Creo has an application dedicated to sheet metal components, with the ability to flip between the folded component and the flat pattern as cut out prior to bending. Most modern cutting machines, whether using punches, laser beams or water ets, can accept D!" files, as produced by many CAD pac#ages. The following notes are a guide to the use of Creo in the %D&.
Creo has an application dedicated to sheet metal components, with the ability to flip between the folded component and the flat pattern as cut out prior to bending. Most modern cutting machines, whether using punches, laser beams or water ets, can accept D!" files, as produced by many CAD pac#ages. The following notes are a guide to the use of Creo in the %D&.
Creo has an application dedicated to sheet metal components, with the ability to flip between the folded component and the flat pattern as cut out prior to bending. Most modern cutting machines, whether using punches, laser beams or water ets, can accept D!" files, as produced by many CAD pac#ages. The following notes are a guide to the use of Creo in the %D&.
Creo has an application dedicated to sheet metal components, with the ability to flip between the folded component and the flat pattern as cut out prior to bending. Most modern cutting machines, whether using punches, laser beams or water ets, can accept D!" files, as produced by many CAD pac#ages. The following notes are a guide to the use of Creo in the %D&.
Sheet Metal Design 1 Philosophy As was demonstrated in the final CAD sessions of part 1A, Creo has an application dedicated to sheet metal components, with the ability to flip between the folded component and the flat pattern (usually referred to as the development) as cut out prior to bending. Most modern cutting machines, whether using punches, laser beams or water ets, can accept D!" files, as produced by many CAD pac#ages, as the main instruction input, thus ma#ing savings of time and effort while decreasing opportunities for error. $he following notes are a guide to the use of Creo in the %D&. 'hilst modelling your design does re(uire some investment of time, it will more than repay this when cutting out and modifying your chassis and other components as well as providing the power to chec# for interferences and to animate mechanisms. As designers, it is important to remember that the primary purpose of producing a drawing or a model is to provide a statement of your re(uirement. 'hilst a good designer will design for a method of manufacture, the role of a drawing as a set of manufacturing instructions is secondary, in that manufacturing processes evolve and s#illed technicians will have their own techni(ues. 'hen modelling a folded sheet metal component, your re(uirement is for the fully folded item and so this is what should be modelled. $he power of Creo can then be employed to derive the flat development for cutting out and subse(uent bending. Example - Production of a simple bracket. )aunch Creo in the normal way, start a new model and immediately change the *+ub, $ype-to Sheetmetal. .ote that the ribbon at the top of the screen has different icons to the solid modeller. /ntil a first wall is present the only icons highlighted as available are labelled Extrude and Planar. &lanar allows the modelling of a flat panel, of any shape, which may be subse(uently bent up. $his would, however, be contrary to the stated principle of *draw the re(uirement- as it would not afford control of the final dimensions of the folded component. Any changes to the material thic#ness or bend allowance would cause variations to overall dimensions. /sing the option of Extrude allows the bent component to be drawn and final, overall dimensions to be fi0ed. +elect this icon and remember that it is the edge view of the component being drawn, complete with bends of suitable radii. $he following diagram shows the creation of a *1- brac#et. .ote that the use of *internal- s#etches is recommended 2 ust press 3M4 and select from the menu that appears. 5r simply select a s#etch plane. +.&.$ebboth August 6716 .ote that the s#etch consists of a single line which is Thickened on the dashboard after leaving the s#etcher. Direction of thic#ening and material thic#ness and bend radii can be selected on the dashboard. .ote that bend radii do not, now, need to be s#etched but can be specified under the *Options menu. $he s#etch can now be accepted by clic#ing on the tic# icon and with a blind e0trusion depth specified the folded brac#et produced as shown below. . 