbend feature is used to unbend the part. In the
third exercise, you create a deformation area feature to isolate all
deformation.
EXERCISE 1: Creating a Regular Unbend Feature

Task 1. Open the TRANS sheetmetal part and create an Unbend All
feature by selecting deformation areas.
1. Open TRANS.PRT.
2. Click Feature > Create > Unbend > Regular > Done .
3. Pick the surface indicated in Figure 9 to remain fixed during the

unbend and click Unbend All > Done .
Surface to remain
fixed (can be the
white or green side)
Figure 9: Specifying Surface to Remain Fixed

NOTES
4. Pro/ENGINEER highlights two of the curved surfaces on the model

and warns you that some deformation surfaces do not reach outside
the part. Select the surfaces to deform as shown in Figure 10.
Pick the white or

green surface
Figure 10: Specifying Additional Surfaces to Deform
6. Click OK in the dialog box. The unbent part should appear as

shown in Figure 11.
Figure 11: Finished Model

NOTES
EXERCISE 2: Cross Sectional Unbend
Figure 12: Cross Sectional Unbend
Task 1. Open XSEC.PRT and unbend the left-hand side of the part.
1. Open XSEC.PRT.
2. Click Feature > Create > Unbend > Xsec Driven > Done .
3. You are prompted to select the fixed edges. Click Surf Chain in
the CHAIN menu and pick the surface shown in Figure 13.
4. Click From-To and pick the highlighted vertices shown in Figure

13. When the system prompts for a chain to use, make sure it is the
three edges shown in Figure 13 by clicking Next or Accept .

NOTES
Surface for
chain
Pick these
two vertices
These edges
make the
desired chain
Figure 13: References for First Unbend
5. Click Done when the chain has been selected.
6. You are asked to specify a curve to control the cross sections.

Click Select Curve > Done .
7. Select the same curves as you did in the previous steps.
8. Once the curves have been selected, click Done .
9. Keep the inside area fixed (right side of curve) and click OK in the
dialog box. The part should appear as shown in Figure 14.

NOTES
Figure 14: First Unbend
Task 2. Unbend the right-hand side of the part with a cross section
unbend.
1. Create another Xsec Driven unbend feature. When prompted to

select fixed edges, click One by One in the CHAIN TYPE menu.
Pick the edge shown in Figure 15 and click Done .

NOTES
Pick this edge for

the second unbend
Pick this
surface as the
sketching
plane
Figure 15: References for Second Unbend
2. Click Sketch Curve and sketch the control curve as shown in

Figure 16. Use the surface shown in Figure 15 as the sketching
plane and DTM3 as the Bottom reference.
Sketch line
referencing
vertices
Fixed Side
Figure 16: Section for Cross Section Unbend

NOTES
3. Select the side shown in Figure 16 to keep fixed, then click OK to

complete the unbend. The finished part should appear as shown in
Figure 17.

NOTES
EXERCISE 3: Creating a Deformation Area
Task 1. Open DEFORM_AREA.PRT and create an Unbend All feature

by selecting deformation areas.
1. Open DEFORM_AREA.PRT.
2. Create a Regular Unbend All feature. Pick the surface indicated in

Figure 19 to remain fixed during the unbend.
Pick this
surface to
remain fixed
Figure 19: Specifying Surface to Remain Fixed
3. Pro/ENGINEER highlights the deformed surfaces inside the model.

Pick the surfaces indicated in Figure 20 to deform when
unbending.

NOTES
Pick these
surfaces to
deform
Figure 20: Specifying Surface to Deform
5. Click OK in the dialog box. The unbent part should appear as

shown in Figure 21. Note the undesirable distortion that occurs
where the system forces the two rounded surfaces that you selected
to “fan out” during the unbending process.
Distorted
surfaces
Figure 21: Distorted Surfaces Resulting from Automatic Selection
6. Delete this undesirable unbend feature.

NOTES
Task 2. Create deformation areas; then use one of the deformation areas
to create an Unbend All feature.
1. Click Feature > Create > Deform Area .
2. Pick the side surface for a sketching plane and DTM1 to face the
right side of the screen.
3. Sketch the deformation area shown in Figure 22. Create entities

from existing geometry as indicated.
Entities
from edges
Sketching
plane
Figure 22: Deformation Area Sketch
4. Complete the deform area feature. A second identical deform area

feature has already been created on the opposite side of the model
for you.
5. Create a Regular Unbend All feature. Specify the same surface to

remain fixed as indicated in Figure 23.
6. Select the deformation areas as the additional surfaces to deform.

After completing the unbend, note that the system isolated the
large deformation in the deformation areas, which it was forced to
stretch considerably, as shown in Figure 24.

NOTES
Fixed
surface
Deform area (same

on other side)
Figure 23: Specifying the Deformation Area
Figure 24: Unbent Geometry with Deformation Areas

NOTES
MODULE SUMMARY
• A regular unbend feature can be used to unbend ruled geometry.

• A cross section driven bend can be used to unbend non-ruled
geometry.
• Rip features can be created to enable sheetmetal geometry to be
unbent.
• When creating a regular unbend feature, Pro/ENGINEER highlights
geometry that it is going to deform as a result of the operation. If the
deformed surface does not extend to the edges of the model, you must
specify a surface or deformation area to deform so that it does extend
to its boundaries

Module
Converting Solid Parts

After you have converted a solid box-type part to a sheetmetal one,
you may need to convert sharp edges to bends and define rips so that
the part can be flattened.
Objectives
• Convert a solid part into a sheetmetal part

• Create a conversion feature to make the converted part developable
Page 9-1
NOTES
CREATING SHEETMETAL PARTS FROM SOLID

PARTS
Solid Pro/ENGINEER parts that are retrieved in Sheetmetal mode can be
converted to sheetmetal parts with two methods.
Driving Srf
The system prompts for a surface to use as the driving (green) surface. If
the part has uniform thickness and can be offset by the material thickness,
the part will be converted.
Figure 1: Using a Driving Surface
Shell
If the part does not have constant thickness, the Shell option can be used
to shell the solid part and convert it at the same time.
Figure 2: Shelling a Model
Co n v e r ti n g So li d P a rt s Pag e 9 - 3
NOTES
Once converted to a sheetmetal part, all of the existing geometry is

referenced to define the base wall feature. Thus this feature and any
feature created in Sheetmetal mode would have to be deleted if you want
to convert the part back to a solid part.
CREATING A DEVELOPABLE PART

Once the part is converted into a sheetmetal part, it may still be
undevelopable. To convert the geometry so that it can be developed, a
single feature can be added to the part. The Conversion feature enables
multiple elements to be defined at once. These elements are as follows:
Point Reliefs
This element creates points along an edge to break the edge into multiple
segments.
Figure 3: Splitting an Edge
Edge Rip
This element rips the geometry along an edge, similar to the Rip feature.
The rip can then be converted from an open type edge to one in which the
wall has overlap.
Rip Connect
This element rips the geometry between two points or vertices in the
model.

NOTES
Edge rips added Rip connect
Figure 4: Using Rip Connect
Bends
This element creates edge bends along non-tangent edges.
Figure 5: Edge Bend
Corner Relief
This element creates round or obround corner relief at eligible corners. As

with the corner relief feature, the vertices selected or affected are
highlighted with symbols that indicate the type of conversion feature or
relief feature defined.
Table 1: Feature Symbols

Symbol Conversion Feature
Ob Obround
Cir Circular
None Square corner is generated
No No relief is applied, the default V-notch is applied
NOTES
Corner relief
created in
combination with
edge rip and
bends
Figure 6: Circular Corner Relief

NOTES
Goal
The goal of this lab is to convert a solid part into a developable sheetmetal
part.
Method
In the first exercise, you retrieve a solid part and use the shell method to
convert it into a sheetmetal part. You also unbend the model by adding a
rip feature. In the second exercise, you use the special sheetmetal
conversion feature to convert a solid part into sheetmetal.
EXERCISE 1: Converting a Sheetmetal Part
Figure 7: Solid Part to Flattened Sheetmetal Part
Task 1. Open the CONVERSION sheetmetal part and convert it to

sheetmetal geometry.
1. Open CONVERSION.PRT.
2. Note that this solid part contains only a protrusion and a round on
three edges. Convert the part to sheetmetal by clicking
Applications > Sheetmetal .
3. Click Shell and specify the removal of the three hidden surfaces
indicated in Figure 8.
NOTES
Pick these three

hidden surfaces
to remove (two
sides and
bottom)
Figure 8: Specifying the Surfaces to Remove
4. Type [0.25] as the shell thickness. Notice that the system makes
the part hollow and converts it to sheetmetal, with the outside of
the model representing the green side of the sheetmetal.
Task 2. Add an edge rip feature to one of the edges and then unbend the
geometry.
1. Click Feature > Create > Rip > Edge Rip .
2. Pick two edges (white or green) as indicated in Figure 9. Complete

the feature.

NOTES
Pick these edges

for the rip
Figure 9: Specifying the Edges to Create the Edge Rip
3. Create a regular, unbend all feature. Specify the top surface to

remain fixed. Note that some deformation of the convex triangular
corner occurs as the system unbends it. Complete the feature.
Note:
If your unbent wall contains a square rather than a small
triangle in the corner, you selected only one edge for the rip
feature. Repeat the previous step.
NOTES
EXERCISE 2: Using the Sheetmetal Conversion

Feature
Figure 10: Solid Part to Flattened Sheetmetal Part
Task 1. Open the CONVERT part and convert it to sheetmetal.
1. Open CONVERT.PRT. This part was created as a solid part. It

consists only of default datum planes and two rectangular
protrusions.
2. Click Applications > Sheetmetal .
3. Click Shell on the SMT CONVERT menu.
4. Pick the three surfaces indicated in Figure 11 to remove with the

shell and type [0.20] as a thickness.
Pick these
three surfaces
to remove: one
on top and two
hidden surfaces
Figure 11: Picking Surfaces to Remove

NOTES
Task 2. Convert the geometry to sheetmetal geometry using the

conversion feature.
1. Click Feature > Create > Conversion . Note that all five elements
in the dialog box are optional.
2. Click Point Reliefs > Define .
3. Click Create to create a datum point to locate the point relief.
4. Pick the edge indicated in Figure 12, click Offset , and pick the
plane to locate the point.
Pick this edge
Pick this
offset plane
Figure 12: Creating the Datum Point
5. Type [1.8] for the offset distance and click Done. Do not click
OK .
6. Double-click Edge Rip from the dialog box, pick the three edges
indicated in Figure 13, and click Done Sets . Do not click OK .
Conv erting So lid P a rt s Pag e 9- 11

NOTES
Pick these three

edges
Figure 13: Specifying Edges on Which to Create the Edge Rip
7. Double-click Rip Connect in the dialog box and click Add .
8. For the first end, pick the end of the existing rip at the datum point.
The system then highlights all of the possible corners and other rip
features to which you could connect the rip. Pick the bottom of the
other rip, as shown in Figure 14.
Pick this point

for second end
Pick this point

for first end
Figure 14: Creating the Rip Connect
9. Click OK > Done Sets .

NOTES
10. Double-click Corner Reliefs in the dialog box and click Add . One
corner of the model has a note attached to it that reads, “No”. This
note indicates that this corner is eligible for corner relief but
currently has none.
11. Pick the note and click Redefine .
12. Click Corner # 1 > Done .
13. A dialog box appears. Double-click Corner Relief .
14. Click Circular > Enter Value and type [0.5] for the diameter.
15. Click OK > Done Sets > Preview .
16. Note that the conversion feature is about to add edge bends
automatically to all remaining sharp corners, using the thickness of
the material as an inside radius. Instead of selecting the Bends
element to manually add or remove edges, allow the system to
select them all automatically. Click OK to complete the conversion
feature. The part should appear as shown in Figure 15. The corner
relief does not appear until the part is unbent.
Figure 15: Final Geometry after Using the Conversion Feature

NOTES
Task 3. With the conversion feature in place, unbend the part.
1. Create a regular, unbend all feature. Specify an appropriate surface

to remain fixed. The finished part should appear as shown in
Figure 16.

NOTES
MODULE SUMMARY
• Solid Pro/ENGINEER parts that are retrieved in Sheetmetal mode can

be converted to sheetmetal part.
• To convert the geometry so that it can be developed, a Conversion
feature can be added to the part.
• The Conversion feature enables multiple elements to be defined at
once, including Point Reliefs, Edge Rips, Rip Connects, Bends, and
Corner Reliefs.

Module
Sheetmetal Drawings with Flat States

and Bend Order Tables
When documenting a sheetmetal part, you may want to show in one
drawing the part as it appears when first cut out of the sheetmetal
(flat pattern) and, in another drawing, as it appears when assembled
(design condition).
Objectives
• Create a production drawing of a sheetmetal component

• Document the bend order of a sheetmetal part
Page 10-1
NOTES
FLAT STATES
In order to simplify and streamline the creation of Flat Pattern
Representations for manufacturing, the FLAT STATE menu (called FLAT
STAT) is provided. It is accessed through the SHEET METAL SETUP
menu. It can be used to create instances directly, without having to edit the
part’s family table.
The family table offers a very efficient method for quickly and easily
developing variations of your sheetmetal design. You can generate
variations of the original model by reusing the existing data. In a family
table, the variations are referred to as instances and the original model is
known as the generic model. Using this method, you can increase your
productivity by accomplishing the following:
• Store multiple similar models within the same file

• Save different steps of the manufacturing of a model
• Save a developed flat instance inside a formed generic model
The instances created with the Flat State option are initially completely
unbent. Features created in Flat State instances behave just like those
created in regular family table members. For more information on family
tables, see “Family Tables” in PTC Help.
You can create the first flat state instance from a generic that is either fully
formed or fully flat.
• If the generic is (fully) formed, the UNBEND FEATURE dialog box

appears and prompts you for the unbends necessary to make it fully
flat. After you click Done , the system creates the instance. The family
table for the generic now contains a new column listing that new
unbend. The unbend is suppressed for the generic and enabled for the
instances.
• If the generic is already flattened (fully flat), the system prompts you
to select the unbends that you created to make it that way. It creates
the first flat state instance and bends back the generic (by suppressing
the unbend). The Family Table for the generic now contains a new
column listing that unbend. The unbend is suppressed for the generic
and enabled for the instances.
Retrieving Instances
Once the family table resulting from the flat state is created, you can
retrieve the flat state instance using one of the following three methods:
Sh e etmet al D ra wing s w ith F lat St ates and B end O rde r T able s Pag e 1 0-3
NOTES
• Highlight the instance name in the FAMILY TABLE dialog box and
click Open .
• Open the generic model to obtain a list of its instances. You can
retrieve either the generic model or a specific instance. When
retrieving an instance, you can select the instance by its name or by a
specific parameter.
• Retrieve the instance directly if an instance index file is present.
CREATING MULTI-MODEL DRAWINGS

Once you have defined a flat state, you can use both instances of the
model in a production drawing. By creating a multi-model drawing, you
can add details, drawing annotations, and dimensions for both states, as
well as independently scale views of the instances. For more information
on multi-model drawings, see “MultiModel Drawings” in PTC Help.
Note:
When you add a model to a drawing, Pro/ENGINEER only
associates that model. Once you have associated both instances
of the sheetmetal model to the drawing, you can change the
active model using the Set Model option in the DWG
MODELS menu.
Tweaking the Flat Pattern

The flat pattern that the system generates when you create an unbend
feature may not represent the exact outline of the model because
deformation areas may exist in the model geometry. From your knowledge
of sheet geometry, you can add material to the flat pattern by using the
Deform Control element discussed earlier.
Pag e 1 0- 4 F u n d a m e n t a l s o f Sh e et m e t a l
NOTES
Figure 1: Using Deform Control to Tweak the Flat Geometry
DOCUMENTING THE BEND ORDER

To document the bend order for manufacturing, you can use a bend order
table, as shown in Figure 2. With the model completely unbent, you can
select the bend or groups of bends in sequence; then save the bend order
table to a file named PARTNAME.BOT. You can show it on a production
drawing by creating a note and reading it in the .bot file. If you change the
table in Sheetmetal mode, the note on the drawing automatically updates;
however, you must add any new bends to the table manually.
NOTES
sequence 3, bend 1 sequence 1, bend 1
sequence 2, bend 1 sequence 1, bend 2
sequence 4, bend 1
sequence 2, bend 2
Figure 2: Creating a Bend Order Table
NOTES
Goal
The goal of this lab is to document the manufacturing process of a
sheetmetal model.
Method
In this exercise, you add a solid protrusion to a sheetmetal part and
document the manufacturing process by creating a production drawing.
EXERCISE 1: Documenting the Model

Task 1. Retrieve the DOC_CONVERSION sheetmetal part and create a
flat state.
1. Open DOC_CONVERSION.PRT. Select the Generic and click Open

in the SELECT INSTANCE dialog box. This part contains an edge
rip feature that enables it to be flattened.
Pick this
surface to
remain
fixed
The edge rip

feature is
located along
this edge
Figure 3: Specifying the Surface to Remain Fixed
NOTES
2. Click Set Up > Sheet Metal > Flat State > Create .
3. Accept the default name for the flat pattern instance and click
Fully Formed .
4. Pick the top surface, as shown in Figure 3, to remain fixed. It

highlights the corner surface in red and indicates that it will be
deformed.
5. Click OK . The system automatically creates a third version of the

model in the family table, which now includes the following:
• a fully formed version (the generic)
• a fully flat version (the flat state named
DOC_CONVERSION_FLAT1) using edge rips
• a special version for the bend order table with the corner
removed by a surface rip
Task 2. Open the flat state instance.
1. Close the active window.
2. Open DOC_CONVERSION.PRT. Select

DOC_CONVERSION_FLAT1 and click Open in the SELECT
INSTANCE dialog box.
Task 3. Redefine the unbend feature to define Deform Control to better

represent the flat state geometry.
1. Redefine the unbend feature.
2. Select the Deform Control element and click Define .
3. Click Auto Area # 1 . The Unbend dialog box appears.
4. Select the Deform Type element and click Define .
5. Click Manual. The system automatically places you in Sketcher so

that the deform area can be sketched.
6. Sketch a single arc, as shown in Figure 4, to define the deformed

area.
NOTES
Have the endpoints

and centerpoint of
the arc snap to these
vertices
Figure 4: Sketching Protrusion to Add to the Instance
7. Exit from Sketcher and click OK > Done > OK . The unbent part
Figure 5: Unbent with Deform Control
8. Close the active window.
Task 4. Create an additional wall on the generic and check the Model
Tree for the suppressed unbend feature.
1. Open the generic part and create a flat, use radius wall. Specify the
part bend table and an inside radius. Pick the edge indicated in
Figure 6, accept the default bend angle of 90 degrees, and click
Okay to accept the default viewing direction.
NOTES
Pick this edge

(green side)
Figure 6: Specifying the Edge for the Wall Feature
2. Sketch the section, as shown in Figure 7. After finishing the

sketch, click No Relief > Enter Value and type [0.25] as the
bend radius to complete the feature.
Figure 7: Sketching Section of the Additional Wall
Pag e 1 0-1 0 Fundam ent al s of Sh e etm e t a l

NOTES
3. Close the GENERIC window and activate the fully flat state (i.e.,
DOC_CONVERSION_FLAT1). Notice the new wall in the flat
instance. Regenerate if necessary.
4. Close the window.
Task 5. Create a bend order table for the DOC_BND_ORD_TBL

instance.
1. Open DOC_CONVERSION.PRT. Select DOC_BND_ORD_TBL and

click Open in the SELECT INSTANCE dialog box. Since the bend
order table cannot unbend any geometry that has to be deformed,
this instance contains a surface rip that removes the convex corner
from the model.
Specify this
surface to remain
fixed
Figure 8: Specifying the Top Surface to Remain Flat
2. Click Set Up > Sheet Metal > Bend Order > Show/Edit and pick
the top flat surface of the part. The part should now appear fully
unbent, as shown in Figure 9.
NOTES
3. Pick the first two bends as indicated in Figure 9. These will be

included in the first bend sequence.
Pick these two

bends
Figure 9: Specifying Bends for Bend Order Table
4. Click Done Sel > Next and specify the top surface that you picked
previously to remain fixed. The system bends back the two
selected bends and displays the model, as shown in Figure 10.
5. Pick the bend indicated in Figure 10 for the second sequence, click
Done Sel > Next , and specify the same top surface to remain
fixed.
Pick this bend
Figure 10: Specifying Bend for Second Sequence

NOTES
6. The model should now have the bend in the second bend sequence
bent back, as shown in Figure 11. Pick the last bend, click Done
Sel > Done , and specify the same surface to remain fixed. The
system should now inform you that the bending sequence is
successful.
Pick this bend
Figure 11: Specifying Bend for Third Sequence
7. Click Info to view the bend order table; then close the
INFORMATION window.
Note:
The “out” and “in” references in the bend order table refer to
the GREEN side of the sheetmetal. Since it is a text file, you
can modify text in the .bot file at any time.
8. To create a drawing with the bend order table that includes the
notes to the appropriate bend, create a regular unbend all feature in
the DOC_BND_ORD_TBL instance. Pick the same top surface to
remain fixed.
9. Close the window.
NOTES
Task 6. Create a two-sheet multi-model drawing to document the flat

state and bend order table that you just created.
1. Before proceeding, close all working windows.
2. Create a new drawing called DOC_CONV. Remove the check mark

from the Use default template option at the bottom of the NEW
dialog box.
3. Click Browse to select DOC_CONVERSION.PRT as the default

model. Accept all other defaults and click OK .
4. Select the Generic and click Open in the SELECT INSTANCE

dialog box.
5. Create a general view of the generic model by clicking Views >

Add View > General > Full View > No Xsec > Scale > Done .
6. Pick a point in the right upper corner of the drawing to place the
view.
7. Type [0.3] as the scale and leave the view in the default
orientation by clicking OK .
8. Add the flat state instance to the drawing by clicking Dwg Models
> Add Model > DOC_CONVERSION.PRT > Open >
DOC_CONVERSION_FLAT1.PRT > Open .
9. Click Add View > General > Full View > No Xsec > Scale >
Done .
10. Pick a point in the lower left-hand corner.
11. Type [0.3] as the scale.
12. Orient the view by specifying the green surface as the Front
reference and the top edge of the model as the Top reference. Click
OK . Move the view if necessary to locate it as shown in Figure 12.
13. Click Done/Return > Show/Erase .
14. Click Show > . Click Show All in the Show By section.
Click Yes to confirm the Show All. Click Accept All in the
Preview tab.
15. Close the dialog box.

NOTES
16. Click Create > Dimension . Create the dimensions shown in

Figure 12.
Figure 12: First Sheet of Drawing
17. Create a second sheet to display the bend order table by clicking
Done/Return > Sheets > Add > Done/Return .
18. Click Views > Dwg Models > Add Model .
19. Click DOC_CONVERSION.PRT > Open> DOC_BND_ORD_TBL

> Open .
20. Click Add View > General> Full View> No Xsec > Scale >
Done .
21. Pick a point in the middle of the screen.
22. Type [0.3] as the scale.
23. Pick the green side as the Front reference and the top edge as the
Top reference and click OK . If necessary, move the view to locate
it as shown in Figure 13.
NOTES
24. Click Done/Return > Show/Erase > Show > > >
Show All > Yes >Accept All > Close to show the bend order table
on the drawing.
25. Close the dialog box. The second sheet should appear as shown in
Figure 13.
Figure 13: Second Sheet of Drawing
26. Save the drawing and erase it from memory.