6 2 Starting the Chassis 'hilst comple0 parts can be built up by creating an unattached wall and subse(uently attaching e0tra features to it, it is usually (uic#er and simpler to start off with a solid e0trusion when designing something li#e a chassis with multiple bends. $he recommended procedure is described below, using an e0ample to illustrate the various stages. 2.1 Shelling from solid model Draw your chassis design in the standard Creo modeller as a solid *bric#- 2 see "igure 1. 3emember to ma#e sensible choices of datum plane positions 2 you will be pleased you did later. +elect, under *5&83A$%5.+-, the convert to sheet metal option and from the menu that appears choose shell. %t is now necessary to select which faces of the solid will be removed, bearing in mind that one piece of material from the flat pattern cannot be in two places at once. 5nce surface choices are complete you will be as#ed for the material thic#ness. $he sheet steel used for %D& construction is 7.9mm. "igure 6 shows the resulting shell. "igure 1 "igure 6 . : 2.2 Sheet metal conersion 2.2.!ippin" $he shell in "igure 6 does not yet represent a piece of bent sheet metal, as it is not yet obvious which edges are folded and which are not continuous (*ripped-). +elect the *conversion option (from the 5&83A$%5.+ menu) and note that the *dashboard- becomes ;, "igure : $he left hand icon represents edge rips. +elect this and choose which edges are ripped. 2.2.2 #end $efinition .e0t select the third icon and define the bends. $he actual bend radius achieved on the hand bender in the wor#shop, with this material, is 1.9mm (internal). $he bend properties of the %D& materials are shown in the following diagram. .ote that the Aluminium alloy is 1.<mm thic# and that an internal bend radius of 1.= is achieved. "igure > 2.2.% &lat Pattern %t should now be possible to produce a development of the model by selecting 'reate &lat Pattern by selecting the icon , Chec# that the model is now flat, by selecting any saved view other than $op or 4ottom. Any edges still folded indicate that not enough edge rips were selected. Chec# also that a consistent bend allowance of :.1 has been allocated. "igure < . > 2.2.( !elief %n "igure < a typical flat pattern is shown. .ote that as no corner relief was selected then sharp darts are cut into the start of the bend, resulting in a high rate of material deformation in this corner. Although, for the thin material being used, this is acceptable, the ease of bending will be improved by removing some material from this area. Choose the Smt 'onversion from the family tree and, on the 3M4 menu select Edit $efinition to redisplay the dialogue bo0 shown above in "igure :. ?ighlight the right,hand icon and see the effect of choosing one of the options shown in "igure =. 3ecommended dimensions are shown. "igure = Another nicety is illustrated in "igure 9 where part of a sheet is to be bent down and part not. Although &ro,8 does offer bend relief for such instances, cutting machines cannot produce slits of @ero width. %t is, therefore, suggested that a cut is inserted which goes ust beyond the bend area, terminating in a full radius, as shown. "igure 9 . < 2.% )ddin" 'uts $o save time it is strongly recommended that all mounting holes and cut,outs are included in the initial cutting stage to avoid the need for drilling later. $he *"lat &attern- feature, li#e any other in the model tree, can be suppressed and resumed at will. $his allows you to toggle between the development and the folded up form of the model. ?owever this should only for viewing 2 as soon as you threaten to ma#e a new feature the flat pattern is automatically suppressed and the new feature is inserted before it in the table. Mounting holes and other features are added to the folded form, and will automatically be placed correctly on the flat pattern. 5nce a feature has been made it is recommended that you call it something sensible by highlighting it in the model tree with the left mouse button and then, from the 3M4 menu, selecting !ename . $here are 6 methods of ma#ing holes and cuts, the Extrude icon to the right of the screen and from the %.+83$ menu either Extrude or *ole (although *hole- will only do round ones). . = 2.! "amily #a$le %t is vital to define a "amily $able for all folded components as they will be re(uired in both bent and flat forms in drawings, and in the folded form in assembly models. $he family table should be started as soon as possible so that the correct instance can be inserted. "rom the $55)+ menu select &amil+ Table and the following bo0 appears , +elect the *Add a Column- icon and the dialogue bo0 shown appears; ?ighlight &eature under *Add %tem- and select the "lat &attern so that the form loo#s as the one depicted. Accept selections with 5A. 3eturning to the "amily $able window will show it to be partially filled in. +electing the *Add a row- icon allows a further instance to be added. +uggest it be called *chassisBfolded-. .ote that the generic will have the flat pattern turned on and the folded instance must have it turned off. %t is also useful to have a further instance of your chassis in the flattened state so adding a further instance will result in the "amily $able shown below. . 