NOTES
MODULE SUMMARY
• You can create a flat state instance of a sheetmetal part for use in
documenting the design for manufacturing.
• You can create the flat state instance from a generic sheetmetal part
that is either fully formed or fully flat.
• Once you have defined a flat state, you can use both instances of the
model in a production drawing.
• From your knowledge of sheet geometry, you can tweak the flat
pattern by creating a flat wall or solid protrusion in the model.
• To document the bend order for manufacturing, you can use a bend
order table.
Module
Additional Features
When creating a part in Sheetmetal mode, there are a number of
additional features and techniques that can be used to aid in the
design.
Objectives
• Use a flat pattern to get started on drawings and manufacturing

• Use projected datum curves as a guide for creating sheetmetal cuts
Page 11-1
NOTES
FLAT PATTERN
A Flat Pattern is equivalent to an Unbend All feature, but is always
positioned last in the regeneration cycle. You can create a Flat Pattern
feature early in the design to get started on drawings and manufacturing. If
new features are later added to the part, they are automatically reordered
before the Flat Pattern feature.
After the Flat Pattern is created, the part is always displayed in the
flattened state; however, once you start creating a new feature, the Flat
Pattern is temporarily suppressed, and then automatically resumed and
reordered when the new feature is completed. If you do not want the part
to be constantly flipping back and forth, you can suppress the Flat Pattern
feature and resume it only when you want to see or use the flat pattern of
the part.
SOLID FEATURES
Some solid features are available for use in sheetmetal parts. They can be
added in Sheetmetal mode, as well as in Part and Assembly modes. Holes,
rounds, chamfers, cuts, and protrusions are available. All features can be
placed on white surfaces and edges as well as green surfaces and edges.
EDGE TREATMENTS
You can create solid features, such as round and chamfers, to denote
multiple types of sheetmetal geometry (for example, a radius in the corner
of a cut). You can also use them to show edge treatments in order to make
the sheetmetal a nonconstant wall thickness, as shown in Figure 1.
Figure 1: Edge Treatments
Addit ional Fe atu res Pag e 1 1- 3

NOTES
Determining the Developed Length

If you apply an edge treatment to the edge of a sheetmetal model using a
forming operation such as rolling, you must adjust the developed length of
that model. Using the optional Edge Treatment element of the Flatten
Form option, you can adjust the length based on the volume of material
that you remove.
Chamfer
Model
shortened to
keep same
volume
Figure 2: Determining the Developed Length
Using Projected Datum Curves

When you develop geometry in the formed state of the model, you can use
the projected datum curve to communicate information from the formed
state to the flat state. The system projects a datum curve onto the surface
of a sheetmetal part from a defined sketch or a selected curve. You can
place the curve by following a surface when the model is bent or unbent,
or by following a surface during a bend back operation if the curve is
projected in the unbent state.
• Follow Surface – Using the Follow Surf option, you can specify that
the curve follows the surfaces of the sheetmetal model when you bend
or unbend the model (Figure 3). This enables you to create the curve in
the bent state, then unbend the model to use the curve as a reference
for another feature such as a sheetmetal cut.
Figure 3: Placing a Curve Using the Follow Surface option
NOTES
• Regular – Using the Regular option, you can have the curve follow a
surface during a bend back operation if the curve is projected in the
unbent state (Figure 4). This can be helpful if you need to
communicate information, such as a curve length, between the bent
and unbent state of the model. However, the curve does not unbend if
you project it in the bent state.
Figure 4: Placing a Curve Using the Regular Option
For more information on projected datum curves, see “Working with

Datum Curves” in PTC Help.

NOTES
Goal
The goal of this lab is to create a single cut in the flat state that results in
the desired formed geometry.
Method
In this exercise, you use a projected datum curve as a guide as you create a
cut in the flat.
EXERCISE 1: Using a Projected Datum Curve to

Create a Cut
Figure 5: Cut Created Using a Projected Datum Curve
Task 1. Open PROJ_CURVE.PRT and create a projected datum curve.
1. Open PROJ_CURVE.PRT.
2. Click to create a datum curve.
3. Click Projected > Done > Follow Surf > Sketch > Done .
4. Pick the surface indicated in Figure 6 as the sketching plane. Click

Okay for the direction of viewing the sketching plane and Flip >
Okay for the direction of feature creation.
5. Pick the FRONT datum plane to face bottom.

NOTES
Sketching plane
Figure 6: Sketching Plane for Projected Datum Curve
6. Sketch the section shown in Figure 7.
Figure 7: Sketch for Projected Datum Curve
7. When finished in Sketcher, reorient to the default view and pick

the surfaces indicated in Figure 8 on which to project the datum
curve.
NOTES
Pick these five

surfaces
Figure 8: Surfaces on which to Project Datum Curve
8. Click Done Sel > Done .
9. Click Norm to Sket > Done . Click OK . The datum curve should
appear as shown in Figure 9.
Projected datum curve
Figure 9: Projected Datum Curve
Task 2. Unbend the entire part and create a sheetmetal cut using the
projected datum curve as a guide.
1. Create an unbend feature to flatten the entire part. Pick the top
surface of the part to remain fixed. The unbent part should appear

NOTES
This surface should

remain fixed
Figure 10: Unbent Part
2. Create a sheetmetal cut using the surface you picked to remain

fixed as the sketching plane. Pick the FRONT datum plane to face
bottom. Sketch the section shown in Figure 11. Create entities
from the projected datum curve.
Figure 11: Sketch for Sheetmetal Cut
3. Create the cut Thru All . The completed cut is shown in Figure 12.

NOTES
Figure 12: Sheetmetal Cut
4. Create a dependent, mirrored copy of the cut about the RIGHT

datum plane. The part should appear as shown in Figure 13.
Figure 13: Mirrored Cut
5. Create a bend back feature to return to the fully formed part. The
final part should appear as shown in Figure 14.
Figure 14: Fully Formed Part with Cut
Addit ional Fe atu res Pag e 1 1-11

NOTES
MODULE SUMMARY
• A Flat Pattern is equivalent to an Unbend All feature, but is always

positioned last in the regeneration cycle.
• You can create solid features to denote multiple types of sheetmetal
geometry.
• If you apply an edge treatment to the edge of a sheetmetal model using
a forming operation such as rolling, you can adjust the length based on
the volume of material that you remove using the optional Edge
Treatment element of the Flatten Form option.
• When you develop geometry in the formed state of the model, you can
use the projected datum curve to communicate information from the
formed state to the flat state.
Addit ional Fe atu res Pag e 1 1-13

Module
Setting Up for Design

In this module, you learn how to set up your Pro/ENGINEER
session in preparation for sheetmetal modeling to ensure that you
effectively capture your design intent.
Objectives
• Calculate the developed length of a sheetmetal model

• Specify a default radius for bends
• Specify default fixed geometry
Page 12-1
NOTES
CALCULATING DEVELOPED LENGTH

When you unbend a sheetmetal model, the developed length that
Pro/ENGINEER calculates may not be appropriate for your particular
manufacturing process. You can override the bend calculation by simply
modifying the bend. If you change the dimension of the developed length
manually to override the system calculation, you can reset it at any time in
the design cycle.
Many factors determine if Pro/ENGINEER calculates the proper

developed length for a sheetmetal model. You should make it a practice to
determine in advance how the system calculates the developed length and
the adjustments that you can make, if necessary.
Using the Default Formula

Pro/ENGINEER uses a standard bend formula to calculate the developed
length of a sheetmetal model. If you currently use this formula to calculate
the developed length of bends, you should not need to make any further
adjustments:
L = (π/2 x R + yfactor x T) θ/90
where:
L = developed length
R = inside radius
T = material thickness
θ = bend angle
The y-factor
The developed length calculation includes a parameter called the y-factor,
which is a ratio based on the neutral bend line with respect to the thickness
of the material, as illustrated in Figure 1. The y-factor’s default value is
.50, but you can change it in each part by modifying the sheetmetal setup.
You can also specify a new default value by setting the configuration file
option INITIAL_BEND_Y_FACTOR; however, the setting only affects new
parts.
Set t i n g Up f o r D e s i g n Pag e 1 2- 3
NOTES
A. Before the Bend y factor = (π / 2) * K factor

B. After the Bend K factor = δ / T
1. Neutral bend line
Figure 1: The y-factor
Using Bend Tables

Instead of using the default formula to calculate the developed length of a
sheetmetal model, you can use a bend table. Bend tables consist of
tabulated data, as shown in Figure 2, with the radii in columns across the
top and varying thicknesses in rows. The body of the table documents the
various developed lengths.
• If the radius and thickness exactly match the values in the table, the
system uses the exact value.
• If a value falls between two table values, it is interpolated.
• If a value is outside the table, it uses the table’s formula, if it has one.
If it does not have a table formula, it uses the default formula and the
y-factor.
Figure 2: Radius and Thickness Entries
NOTES
Tip:
To be sure that the bend table uses the same material type that
you have specified in the SETUP menu, you can assign
materials within the bend table to check the material properties
of the sheetmetal model.
Predefined Bend Tables

The three bend tables listed below are available with Pro/ENGINEER.
You can use them without changing them, or use them as a starting point
to develop your own company standard table.
• TABLE1 – Used for Soft Brass and Copper, as shown in Figure 3

• TABLE2 – Hard Brass, Copper, Soft Steel, and Aluminum
• TABLE3 – Hard Copper, Bronze, Cold Rolled Steel, and Spring Steel
Figure 3: Standard Bend Table
NOTES
Figure 4 shows an example of a customized bend table.
Figure 4: Customized Table
NOTES
SETTING UP A DEFAULT RADIUS

To reduce the number of selections that you must make and also develop
standards for your sheetmetal models, you can use the parameter
SMT_DEF_BEND_RAD to define a default radius. When you add this
parameter to your model, the system makes the Default option available.
If you choose this option when adding bends or using radius walls, the
system automatically adds a relation to drive the dimension.
Notes:
If you sketch a bend in Sketcher, you cannot make the
dimension equal to the default radius parameter. You must
manually write a relationship to drive the bend with the default
parameter.
If the value of the default radius is changed, all of the radii that
you set using the Default option and any relations that you
wrote using the parameter automatically update.
SETTING DEFAULT FIXED GEOMETRY

When unbending and bending back sheetmetal geometry, it is always good
practice to specify the same surface or edge to remain fixed. You can use
the SETUP menu option Fixed Geom to automatically specify the same
reference when creating unbend and bend back features.
NOTES
Goal
The goal of this exercise is to use set up options to control the default bend
radius, default fixed geometry, and developed length.
Method
In the first exercise, you see how the developed length of a sheetmetal part
is affected by thickness. In the second exercise, you experiment with
various sheetmetal options such as Default Radius , Fixed Geometry , Flat
State , and Bend Table .
EXERCISE 1: Calculating the Length of a

Sheetmetal Part
Task 1. Open the sheetmetal model and create an unbend feature.
1. Open MEASURE.PRT.
2. Create an unbend feature using the surface indicated in Figure 5 as

the fixed surface.
Pick this
surface to
remain fixed
Figure 5: Specifying the Fixed Surface
NOTES
Task 2. Measure the length of the fixed part.
1. Click Analysis > Measure .
2. Click Distance on the Type drop-down list in the MEASURE

dialog box.
3. Specify the “from” and “to” surfaces as shown in Figure 6. The

system calculates the value as 3.91040 and displays it in the
RESULTS box.
Pick the hidden

surface as the
“from”
reference
Pick this
surface as
the “to”
reference
Figure 6: Measuring the Distance Between the Two End Surfaces
Task 3. Save this analysis for future use.
1. Click Saved Analyses to expand the area in the MEASURE dialog

box.
2. Type [distance] in the Name text box and press <ENTER>.
Task 4. Change the thickness of the first wall to update the developed
length.
1. Click Done to access the highest level menu in the menu manager.
2. Click Modify and select FIRST WALL from the Model Tree. Pick
the .25 dimension, as shown in Figure 7, and type [.1].

NOTES
Modify the
thickness
Figure 7: Changing the Thickness
3. Regenerate the part.
4. Check the analysis that you saved earlier by clicking Analysis >
Measure . Click Distance from the Saved Analysis area of the
dialog box. Notice that the distance value is now 3.83540
Task 5. Manually change the developed length so that an internal

equation does not drive it.
1. Click Modify and select FIRST WALL from the Model Tree again.
2. Pick the .84 developed dimension. Click Enter Value and type
[1.00] as the length.
4. Retrieve the saved measure analysis “distance” again. Notice that

the distance is listed as 4.00000.
Sett in g Up f o r D esi g n Pag e 1 2- 1 1

NOTES
EXERCISE 2: Setting Up for Sheetmetal

Task 1. Open the U_SHAPE sheetmetal part and set the default radius
using the SETUP menu.
1. Open U_SHAPE.PRT.
2. Click Set Up > Sheet Metal > Default Rad > Enter Value .
3. Type [0.25].
Attach wall to
this white edge
Figure 8: Specifying the Attachment Edge
Task 2. Create a flat wall that uses the default radius.
1. Create a flat wall with a radius and that uses the part bend table
and an inside radius. Pick the white edge indicated in Figure 8 to
attach the wall. Specify an angle of 90°. Sketch the wall as shown
in Figure 9.
Reference
Sketch to points
Figure 9: Sketching the First Wall

NOTES
2. Finish the sketch and then click W/Relief > Rip relief for both
ends of the wall.
3. Click Default from the SEL RADIUS menu and click OK to

complete the wall. The completed wall should appear as shown in
Figure 10. The inside radius was automatically set to 0.25.
Specify this
edge to extend
Extend to this
outside surface
Figure 10: Creating Extend Wall Feature
Task 3. Extend the flat wall to close the gap.
1. Create an extended wall as shown in Figure 11.

Wall
extended to
outside
Figure 11: Extended Wall Feature Geometry

NOTES
Task 4. Define a default surface to remain fixed and create Unbend All
and Bendback All features.
1. Click Set Up > Sheet Metal > Fixed Geom > Select .
2. Pick the surface indicated in Figure 12.

remain fixed
Figure 12: Specifying a Surface to Remain Fixed
3. Unbend the entire part. Note that you did not have to specify a
fixed surface.
4. Create a bend back feature. Again, note that you did not have to
specify a fixed surface.
5. Since you do not need the two features that you just created, delete
them.
Task 5. Create an additional flat wall and check the relations that the
system created as a result of using the Default radius option.
1. Create a flat wall with a radius and that uses the part bend table
and an inside radius. Pick the white edge indicated in Figure 13 to
attach the wall. Specify an angle of 90°. Sketch the wall as shown
in Figure 14.

NOTES
Attach to this
inside edge
Figure 13: Specifying Attachment Edge for the Wall
Reference
sketch to
outside wall
Reference
endpoints to
attachment edges
Figure 14: Sketching the Additional Wall
2. After you have finished the sketch, click W/Relief > Strtch Relief .
Type [0.25] as the width value of the stretch and [45] as the
angle. Do the same for the other end.

NOTES
3. Click Default for the radius of the bend and OK to complete the
feature. The part appears as shown in Figure 15.
Figure 15: Geometry after Creating the Wall
4. Click Part > Relation > Show Rel . These relations set the bend
radius of the wall features equal to the parameter for the default
radius that you set in a previous step. Close the window.
5. Click Modify and pick the wall you just created. Note that the
developed length of the bend is 0.52.
Task 6. Modify an existing bend table and assign it to the sheetmetal

part.
1. Click Set Up > Sheet Metal > Bend Allow > Bend Table >
Define > From Part . Type [U_SHAPE] as the name.
2. Edit the table as shown in Figure 16.

NOTES
Click Edit > Insert to add a row between START

MATERIALS and END MATERIALS. Type [BRASS].
Edit these
cells by
highlighting
the text and
clicking Edit
> Cut to
delete the
text.
Figure 16: Editing the Bend Table
3. When finished editing, exit the Pro/TABLE editor.
4. Define a material file called Brass by clicking SetUp > Material >
Define . Type [brass] as the name.
5. In the text editor, scroll down to BEND_TABLE. At the end of this

line (next to '='), type [u_shape], which was the bend table that
you created in the previous step. Save the file and exit the editor.
6. Click Set Up > Material > Assign > BRASS > Accept to assign
the material to the part.
7. Click Set Up > Sheet Metal > Bend Allow > Bend Table > Set >
Confirm > From Part > U_SHAPE to assign the bend table to the
part. The system regenerates the model. If you made an error, the
system displays a warning.
8. Click Modify and pick the last wall feature. The developed length
is now 0.53. Show the bend table and confirm this value is correct
for a thickness of 0.25 and radius of 0.25.

NOTES
MODULE SUMMARY
• Pro/ENGINEER uses a standard bend formula to calculate the

developed length of a sheetmetal model.
• Instead of using the default formula to calculate the developed length
of a sheetmetal model, you can use a bend table.
• You can use the SETUP menu option Default Rad to set a default
value for bend radius so that the system automatically adds a relation
to drive the dimension if you choose this option when adding bends or
use-radius walls.
• You can use the SETUP menu option Fixed Geom to automatically
specify the same reference when creating unbend and bend back
features.

Module
Interrogating the Sheetmetal Model

In this module, you learn how to extract information from the
sheetmetal model that you can use to develop your part and satisfy
the design intent. You also become familiar with standard sheetmetal
design rules.
Objectives
• Make measurements on a sheetmetal model

• Use Gaussian Curvature analysis to identify surfaces that cannot be
unbent without deformation.
• Generate sheetmetal bend reports
• Generate sheetmetal radii reports
• Set up design rules
Page 13-1
NOTES
SHEETMETAL INFORMATION
Pro/ENGINEER provides you with unique tools that you can use to
interrogate the sheetmetal part. By using them to extract information, you
can isolate problem areas and correct them.
Measurement
Using the Analysis and Measure options, you can determine the curve
length, angle, surface area, and distance. For example, you can compare
the length of an edge on a bend in its bent state versus its unbent state or
check complex angles between walls. For more information on doing
measurements, see “Measurement Operations” in PTC Help.
Surface Analysis
One of the most common problems encountered when modeling
sheetmetal components is an inability to unbend the geometry. Using tools
such as the Gaussian curvature tool, you can evaluate your ability to
unbend.
Surfaces that curve in two directions must deform drastically to form that
shape in a sheetmetal model. Pro/ENGINEER cannot capture this
deformation through empirical formulation. Using the Gaussian curvature
tool, you can calculate a summation of the maximum and minimum
curvature vectors at any point on a surface, as shown in Figure 1.
Pro/ENGINEER highlights the model with a fringe plot, distinguishing
any surface that curves in two directions from those with zero curvature.
Planar surfaces and ruled surfaces (cylinders and cones) have a Gaussian
curvature value of zero, since there is no curvature in at least one direction
on the surface. For more information on surface analysis, see “Surface
Analysis Operations” in PTC Help.
Inte rrogat ing th e Sh e etmet al M odel Pag e 1 3-3

NOTES
Solid color -
surface is
planar or
curved in one
direction
Fringe plot -
surface is
curved in two
directions
Figure 1: Using the Gaussian Curvature Tool
Sheetmetal Bend Reports

By generating a bend report, as shown in Figure 2, you can interrogate
bends on a model to obtain information on the overall calculation
parameters used in the component. The report can also provide you with
information concerning bends that are not 90 degrees so that you can
interrogate them further. This can be very helpful when you use bend
tables or a bend formula that does not consider the bend angle in its
calculation.
NOTES
Figure 2: Typical Bend Report
Sheetmetal Radii Reports

Using a sheetmetal radii report, as shown in Figure 3, you can investigate
the bend radii that have been created in the model, including the feature
ID, dimension parameter name, and the radius value. You can also use this
tool to quickly determine if the radii values adhere to the company
standard.
Figure 3: Typical Radii Report

NOTES
DESIGN RULES
Design rules vary according to the materials and manufacturing process
that you use to develop your model. To set up design rules for a model,
you can use the Design Rules option in the SHEETMETAL SETUP menu.
Establishing a Design Rule Table

To set up design rules, you must establish a design rule table, as shown in
Figure 4, and assign it to the model. You can develop as many tables as
you would like, based on the different manufacturing practices and
materials that you use. Using the tables, you can establish rules for such
values as minimal slot widths and depths, minimal cut distances from
boundaries, and minimal wall heights.
Figure 4: Default Settings
After you set up the rules for your model, you can check for design
violations in the model. An Information window displays the rule name
and formula, along with the dimensional values, enabling you to determine
why it did not meet the rule criteria, as shown in Figure 5.
NOTES
Figure 5: Violated Rules

NOTES
Goal
The goal of this lab is to learn how to obtain information and verify that
your design rules have not been violated before sending the sheetmetal
part to manufacturing.
Method
In this exercise, you use sheetmetal information tools to obtain certain
information about the sheetmetal part.
EXERCISE 1: Using Sheetmetal Information Tools

Task 1. Open the DOC_CABLEBOX sheetmetal part and review the
geometry.
1. Open DOC_CABLEBOX.PRT.
Figure 6: DOC_CABLEBOX.PRT

NOTES
2. Use the Model Tree and the Feature option in the Info pull-down
menu to review the last three features.
Task 2. Create a bend report.
1. Click Info > Sheetmetal > Bend Report .
2. Clear the File check box to write output only to the screen. Click
OK .
3. Click View > Line Numbers in the Information window. Note that
the part information is displayed on lines 2 through 8, including the
part name, material, thickness, and y-factor.
4. Note that the two bend IDs use a feature bend table (lines 10
through 15). In the Model Tree, identify the two bends with the
IDs shown in the Information window. Pick the two bends and
notice that the system highlights them on the model. You may need
to click View > Model Tree Setup > Highlight Model in the Main
window.
5. Note that the same two bend IDs are listed on lines 17 through 22
as being non-90-degree bends. After reviewing the information,
close the Information window.
Task 3. Create a sheetmetal radii report.
1. Create a radii report that outputs to the screen only. Click View >
Line Numbers in the Information window.
2. Note that the part information is displayed on lines 2 through 8,

including the part name, material, thickness, and y-factor.
3. Four bends were created (on lines 10 through 17) with non-
suggested radii. Use the Model Tree to determine the location of
these bends on the model, then close the window.
Task 4. Create a design rule, assign it to the part, and check the design.
1. Click Set Up > Sheet Metal > Design Rules > Define . Type
[rule_set1] as the name. Pro/TABLE appears.
2. Investigate the seven default design rules. Notice that the left
column contains parameter names for each design rule, and the
right column contains the design rule in the form of a value or

NOTES
equation involving R and T. The design rule value or equation is

always the minimum allowable value.
3. Change the MIN_CUT_TO_BEND to 4*T+R, change

MIN_LASER_DIM to 1.25*T, change MIN_WALL_HEIGHT
0.5*T+R, and change MIN_CUT_TO_BOUND to 5*T. Save and exit
Pro/TABLE.
4. Assign the rule set to the part by clicking Assign > From Part >
RULE_SET1 . Note the message that appears in the message area.
5. Click Info > Sheetmetal > Design Check to check the design
rules. Clear the File check box. Click OK .
6. Display line numbers in the Information window.
7. Review the Information window. Notice that line 3 displays the

design rule set that you assigned to this model.
8. Read line 1. Choose line 9 and observe the model as it highlights

the violating dimension. The current value column corresponds to
the highlighted dimension. Using the DESIGN RULES
VIOLATIONS DIAGNOSTIC window, investigate the model
further, and then click Cancel .
Task 5. Modify the model to avoid the two MIN_CUT_TO_BEND

violations.
1. Click Modify > Query Sel and pick the rectangular form, as shown
in Figure 7.