9 "rom now on, whenever this model is inserted into an assembly or a drawing you will be as#ed which instance you re(uire. (Always choose the generic from the list of files in the ,orkin" director+ and choose the instance from the secondary dialogue bo0 that appears, as shown opposite). .ever put the generic model away with the "lat &attern feature suppressed as this causes trouble with references in assemblies and drawings. -.#. $o a &amil+ Table before insertin" the model into either an assembl+ or a dra,in". . C % &oling the Design +hould the structure of the chassis need modifying, during the design process, then there are several techni(ues to choose from. %.1 Simple Modification of Dimensions $o modify the overall si@e of the chassis one can return to the original solid e0trusion. $o increase, for e0ample, the overall length of the chassis is straightforward. +elect the original e0trusion from the Model $ree and on the 3M4 menu select Edit $efinition. $he relevant dimensions can now be simply altered, although care must be ta#en that other features such as holes are still in the desired position. +ee below. ?owever the same approach cannot be used if it is re(uired to increase the depth of the s#irt. $his cannot be achieved all round the chassis, as the tabs bent down in the central portion must remain narrower than the slots from which they are cut. $herefore the original e0trusion cannot simply undergo a dimension modification but must be 3edefined to include a cut giving a step in depth around the problem area. $his creates more surfaces and so the "irst 'all feature must be redefined to produce the desired shell. $his, in turn, means that the +M$ Conversion feature may need redefinition to re,establish the rips and bends and to achieve this any corner reliefs must be temporarily removed as their references will go missing in the process. $his is, clearly, too complicated and so it is recommended that 3edefinition of the original feature is avoided and simpler techni(ues applied. %.2 Modification of 'alls The most useful tools are given by the two icons below. 'reate &lat /all 'reate &lan"e /all *"lat- wall simply means that the shape is defined by s#etching on the flat face, it may still be attached to the e0isting wall via a single bend of any angle. *"lange- wall is effectively the same as *e0truded- and means that the s#etch is edgewise on, therefore comple0 bend profiles may be defined although they must be constant over the length of attachment. $his command allows attachment to curved edges. 4oth of these commands operate with a dashboard type display of parameters to be defined, with the provisional wall shown in lime,green so that the effect of any alterations can be seen graphically before being committed to. 4oth have the facility for calling up standard shapes whose dimensions can be edited on a simple graphic menu, or to be user,defined by entering the s#etcher. . D %.% (on)uniform &*tension of 'alls $o e0tend walls by an amount varying over the length of the edge in (uestion, choose the 'reate &lat /all icon. $he following dashboard appears. &ic# the edge to attach to and set the shape to !ectan"le as well as the angle to &lat. /nder the +?A&8 tab a simplified s#etch can be displayed and edited as shown below ;, .ote that the effect of changes can be seen *live- in the yellow rendered wall in the main window. $he e0ample shown is a simple rectangular addition over the length of the attachment edge minus 1=mmE observe that the first time the number 1= is entered a minus sign must be used. 3eady,made shapes available for this feature include *Trape0oid-, *1- and *T- while any flat shape can be defined by entering the s#etcher with the Sketch... button. %.( )n )lternative )pproach $o change the shape of a wall the alternative would be to cut a larger than needed wall down to that re(uired. $o effect this, select the Extrude icon and choose the 2id &lane as the +#etch &lane. 3emember that the removed material must be defined by a *closed section- in other words the s#etch must be a oined up shape. 5nce the material to be removed is defined and the s#etcher e0ited then the e0trusion depth should be defined as *$hrough All- and under the *5ptions- pull,down +ide 6 should also be set to *$hrough All-. . 