NOTES
Use Query
Sel to pick
this
rectangle.
Pick the
Form
feature.
Figure 7: Modifying the Dimension
2. The system does not show the actual violated dimension of 0.38
because the form was placed with the offset dimension of 0.75.
Change the dimension to [0.85] and regenerate the model. Use
the same procedure as before to verify that the modification
eliminates the violation.

NOTES
MODULE SUMMARY
• Using tools such as the Gaussian curvature tool, you can evaluate your
ability to unbend.
• By generating a bend report you can interrogate bends on a model to
obtain information on the overall calculation parameters used in the
component.
• Using a sheetmetal radii report you can investigate the bend radii that
have been created in the model.
• Design rules can be used to verify that sheetmetal designs meet with a
set of predefined criteria.

Module
Additional Exercises
This appendix provides you with additional practice of some of the
concepts covered in this training course. The exercises can be
completed during class if time permits, or they can be done on your
own time as they require no pre-existing files.
Page A-1
NOTES
EXERCISE 1: Creating a Blended Primary Wall

In this exercise, you create a blended wall as the sheetmetal primary wall.
Figure 1: Blended Primary Wall
Task 1. Create a new sheetmetal part with a blended wall.
1. Create a new sheetmetal part called BLEND.PRT using the default

template.
2. Click Feature > Create > Sheet Metal > Wall > Blend . Accept
the defaults Parallel > Regular Sec > Sketch Sec > Straight .
3. Pick datum plane FRONT as the sketching plane and Flip the arrow
for the direction of feature creation.
4. Pick datum plane TOP as the Top reference and sketch the first
section as shown in Figure 2.
Addit ional Exe r cis es Pag e A- 3

NOTES
Figure 2: First Blend Section
5. Click Sketch > Feature Tools > Toggle Section (or click Toggle
Section from the pop-up menu) to toggle to sketch the second
section.
6. Sketch the second section within the first as shown in Figure 3.
Figure 3: Second Blend Section
Pag e A- 4 F u n d a m e n t a l s o f Sh e et m e t a l
NOTES
Tip:
If you need to change the start point of one of the blend
sections, pick the desired vertex on the section and click Start
Point from the pop-up menu.
7. After exiting from Sketcher, flip the arrow to the inside. Type
[0.1] as the thickness and [7.0] as the depth for the second
section. The part should appear as shown in Figure 4.

NOTES
EXERCISE 2: Creating a Flat Primary Wall

In this exercise, you create a new sheetmetal part with a flat wall as the
sheetmetal primary wall.
Figure 5: Flat Primary Wall
Task 1. Create a new sheetmetal part with a flat wall.
1. Create a new sheetmetal part called SWEEP.PRT using the default

template.
2. Click Feature > Create > Sheet Metal > Wall > Flat .
3. Pick datum plane FRONT as the sketching plane and datum plane
TOP as the Top reference.
Figure 6: Section Dimensions
NOTES
5. Type [0.1] as the thickness. The completed part should appear as

shown in Figure 7.

NOTES
EXERCISE 3: Creating a Swept Secondary Wall

In this exercise, you create a swept secondary wall along a tangent edge
using the Sweep, No Radius wall options.
Figure 8: Swept Secondary Wall
Task 2. Retrieve the sweep sheetmetal part and create a swept wall.
1. Open SWEEP.PRT.
2. Click Feature > Create > Wall > Swept > No Radius .
3. Click Tangnt Chain and pick the green edges indicated in Figure
9. Note the location of the start point, and click Start Point to
change its location if necessary.
Start point
here
Pick this green

edge for the
tangent chain
Figure 9: Defining the Trajectory Path
4. Accept the default upward direction, and create the cross-section of

the swept hem. Sketch the section as shown in Figure 10. Use a
270-degree 3-point arc, a tangent arc, and a line.
NOTES
Figure 10: Section for the Swept Blend
5. When you have finished sketching, click No Relief > Done > OK .
The part appears as shown in Figure 11.

NOTES
EXERCISE 4: Creating a Twisted Secondary Wall

In this exercise, you create a twist wall along an edge, and then unbend the
geometry to observe the changes that occur in the developed length.
Figure 12: Twisted Secondary Wall
Task 1. Create a flat primary wall.
1. Create a new part called TWIST.PRT using the default template.
2. Create a flat primary wall as shown in Figure 13.
Figure 13: Flat Primary Wall
Pag e A- 1 0 Fundam ent al s of Sh e etm e t a l

NOTES
Task 2. Create a twisted wall along the bottom of the part.
1. Click Feature > Create Wall > Twist > Done.
2. Pick the green or white lower edge of the wall, as indicated in

Figure 14.
Pick this edge to

attach the twist
Figure 14: Attachment Edge
3. Click Use Middle to create a datum point at the midpoint of the

selected edge to locate the twist axis.
4. Type [2.0] as the start width. The default value is the length of
the selected edge.
5. Type [2.5] as the end width.
6. Type [2.5] as the twist length (length after twisting).
7. Type [90] as the twist angle.
8. Type [4.0] as the developed length. This represents the length of

the wall if you unbend it.
9. Click OK . The completed part appears as shown in Figure 15.
Addit ional Exe r cis es Pag e A-11

NOTES

NOTES
EXERCISE 5: Bend Line Adjustment

In this exercise, you control bend line placement with relations.
Task 1. Create a new sheetmetal part called BLA.PRT.
1. Create a sheetmetal part called BLA.PRT using the default

template.
2. Create a flat wall, sketched on datum plane FRONT, as shown in

Figure 16.
Figure 16: Section for Flat Wall
Task 2. Create two angular bend features.
1. Create an regular angular bend using the part bend table and an
inside radius. Sketch the section shown in Figure 17 on the large
front face of the part.

NOTES
BS = bend side
FS = fixed side
Sketched bend line Use RecRelief here
BS FS
Figure 17: Flat Wall Section
2. Specify the bend and fixed sides as shown in Figure 17.
3. Use RecRelief on the right side (inside) and no relief on the other
side. For the rectangular relief, specify a width of [0.5] and Up
To Bend depth.
4. The bend angle should be 90 degrees and the radius is [1.0]. If

the wall bends the wrong direction, Flip the direction. The part

NOTES
Figure 18: First Bend Feature
5. Create the same bend on the other side of the part as shown in
Figure 19.
Figure 19: Second Bend feature
Task 3. Determine if bend line is in the desired location.
1. Click Analysis > Measure . Click Distance from the Type pull-
down menu.
2. Pick the two surfaces shown in Figure 20. The distance reported
should be 0.054. The two surfaces are not coplanar because the
bend line adjustment is incorrect. You used a value of 0.5. The
formula for the BLA is BLA= L - (R+T), where L is the developed
length, R is the inside radius, and T is the thickness.
Measure between
these surfaces
Figure 20: Distance Measurement

NOTES
Task 4. Add a relation to control the BLA.
1. Click Modify and pick the left bend. The dimensions should appear
as shown in Figure 21. The developed length (L) is 1.70.
Figure 21: Bend Dimensions
2. Click Modify and pick the original flat wall feature.
3. With the dimensions shown, click Relations .
4. You now need to identify the symbolic form for the appropriate
dimensions. Find the developed length (d14 in Figure 22), the
inside radius (d13 in Figure 22), the thickness (d8 in Figure 22),
and the BLA (d9 in Figure 22). Your dimension symbols may be
different.
Figure 22: Dimensions Required for Relation

NOTES
5. Click Add . The relation you need is the equation for the BLA. For
this example in Figure 22, the relation is: d9 = d14 - (d13 + d8).
Enter your relation. Be sure to use your dimension symbols. Press
<ENTER> twice.
7. Measure the distance again to ensure that the surfaces are coplanar.
8. Create a relation for the right-side bend.
9. To test the relations, modify both of the bend radii to [2.00].
10. Regenerate the part twice.
11. Measure again to ensure that the surfaces remain coplanar.

NOTES
EXERCISE 6: Creating an Edge Bend and a Rip

In this exercise, you create a part with a constant thickness in Part mode,
convert the part into a sheetmetal part, and unbend it using the edge bend
and rip features.
Figure 23: Part with Edge Bend and Rip
Task 1. Create a new solid part called RIP.PRT.
1. Create a new solid part called RIP.PRT using the default template.
2. Create an extruded thin protrusion with a rectangular section as

shown in Figure 24.
3. Create the feature on both sides of the section.
4. Type [0.1] as the width (thickness) of thin feature, and [4.0] as

the blind depth.
Figure 24: Sketch for Thin, Solid Protrusion

NOTES
Task 2. Convert the solid part into a sheetmetal part.
1. Click Applications > Sheetmetal .
2. Click Driving Surface for the conversion method.
3. Specify the outer surface, as indicated in Figure 25, as the driving

surface (the driving surface is the green side of a sheetmetal part).
4. Accept the default value of [0.1000] for the thickness. The

system automatically converts the part into a sheetmetal part.
Pick this surface as

the green surface
Add Edge Bend to

these edges
Figure 25: Specifying Driving Surface and Adding Edge Bends
Task 3. Create edge bends on the four corner edges.
1. Click Feature > Create > Edge Bend .
2. Pick all four edges shown above in Figure 25 (you can pick inside
or outside). Complete the feature. The system creates the edge
bends using the thickness of the material as the inside radius of the
bend.
3. Modify the radii of each bend to [2.0]. The model should appear

NOTES
Sketch the rip on

this surface
Figure 26: Sketching Plane for the Rip Feature
Task 4. Create a regular rip.
1. Click Feature > Create > Rip > Regular Rip > Done .
2. Pick a surface, as indicated in Figure 26, as the sketching plane.

Use the Default reference plane.
3. Sketch a spline similar to the one shown in Figure 27. Reference

and dimension the ends of the spline and complete the rip feature.
Figure 27: Section Sketch for the Rip Feature

NOTES
Task 5. Create a flat pattern of the model.
1. Click Feature > Create > Flat Pattern .
2. Specify a surface to remain fixed, as indicated in Figure 28.
Pick this surface

to remain fixed
for flat pattern
Figure 28: Specifying Top Flat Surface to Remain Fixed
3. The completed flat pattern should appear as shown in Figure 29.

Module
Sketcher Basics
You have learned that “Pick and Place” features allow for very fast
creation of features such as holes and rounds whose geometry is
easily understood as part of standard engineering operations. For
any geometry that involves the definition of more complex,
individual shapes, you will actually sketch them.
To enable this, Pro/ENGINEER provides a Sketcher mode and
includes a built-in Intent Manager to help you capture design intent.
This module starts with the basics of the Sketcher mode.
Objectives
• Describe the functions and tools in the Sketcher mode.

• Explain how the Sketcher dimensioning scheme allows you to
capture design intent.
• Create geometry including lines, centerlines, arcs, circles,
rectangles, and sketched points.
• Apply geometrical constraints to sketched entities, such as the
“equal lengths” constraint and the “perpendicular” constraint.
• Employ Sketcher Tools to change section sketches.
Page B-1
NOTES
THE SKETCHER ENVIRONMENT

The Sketcher Interface
The Sketcher interface consists of:
• A menu bar with the usual Pro/ENGINEER pull-down menus and two
additional Sketcher-specific menus—EDIT and SKETCH.
• A standard Pro/ENGINEER toolbar.
• An additional Sketcher toolbar with specific Sketcher functionality
such as Undo , Dimensions On/Off , and Grid On/Off .
• A message area below the toolbars.
• An Intent Manager with fly-out icons on the right to perform
frequently used actions.
• An additional Sketcher-specific message area at the bottom left of the
window describing Intent Manager’s fly-out icons.
Figure 1: Sketcher Interface
Pag e B- 2 Nam e o f T r ain in g Gu id e

NOTES
• The color red is used to highlight and select entities. This provides
accurate and easily identifiable entities selections.
• Using the mouse, you can select individual or multiple-specific
sketched entities, or all entities that fall within a swept box.
Intent Manager
• The Intent Manager with fly-out icons appears automatically on the
right side of the screen when you enter the Sketcher mode.
• These icons are logically grouped together, based on capability.
Default cursor to
pick entities
Icons to create
different kinds of
geometry
To create dimensions
To modify dimensions
To impose constraints
To trim Entities
Figure 2: Intent Manager’s Fly-Out Icons
• With fly-out icons, you can access the most frequently used sketching
tools with a single click without having to go to pull-down menus.
Sk etche r B asi cs Pag e B- 3

NOTES
Pop-Up Menus
• Additional pop-up menus can be accessed by holding the right-mouse
button in the Sketcher mode display area.
• These pop-up menus aid ease-of-use.
• They offer short-cut methods for sketching, modifying, dimensioning,
deleting, and undoing steps.
Figure 3: A Typical Sketcher Pop-Up Menu
SKETCHER MODE FUNCTIONALITY

Sketcher Menus
• EDIT and SKETCH are two top-level menus specific to the Sketcher
mode.
• They contain all the commands needed in the sketching environment.
They are shown in Figure 4.

NOTES
Figure 4: Edit and Sketch Menus
• In addition, all Intent Manager commands are available through these

menus.
• You can insert Text into the Sketching area using the Text option in
the SKETCH menu.
• With the new EDIT menu, you can manipulate your sketched geometry
with the Modify, Move , Trim , Toggle Construction , and Toggle
Lock commands.
Specifying References
One of the first things you will be prompted for after beginning a sketch in
the Sketcher mode will be to specify references of the section you are
about to sketch.
You will need to provide references when you:
• Create a new feature.

• Redefine a feature with missing or insufficient references.
• Provide insufficient references to place a section.

NOTES
It is good practice to reference before sketching. This provides the

sketched entities a location to automatically align to and dimension from.
Note:
The references that you select for a section create Parent/Child
relationships.
Creating Geometry
Sketcher mode enables the creation of a variety of geometrical shapes and
entities. The basic ones—lines, arcs, and circles—are discussed below.
Lines
Figure 5: Lines Fly-Out Icons
Using the Line fly-out icons in the Intent Manager, you can create two
types of sketched lines—straight lines from point to point or centerlines
for referencing or constraining entities.
Arcs
Figure 6: Arcs Fly-Out Icons
Using the Arcs fly-out icons in the Intent Manager, you can create four
types of arcs. You can create:
• An arc by 3 points or tangent to an entity at its endpoint.

• A concentric arc.
• An arc by picking its center and endpoints.
• A conic arc.

NOTES
Circles
Figure 7: Circle Fly-Out Icons
Using the Circle fly-out icons in the Intent Manager, you can create three
types of circles. You can create:
• A circle by picking the center and a point on the circle.

• A concentric circle.
• A full ellipse.
Sketched circle
Concentric to this
edge
Figure 8: Sketching a Concentric Circle to an Edge
Dimensioning
After completing a sketch, you must dimension it. To place dimensions in
Sketcher, pick the entity with the left mouse button and place the
dimension with the middle-mouse button.
The following figure illustrates the simple dimensioning of a rectangle.

NOTES
Figure 9: Creating Dimensions for a Rectangle
• You can grab a dimension and place it at a more convenient position in

the Sketcher at any point during or after sketching.
• An orderly arrangement of dimensions helps visual clarity, particularly
when the sketch gets complex.
Figure 10: Grabbing and Moving Dimensions
Modifying Dimensions
• Sketcher makes it easy to modify dimensions of geometric entities at
any time.
• With the MODIFY DIMENSIONS dialog box, shown below, you can
change the dimension values of multiple entities with just a click of the
mouse.

NOTES
Figure 11: Modify Dimensions Dialog Box
• In addition, you can now double-click on an individual dimension to

change its value.
• The SENSITIVITY scrollbar at the bottom right of the dialog box allows
you to adjust the sensitivity of the control wheels for changing
dimensions dynamically.
• You also have the options to dynamically Regenerate and Lock
Scale the sketch.

NOTES
Constraining
• Sketcher assumes certain constraints for the geometrical entities you
create.
• You are free to impose your own constraints overriding the system’s
default constraints to capture your design intent.
• This can be done easily by accessing the CONSTRAINTS dialog box
shown below.
Figure 12: Sketcher Constraints Dialog Box
You can use constraint options to:
1. Make a line or two vertices vertical.
2. Make two entities tangent.
3. Make two points or vertices symmetrical about a centerline.
4. Make a line or two vertices horizontal.
5. Place a point on the middle of the line.
6. Create equal lengths, equal radii or same curvature constraint.
7. Make two entities perpendicular.
8. Creates same points or points on entities.
9. Make two lines parallel.

NOTES
Additional Sketcher Tools

EDGE
The Edge tool has two instances represented by its two fly-out icons in the
Intent Manager, as shown below:
Figure 13: Edge Fly-Out Icons
• Use Edge – Uses an existing model edge to create sketched entities.

Automatically selects that edge as a specified reference.
Figure 14: Using Existing Model Edge to Create Sketched Entities

NOTES
• Offset Edge – Uses existing model edge to create sketched entities at

an offset distance.
Figure 15: Creating Sketched Entities at an Offset Distance
Note:
The Use Edge and Offset Edge options create parent/child
relationships with the referenced feature.
Copy
Copies 2-D draft/imported entities from a drawing. You can dynamically
move and scale a section, making legacy data easier to manipulate. This
functionality can be accessed by clicking Edit > Copy from the pull-down
menus.
Mirror
This tool mirrors sketched entities from one side of a centerline to the
other. This can be accessed by Edit > Mirror.
Move
• Repositions sketched entities. The MOVE ENTITY menu displays the
following options:
• Drag Item – Moves an entity or its vertex to a new location.
Drag Many – Translates picked entities within a sketch.

NOTES
Rotate90 – Rotates sketched entities about a specified point by

multiples of 90 degrees.
Dimension – Repositions a dimension within a sketch.
Trim
This can be accessed by clicking Edit > Trim . Trim shortens (or extends)
an entity in three different ways corresponding to the three fly-out icons
shown below:
Figure 16: Trim Fly-Out Icons
The first dynamically trims section entities

The second cuts or extends entities to other entities or
geometry.
The third divides an entity at the point of selection, replacing
the original with two new entities.
Replace
Replaces a sketched entity from the original section with a newly sketched
entity.
Section Analysis
To obtain information about a particular section within Sketcher, click
Analysis > Section Analysis . This option provides you with information
about
• intersection and tangency points

• angles and distances
• dimensioning references
• entity curvature display
Sketcher Points
They force coincidence among sketched entities.
Allow slanted dimensions between sketched entity end-points.

NOTES
Figure 17: Midpoint Definition Using Sketcher Point
Figure 18: Defining Theoretical Sharps Using Sketcher Points
SETTING SKETCHER PREFERENCES

You can now modify the Sketcher environment in the new SKETCHER
PREFERENCES dialog box in the UTILITIES menu.

NOTES
Figure 19: Sketcher Preferences Dialog Box
Use the SKETCHER PREFERENCES dialog box to:
• Modify the display options of various sketcher entities.

• Set constraints preferences by enabling or disabling constraints
assumed by Sketcher.
• Set grid, grid spacing, and accuracy parameters.
• Click the Default button to reset the preferences.
Sketching in 3-D
When you select the Use2D Sketcher option from the ENVIRONMENT
dialog box. Sketcher starts in 2-D orientation (that is, with the sketching
plane parallel to the computer screen).

NOTES
Figure 20: The Environment Dialog Box
When you do not select this option, Sketcher starts in 3-D orientation. You
may change the view orientation at any time and sketch in 3-D. Using
View > Sketch View , you can re-orient a Sketcher section into the 2-D
view while in Sketcher mode.

NOTES
SKETCHER PHILOSOPHY
Rules of Thumb
Certain rules of thumb must be rigorously adhered to gain maximum
advantage from the power of the Sketcher mode’s diverse capabilities,
1. Keep sketches simple.

This makes the final model flexible and helps regeneration.
2. Use the Undo option

The Undo option restores a sketched section to its prior state.
This is extremely useful when sketching features
incrementally.
3. Do not sketch to scale.

Firstly, concentrate on getting your geometry straight by
sketching large.
Secondly, resolve the sketch by modifying dimensions.
This rule is particularly helpful when the sketched entities are
small.
4. Use the grid as an aid.

Create lines equal, parallel, or perpendicular.
Align sketched entities.
Align centers horizontally and vertically.
5. Do not extend the sketch outside of the part.

There is no need to sketch sections that extend outside the part,
as is required with some solid modeling packages.
6. Make effective use of Sketcher accuracy.

The range for the accuracy is 1.0 e-9 through 1.0 (default).
To prevent Sketcher from making constraints, you can increase
Sketcher accuracy by changing it from 1.0 to a lower number.
7. Use open and closed sections appropriately.

When sketching an open section, you cannot have more than
one open section per feature.

NOTES
If you use an open section, you must explicitly align its open
ends to the part.
When in doubt over whether you should use an open or closed
section, you should use a closed one since it is easier to
regenerate, and is less prone to failure.
Protrusion B
Protrusion A
Cut
Figure 21: Open and Closed Sections

NOTES
Goal
By the end of this lab, you will be conversant with basic sketching skills
such as entering sketcher mode, creating straight lines, creating arcs,
applying constraints, dimensioning, and generating solid models.
Method
In Exercise 1, you learn sketching basics.
In Exercise 2, you create a snap ring by sketching in steps.
In Exercise 3, you create a hex section using construction entities.
EXERCISE 1: Sketching Basics
Figure 22: Completed Sketch after Exercise 1
Task 1. Create a new sketch named ROUND_RECTANGLE.
1. Click File > New .
2. In the NEW dialog box, select Sketch .
3. Type [ROUND_RECTANGLE].
4. Sketcher mode activates.

NOTES
Task 2. Sketch four lines as shown, the bottom line being horizontal.
Figure 23: Sketching a Quadrilateral
Task 3. Apply the constraint to make the lines perpendicular.
1. Click > , then pick two lines to make them perpendicular.
2. Similarly, once again pick the other two lines to make them
perpendicular.

NOTES
Figure 24: Applying the Perpendicular Constraint
3. Close the CONSTRAINTS dialog box.
Task 4. Delete the two vertical lines.
1. With the pointer icon pick the left vertical line.
2. Hold shift and pick the right vertical line.
3. Right-click and select Delete from the pop-up menu.
Task 5. Sketch a tangent end arc on the left side of the section.
1. Click .
2. Pick the top left vertex and drag the mouse out of the left quadrant
of the circle to get a tangent end arc.
3. Pick the end point to be the bottom left end point, as shown below.

NOTES
Figure 25: Sketching a Tangent End Arc
Task 6. Repeat the process on the right side of the section.
Figure 26: Sketching Tangent End Arcs on Both Sides
Task 7. Add the proper dimensions.
1. Click .
2. Pick each arc with the left mouse button, then place the dimension
where you would like it to appear with the middle button.
3. Select Tangent and Horizontal for type and orientation.

NOTES
Figure 27: Dimensioning the Arcs
Task 8. Create a diameter dimension on the left arc.
1. Click .
2. Pick the left arc twice with the left mouse button and place it with
the middle.
Figure 28: Dimensioning the Left Arc

NOTES
Task 9. Modify both dimensions.
1. Pick both the horizontal dimension and the diameter dimension

using the <SHIFT> key and click icon.
Figure 29: Modify Dimensions Dialog Box
2. Modify the diameter to [2] and the linear dim to [4].
3. Save and close the MODIFY DIMENSIONS dialog box.
Figure 30: Sketch with Modified Dimensions

NOTES
EXERCISE 2: Sketching in Steps
Figure 31: Completed Snap Ring after Exercise 2
Task 1. Create a new sketch called SNAP_RING.
1. Click File > New .
2. Select Sketch .
3. Type [SNAP_RING] as the name of the sketch.
Task 2. Create two offset circles aligned horizontally.
1. Click and draw two circles as shown in the next figure.