17 %.3 )ddin" /alls ,ith #ends $his command also allows walls to be attached via a bend, by selecting the re(uired angle in the field that had been set to &lat above. %n the e0ample below, a bo0 with > sides bent up has a further return added. As we re(uire to ma#e this addition to all > sides, the shape will be trape@oidal, with ><F ends, to avoid interference. .ote the effect of the various flip arrows 2 modifications can be seen *live- in the model window. Accepting the options above gives the result shown; . 11 %.+ Copying of "eatures $o repeat the feature on all > walls the *copy and paste- method can be used. ?ighlight the feature to be copied and under the 8D%$ menu select 'op+. $he Paste and Paste Special commands are now available. Paste allows an independent copy to be created on any selected edge. ?owever, in this case it would be preferable to have dependent copies, i.e. copies which change to match alterations made to the original feature. $herefore select Paste Special and in the dialogue bo0 which appears (see opposite) tic# the bo0 for dependency as shown. 5A,ing this causes the dashboard to appear and it simply remains to select the attachment edge re(uired for the copy. 8nsure that if the e0ternal edge was selected for the original then the same is selected here and vice,versa. .ote that the *clipboard- is now empty and that further pasting operations re(uire the master feature to be highlighted and copied each time. 3epeating the procedure for each wall produces the structure shown below; %f the dimensions of the original trape@oidal wall are now varied then the copies will change as well. %f, however, a difference was re(uired then any dependent feature can always be made retrospectively independent by highlighting it and using the 2ake Sec 4ndep option from the 3M4 menu. .ote that, in this case, the new walls all e0tend over the entire length of their attachment edges despite being of differing lengths. $his is because they are defined as doing this. %f the original feature had been s#etched and had been defined with all finite dimensions rather than attached to ends of e0isting entities, then some modification of copies might have been necessary to achieve the desired result. . 16 %., #a$s -e.uiring Bend -elief %n our e0ample, it is desired to stiffen the chassis by e0tending the side walls into tabs to be bent round and pop,riveted to the end walls, as below. $he neatest result is obtained by folding the tabs behind the adacent end wall. $his can be achieved with the same 'reate &lat /all command which will ensure correct, flush alignment of surfaces automatically. 8nter the dashboard for this command as before, highlight the attachment edge (it is suggested that a consistent choice of outside edge is chosen) and define the shape. A nice little wrin#le is to use a trape@oid with a very slight angle (e.g. 6 degrees) to provide clearance from the top edge and from the bend at the base, in case the bending is not (uite 177G accurate. At the bottom corner of the tab, where its bend meets the bend between base and side wall, there is a region of infinite deformation. $his must be resolved by some sort of relief and the default (set under the dashboard heading 38)%8")is a simple rip, giving the effect shown highlighted opposite. $his is actually undesirable, as it would be both difficult to bend and would leave a dangerous sharp corner. %nstead some material would be removed from this area to avoid the situation altogether. Although there are bend reliefs available from the dashboard defining the wall in (uestion, these do not wor# very well when adacent to other bends (their purpose is to lie between bent material and flat material, as shown later). $here are 6 recommended methods to resolve this; . 1: - 5sin" ori"inal 'orner !elief 3eturn to the +M$ Conversion feature and edit its definition. +elect 'orner !eliefs from the +M$ Conversion definition and then select 'ircular. Choose Enter 6alue and set diameter to <mm ($his is the value re(uired to avoid all traces of a rip relief). Accept by selecting the tic#, twice. $his results in the "lat &attern now showing large circular cut,outs at the corners. ?owever, if the "lat &attern is suppressed, it will be observed that the corners loo# the same as before on the folded,up version (ie with no . 1> relief). $his is because the cuts cannot be computed until the fabrication is flat and, at the moment, the "lat &attern feature is the first time that the sheet has been flat. $o observe the effect in the folded,up model, it is necessary to insert two features into the model tree. "irst the 5nbend feature, using the icon shown.