NOTES
Figure 32: Two Offset Circles Aligned Horizontally
Task 3. Create a rectangle that snaps to the inside circle on both upper
vertices.
Stop cursor here
Delete
Start dynamic
trim here
Figure 33: Sketching a Rectangle Inside Circles
1. For the rectangle, click . Just click once to start and then click
again to end sketching.
2. Then use the dynamic trim to create intersections. Click , Put

your cursor below the bottom horizontal line and drag it to above
the top horizontal line.

NOTES
3. Make sure that each item becomes highlighted. If all the crossed
items are not highlighted continue to hold the mouse button and
drag over the lines until they do highlight.
4. The result is shown in the figure below.
Figure 34: Using Dynamic Trim
Task 4. Sketch another rectangle.
1. This time snapping to the outside circle and the bottom of the two
vertical lines as shown below.
2. Make sure not to snap through any of the arc's vertices.

NOTES
Figure 35: Sketching a Second Rectangle
Task 5. Use the dynamic trim to remove the final lines and arc.
1. Click to trim the unwanted entities.
2. The result is shown below.
Figure 36: Capturing Intent with Dynamic Trim

NOTES
Task 6. Dimension the entities.
1. Click to create the dimensions.
2. Pick each entity with the left mouse button and place the
dimension with the middle mouse button.
3. Click to modify the six dimension values.
Figure 37: Modifying Dimensions
4. Save and close.

NOTES
EXERCISE 3: Sketching a Hexagon

Task 1. Create a new sketch called HEX.
1. Click File > New . Select Sketch and type [HEX] as the name.
Task 2. Create a sketcher point
1. Click the point button.
2. Place a point in the center of the screen.
Task 3. Add vertical centerlines passing through the Sketcher Point.
1. Click on the centerline button in the line fly-out icons.
2. Create a vertical centerline that passes through the point.
3. Create two additional centerlines that pass through the point at an

angle.
Task 4. Modify the angles to 60°.
1. Modify the angle between centerlines to 60° as shown below.
Figure 38: Modifying Angles between Centerlines

NOTES
Task 5. Create a circle centered on the point.
1. Left-click on the circle to highlight it in red.
2. Right-click and hold on the circle for a pop-up menu.
3. Click Toggle Construction to convert it to a construction circle
Figure 39: Creating a Construction Circle
Task 6. Create a hexagon by sketching 6 lines from the intersection

points of the circle and the centerlines.
Figure 40: Creating a Hexagonal Sketch

NOTES
1. Add a diameter dimension to the construction circle and modify it's

value to [1.0]
2. Save and close.

NOTES
MODULE SUMMARY
• The Sketcher interface consists of the main sketcher area, pull-down

menus, toolbars, message areas, the INTENT MANAGER with fly-out
icons, and pop-up menus.
• All geometry has to be sketched, dimensioned, and constrained.
• You can create lines, arcs, circles, rectangles, splines, and many other
geometrical entities using the Intent Manager.
• The EDIT and SKETCH menus contain most of the tools that are
unique to Sketcher mode such as Copy , Mirror , Move , and Trim .
• System dimensions can be over-ridden and dimensions can always be
modified at any stage of model generation.
• It is possible to over-constrain a model. The system notifies you when
there is a clash of constraints though.
• Sketcher preferences can be set using the SKETCHER PREFERENCES
dialog box.

Appendix
Using PTC.Help
PTC is continuing its commitment to provide integral
internet/intranet enhancements through the i-series of software
products, including the innovative changes in this release of PTC
Help.
Objectives
• Start the PTC.Help system.

• Obtain help while performing a task
Page C-1
NOTES
PTC HELP OVERVIEW

PTC Help is integrated with fully functional, highly flexible CAD/CAM
and Data Management software available from PTC. It is easy to locate a
desired topic. PTC Help can be installed on a Web server, allowing Web
clients to access PTC Help without having direct mounts to file server
machines, thus reducing network traffic and enabling a LAN/WAN
configuration.
PTC HELP FEATURES

PTC Help offers:
• A new help system with integrated table of contents, index, and search
capability
• Full certification of Internet Explorer 4.0 and Netscape 4.06
• Web server installation capabilities
• Full context-sensitive help, allowing access to PTC Help with a click
of the mouse
• Expanded context-sensitive help in dialog boxes
Also, please visit the PTC Technical Support Online Knowledge
Database , which features thousands of Suggested Techniques. For more
information, see the Technical Support Appendix.
USING THE PRO/ENGINEER HELP SYSTEM

The Pro/ENGINEER Help System (also called PTC Help) provides you
with help topics that give you the information you need while you work.
Getting Help While Performing a Task

You can get Help on your current task when you are working in a dialog
box or with a menu by using one of these three procedures.
Pag e C- 2 F u n d a m e n t a l s o f Sh e et m e t a l
NOTES
To Get Help on Tasks in a Dialog Box
1. Click on the right end of the main Pro/ENGINEER toolbar.
2. Click anywhere inside the dialog box. A navigational topic opens

in a Help window. The navigational topic contains a list of links to
Help topics about tasks that you perform in the dialog box.
3. Click the topic you want to read.
4. Click Back on the browser toolbar to return to the navigational

topic and choose another topic.
To Get Help on Commands on the Pro/ENGINEER Menu Bar
1. Click on the right end of the main Pro/ENGINEER toolbar.
2. Click a menu command. A navigational topic opens in a Help

window. The navigational topic contains a list of links to Help
topics about that command.
3. Click the topic you want to read.

To Get Help on Commands on Vertical Menus
1. Click a menu command with the right mouse button and hold the
button down until the GetHelp window appears.
2. Point to GetHelp and then release the mouse button. A

navigational topic opens in a Help window. The navigational topic
contains a list of links to Help topics about the command.
GETTING HELP THROUGH THE PTC HELP SIDEBAR

With the PTC Help Sidebar, you can browse the Contents or Index of the
PTC Help System and get help anytime you are using Pro/ENGINEER.
1. On the Pro/ENGINEER menu bar, click Help > Pro/E Help

System to display the Help home page as shown below
Append ix B Pag e C- 3
NOTES
Figure 1: Starting PTC Help
2. Click Contents to browse Help topics by functional area, Index to

view Help keywords for a specific domain, or Search to find topics
in both the Contents and the Index that match a word or phrase
PTC HELP MODULE LIST

There are four main branches in the PTC Help table of contents:
Welcome, Pro/ENGINEER Foundation, Using Foundation Modules, and
Using Additional Modules.
Consult the following list to find a particular module in the table of

contents.
• Associative Topology Bus-CADDS 5 Using Foundation Modules

• Associative Topology Bus-ICEM Using Foundation Modules
• Basic Assembly Using Foundation Modules
• Behavioral Modeler Using Additional Modules, Behavioral Modeling
Extension
• Configuration File Options Pro/ENGINEER Foundation
• Core Pro/ENGINEER Foundation
• Design Animation Using Additional Modules, Behavioral Modeling
Extension
• Expert Machinist Using Additional Modules, Machining
• Import Data Doctor Using Foundation Modules
• Mechanism Design Using Additional Modules, Behavioral Modeling
Extension
• Part Modeling Pro/ENGINEER Foundation
Pag e C- 4 F u n d a m e n t a l s o f Sh e et m e t a l
NOTES
• Pro/ASSEMBLY Using Additional Modules, Advanced

Pro/ASSEMBLY Extension
• Pro/CABLING Using Additional Modules, Routed Options
• Pro/CASTING Using Additional Modules, Tooling
• Pro/CMM Using Additional Modules, Computer Aided Verification
• Pro/COMPOSITE Using Additional Modules, Advanced Surface
Extension
• Pro/DETAIL Using Foundation Modules
• Pro/DIAGRAM Using Additional Modules, Routed Options
• Pro/DIEFACE Using Additional Modules, Tooling
• Pro/ECAD Using Foundation Modules
• Pro/HARNESS-MFG Using Additional Modules, Routed Options
• Pro/INTERFACE Using Foundation Modules
• Pro/LEGACY Using Foundation Modules
• Pro/MOLDESIGN Using Additional Modules, Tooling
• Pro/NC Using Additional Modules, Machining
• Pro/NC-SHEETMETAL Using Additional Modules, Machining
• Pro/PHOTORENDER Using Foundation Modules
• Pro/PIPING Using Additional Modules, Routed Options
• Pro/PROCESS for ASSEMBLIES Using Additional Modules,
Advanced Pro/ASSEMBLY Extension
• Pro/PROCESS for MFG Using Additional Modules, Machining
• Pro/PROGRAM Using Foundation Modules
• Pro/REPORT Using Foundation Modules
• Pro/REVIEW Using Foundation Modules
• Pro/SCAN-TOOLS Using Additional Modules, Advanced Surface
Extension
• Pro/SHEETMETAL Design Using Foundation Modules
• Pro/SURFACE Using Additional Modules, Advanced Surface
Extension
• Pro/VERIFY Using Additional Modules, Computer Aided Verification
• Pro/WELDING Using Foundation Modules
• Sketcher Pro/ENGINEER Foundation
Append ix B Pag e C- 5
Appendix
PTC Global Services: Technical Support

PTC Global Services is committed to making the best possible
resources available for customers. In addition to our telephone-
based Technical Support, we also have Internet-based offerings that
are designed to fit a customer's individual needs, leveraging the
Internet to provide availability on a 24 x 7 basis.
PTC Global Services is committed to continually improving service
to our customers. Through continuous improvement and our Quality
Monitoring program, we have demonstrated our commitment to
service by achieving Global ISO 9000 Certification for our Technical
Support offerings. We strongly believe that our commitment to
support is unmatched in the industry..
Objectives
• Technical Support Call

• Register for on-line Technical Support
• Navigate the Knowledge Base
• Locate contact numbers for support and services
Page D-1
NOTES
FINDING THE TECHNICAL SUPPORT PAGE

Choose Support from the PTC Home Page http://www.ptc.com or go
directly to http://www.ptc.com/support/support.htm.
OPENING A TECHNICAL SUPPORT CALL

Opening a call via email:
PTC Customers
Send email to cs_ptc@ptc.com with copen as the subject of the email.
Please use the following format: (or download the template from
http://www.ptc.com/cs/doc/copen.htm)
FNAME: FirstName
LNAME: LastName
CALLCENTER: U.S., Germany, France, U.K., Singapore, or
Tokyo
PHONE: NNN NNN-NNNN x-NNNN
CONFIG_ID: NNNNNN
PRODUCT: X
MODULE: XX
PRIORITY: X
DESC_BEGIN:
description starts
description continues
description ends
DESC_END
Rand Customers
To open calls by email with RAND, send your questions to

tech.support@rand.com.
Pag e D- 2 F u n d a m e n t a l s o f Sh e et m e t a l
NOTES
Opening a Call via Telephone:

PTC Customers
Call us directly by phone (refer to Contact Information page for your

Local Technical Support Center).
The Technical Support Engineer will ask you for the following
information to log a call:
• PTC Software Configuration ID

• Your name, telephone number
• PTC Product (module) name
• Priority of the issue
Opening calls on the PTC Web Site:

You can use the PTC Web site www.ptc.com/support to open Technical
Support calls 24 hours a day, 7 days a week, by using the Pro/CALL
LOGGER
This application provides easy to follow instructions and returns a call

number immediately upon submission of all information. To open calls
through the Web with RAND, visit the Rand Customer Service Web site
at www.rand.com/cust_serv.
Sending Data To Technical Support

If you want to sent data to the Technical Support please follow the
instructions on the external PTC Web site
‘http://www.ptc.com/support/cs_guide/additional.htm’.
When the call is resolved your data will be deleted by the Technical
Support Engineer and will not divulged to any third party vendors under
any circumstances.
For secure data you can request from the Technical Support Engineer a
Non-Disclosure agreement template.
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e D- 3
NOTES
CALL / SPR FLOW CHART AND PRIORITIES

Call
Customer question
Telephone Call Web Call
Tech SupportEngineer Call is automatically created

creates a call in the database in the database
Investigation Call Back and Investigation
Support Engineer
solves issue or
reports it
to Development (SPR)
SPR
Software Performance Report
SPR fixed from Development
Software Performance Report (SPR)
SPR Verification through Tech. Support Engineer
Update CD to customer
Figure 1: Call / SPR Flow Chart
Call Priorities:
• Extremely Critical - Work stopped
• Critical - Work severely impacted
• Urgent - Work impacted
• Not Critical
• General Information
NOTES
Software Performance Report Priorities

• Top Priority - Highly critical software issue that is causing a work
stoppage.
• High - Critical software issue that affects immediate work and a
practical alternative technique is not available.
• Medium - Software issue that does not affect immediate work or a
practical alternative technique is available.
REGISTERING FOR ON-LINE SUPPORT

Go to www.ptc.com/support and click Sign-up Online , to open the
registration form and enter your Configuration ID.
To find the Configuration ID, in Pro/ENGINEER, click Help > About

Pro/ENGINEER , for example.
Complete the information needed to identify yourself as a user with your

personal details.
Figure 2: On Line Support Registration
Please write down your username and password for future reference.
NOTES
ONLINE SERVICES
After you have registered you will have full access to all Online Tools.
Figure 3: On line service options
You can search our Knowledge Base using a Search-Engine. Our Online
Support Applications allow to control the status of Calls (Call Tracker)
and SPRs (SPR Tracker) and to add comments to these. If you add an
comment the Technical Support Engineer assigned to your call will be
notified automatically.
Additionally contact information such as the customer feedback line and

electronic order of software and manuals are available.
The Software Update Tool allows you to request to newest software

updates for any PTC product.
FINDING SOLUTIONS IN THE KNOWLEDGE BASE

The Technical Support Knowledge Base contains over 18.000 documents,
which are updated from our engineers. Technical Application Notes TAN,
Technical Point of Interest TPI, Frequently Asked Questions FAQs and
Suggested Techniques offer up-to-date information about all relevant
software areas. Limit the search by entering the PTC product/module and
the search string. All FAQs and Suggested Techniques are translated in
French and German.
NOTES
Figure 4: Searching The Knowledge Database
Definitions:
TAN - Technical Application Note - A technical document that provides
information about SPRs that may affect more than just the customer
originally reporting an issue. TANs also may provide alternative
Techniques to allow a user to continue working.
TPI - Technical Point of Interest - A document that provides additional

technical information about a software product. TPIs are created by
Technical Support to document the resolution of common issues reported
in actual customer calls. TPIs are similar to TANs, but donot reference an
SPR.
Suggested Techniques: Provides step-by-step instructions including

screen snapshots, on how to use PTC software to complete common tasks.
FAQ - Frequently Asked Questions – Provides answers to many of the

most commonly asked questions compiled from the PTC Technical
Support database.
NOTES
GETTING UP-TO-DATE INFORMATION

To subscribe to our email service, the Knowledge Base Monitor, go to
www.ptc.com/support.
1. Click Technical Support > Online Support Applications >

Knowledge Base Monitor .
2. Select the PTC product/module for which you want to get

information.
3. You will receive a daily email with update information, this can
help you by upgrading to a new PTC Product or to a new Release.
Figure 5: Knowledge Base Monitor sign-up
CONTACT INFORMATION
Internet
Rand Customers
Rand Worldwide customers can visit the following Web site for phone
numbers:
http://rock.rand.com/webtracker/CustomerServicesWorldwide.htm
PTC Customers
PTC Technical Support Worldwide Electronic Services
NOTES
These services are available seven days a week, 24 hours a day.
URL:
• http://www.ptc.com/support/index.htm (Support)
• http://www.ptc.com/company/contacts/edserv.htm (Education)
E-mail
• cs_ptc@ptc.com (for opening calls and sending data)

• cs-webmaster@ptc.com (for comments/suggestions on CS Web
site)
FTP:
• ftp.ptc.com
Technical Support Customer Feedback Line
The Customer Feedback Line is intended for general Customer Service
concerns that are not technical product issues.
E-mail
• cs-feedback@ptc.com
Phone: Numbers are listed at:
• http://www.ptc.com/cs/doc/feedback_nums.htm
Telephone
For assistance with technical issues contact should be directed through the
Electronic Services noted in the previous section, or through the Technical
Support line as listed in the Phone and Fax Information sections below.
PTC has nine integrated Technical Support Call Centers, in North

America, Europe, and Asia. Our worldwide coverage ensures telephone
access to Technical Support for customers in all time zones and in local
languages.
North America Phone Information

Customer Services (including Technical Support, License Management,
and Documentation Requests)
NOTES
Within the U.S.:
• 800-477-6435
Outside the U.S.:
• 781-894-5332
• 781-894-5513
Maintenance
• 888-782-3774
Education
• 888-782-3773
EUROPE Phone Information

Technical Support Phone Numbers
Austria 0800 29 7542

Belgium 0800-15-241 (French support)
0800-72567 (Dutch support)
Denmark 8001-5593
Finland 0800-117092
France 0800-14-19-52
Germany 0180-2245132
49-89-32106-111 (for Pro/MECHANICA® outside of
Germany)
Ireland 1-800-409-1622
Israel 1-800-945-42-95 (All languages including Hebrew)
177-150-21-34 (English only)
Italy 800-79-05-33
Luxembourg 0800-23-50
Netherlands 0800022-4519
Norway 8001-1872
Portugal 05-05-33-73-69
South Africa 0800-991068
Pag e D- 1 0 Fundam ent al s of Sh e etm e t a l

NOTES
Spain 900-95-33-39
Sweden 020-791484
Switzerland 0800-55-38-33 (French support)
0800-83-75-58 (Italian support)
0800-552428 (German support)
United Kingdom 0800-318677
License Management Phone Numbers
Belgium 0800-75376
Denmark 8001-5593
Finland 0800-117-092
France 0800-14-19-52
Germany 49 (0) 89-32106-0
Ireland 1800-409-1622
Italy 39 (0) 39-65651
Netherlands 0800-022-0543
Norway 8001-1872
Portugal 05-05-33-73-69
Russia/Eastern Europe 44 1252 817 078
Spain 900-95-33-39
Sweden 020-791484
Switzerland 41 (0) 1-8-24-34-44
United Kingdom 0800-31-8677
Education Services Phone Numbers
Benelux 31-73-644-2705
France 33-1-69-33-65-50
Germany 49 (0) 89-32106-325
Italy 39-039-65-65-652 39-039-6565-1
Spain/Portugal 34-91-452-01-00
Sweden 46-8-590-956-00 (Malmo)
46-8-590-956-46 (Upplands Vasby)
Switzerland 41 (0) 1-820-00-80
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e D- 1 1
NOTES
United Kingdom 44-0800-212-565 (toll free within UK)

44-1252-817-140
Asia and Pacific Rim Phone Information

Technical Support Phone Numbers
Australia 1800-553-565
China* 10800-650-8185 (international toll free)
108-657 (manual toll free)
Hong Kong 800-933309
India* 000-6517
Indonesia 001-803-65-7250
97-2-48-55-00-35
Japan 0120-20-9023
Malaysia 1-800-80-1026
New Zealand 0800-44-4376
Philippines 1800-1-651-0176
Singapore 65-830-9899
South Korea 00798-65-1-7078 (international toll free)
080-3469-001 (domestic toll free)
Taiwan 0080-65-1256 (international toll free)
080-013069 (domestic toll free)
Thailand 001-800-65-6213
*Note: Callers dialing from India or China must provide the operator with
the respective string:
China MTF8309729
India MTF8309752
The operator will then connect you to the Singapore Technical Support
Center.
License Management Phone Numbers
Japan 81 (0) 3-3346-8280

Hong Kong (852) 2802-8982
Pag e D- 1 2 Fundam ent al s of Sh e etm e t a l

NOTES
Education Services Phone Numbers
Australia 61 2 9955 2833 (Sydney)

61 3 9561 4111 (Melbourne)
China 86-20-87554426 (GuangZhou)
86-21-62785080 (Shanghai)
86-10-65908699 (Beijing)
Hong Kong 852-28028982
India 91-80-2267272 Ext.#306 (Bangalore)
91-11-6474701 (New Delhi)
91-226513152 (Mumbai)
Japan 81-3-3346-8268
Malaysia 03-754 8198
Singapore 65-8309866
South Korea 82-2-3469-1080
Taiwan 886-2-758-8600 (Taipei)
886-4-3103311 (Taichung)
886-7-3323211 (Kaohsiung)
ELECTRONIC SERVICES
Up-to-Date + Worldwide = Maximum

Information ISO 9000 Productivity
Certification with
Quality Control
PTC
System
Products
Cu s t o m e r Su p p o rt I n f o rm a t i o n Pag e D- 1 3

Sheetmetal Funda

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- For University Use Only -

Commercial Use Prohibited

PTC Global Services

COPYRIGHT © 1989-2000 PARAMETRIC TECHNOLOGY CORPORATION. ALL RIGHTS

US GOVERNMENT RESTRICTED RIGHTS LEGEND

Order Number DT-869-310-EN

PTC Telephone and Fax Numbers

Education Services Registration in North America

Technical Support (Monday - Friday)

PTC RAND Worldwide

INTRODUCTION TO SHEETMETAL DESIGN 1-1

PRIMARY WALLS 2-1

SECONDARY AND UNATTACHED WALLS 3-1

NOTCHES AND PUNCHES 5-1

SHEETMETAL FORMS 6-1

BEND FEATURES 7-1

UNBENDING SHEETMETAL GEOMETRY 8-1

CONVERTING SOLID PARTS 9-1

SHEETMETAL DRAWINGS WITH FLAT STATES AND BEND ORDER

ADDITIONAL FEATURES 11-1

SETTING UP FOR DESIGN 12-1

INTERROGATING THE SHEETMETAL MODEL 13-1

ADDITIONAL EXERCISES A-1

SKETCHER BASICS B-1

USING PTC.HELP C-1

PTC GLOBAL SERVICES: TECHNICAL SUPPORT D-1

- For University Use Only -

Introduction to Sheetmetal Design

• List benefits of designing sheetmetal components using

THE SHEETMETAL DESIGN ENVIRONMENT

• Design a sheetmetal part that defines the supporting structures in an

Pro/ENGINEER offers specialized feature types for the sheetmetal design

Introducti on to Sh eetm etal D esig n Pag e 1- 3

Sheetmetal Part Display

Orienting the Sheetmetal Part

Figure 1: Orienting a Sheetmetal Part

Pag e 1- 4 Fundament als of Sh e etme t al

Figure 2: The Developed Length

The following is a typical design approach for creating sheetmetal parts at

1. Create the assembly by assembling all major components relative

Introducti on to Sh eetm etal D esig n Pag e 1- 5

Figure 3: Assembly of Sheetmetal Components

2. Create or modify sheetmetal parts in Assembly mode using the

Pag e 1- 6 Fundament als of Sh e etme t al

Cover created in Additional

Figure 4: Modify Sheetmetal Parts in Assembly Mode

3. After the cabinet and supporting structures are defined relative to

4. Create or select a bend table to provide material allowances when

5. In Sheetmetal mode, create a bend order table to define the

Introducti on to Sh eetm etal D esig n Pag e 1- 7

designed” instance. These instances are automatically created

8. Document the parts by creating drawings. You can include both

Figure 5: Drawing of Sheetmetal Part

Pag e 1- 8 Fundament als of Sh e etme t al

• The benefits of using Sheetmetal mode to design sheetmetal parts

Introducti on to Sh eetm etal D esig n Pag e 1- 9

• Create the primary wall in a sheetmetal model

CREATING THE FIRST WALL

The following options are available for creating walls:

• Extrude – Sketches the side section of the wall and extrudes it to a

Figure 1: Extruding to a Specified Depth

P rim a ry Wa lls Pag e 2- 3

Figure 2: Revolving about a Centerline