"ollow this with the #end #ack feature, using this icon. "or both of these features a surface or edge must be selected to stay fi0ed,(ma#e it the same reference for both features) and the options; 5nbend )ll and #end #ack )ll should be chosen. .ow, if the "lat &attern is suppressed, the folded corner loo#s li#e this;, .ote that the regions of bent metal are separated by the circular relief. 2 - 5sin" relief added b+ hand in the unbent state $he method above does result in (uite a large hole in the corner but it is possible to remove the minimum amount of material if done manually. Add an 5nbend feature as above and e0amine the flattened corner detail as e0ample below. A sheet metal cut can be inserted into the flattened material to remove the line shown, where two bent regions meet. . 1< $he first s#etch shown below removes a triangle, whereas the second removes a circle attached to points at the unctions of the bend @ones (diameter comes out at about :.>). .ote that in both cases there are no dimensions because e0isting features are used for all definitions. 7*int8 4n the sketcher9 add % points first.: $heir effects in the folded state are shown below. $he cut feature can be mirrored onto the opposite corner by selecting it (either from the model or the tree) and choose 2irror . A mini dashboard appears, on which the only item which must be filled in is the mirror plane selection. $o mirror onto the bac# corners a datum plane could be inserted halfway down the chassis. Alternatively either 6 or all > corners could be cut on the same s#etch. . 1= %./ 0dding Bent #a$s from a "lat Bac1ground $he same *'reate &lat /all-command allows tabs to be bent up from surrounding flat material in the manner shown below. %n the e0ample being used it is first necessary to cut away the side walls where the tabs are re(uired. %t is also desirable to be able to alter the positions of these features by editing one single dimension and so an au0iliary datum plane may be inserted at an offset from the front plane. /se Extrude to remove a rectangle of material symmetrical to au0iliary datum plane(D$M6) and attached to outer surface of side wall. 5nly two dimensions will be shown on the s#etch, width and depth as seen below. $his cut may be mirrored about the M%D datum plane, using *options- on the dashboard to ma#e the copy dependant, (thus ensuring ease of subse(uent modification while maintaining symmetry of chassis). . 19 +elect 'reate &lat /all icon and pic# edge of cut for attachment as shown. Define shape, angle and bend radius. $his case is where the inbuilt relief options are particularly useful. 5pen the 38)%8" menu from the dashboard;, %t is recommended that the options shown opposite are used , )eave both sides the same Choose Obround. +elect *Tan to #end- as the length. +elect *Thickness x 2- as the width. .ote that the material removed is from the surrounding flat area 2 the tab width is unaffected. $herefore the width of the original cut must be the tab plus two desired reliefs. $hese choices result in a flat pattern that is both easy to cut and to bend and which produces the result pictured opposite. $his feature can now be copied to the other cut using the *Copy H &aste- method previously described. 3emember to use *Paste Special- to ma#e the copy dependant. .ote that using the mirror function on this feature does not produce the simple result e0pected and is unnecessary if the tab is, itself, symmetrical. Cuts can be added to these walls, noting that if M%D datum plane is selected as the s#etching plane then *Throu"h )ll- produces the result below. 3eference the cuts to D$M6 hori@ontally and surface of chassis vertically. . 1C +hould the model need modifying then the position of the whole feature can be controlled with the dimension to D$M6 and the width of spacing by the depth of original cuts. $he width of brac#ets is controlled by the width of original cuts and the height of brac#ets by the brac#et definition. $he cuts and the holes should always remain symmetrical to D$M6 as this is how they were originally defined.. 4t is al,a+s a "ood idea to spend a little time considerin" ho, to define positions and ,hat datums to refer dimensions to in order to simplif+ subse;uent modification. %.2 Create "lange 3all All the above modifications and additions have used the 'reate &lat /all function. ?owever, occasionally, it is useful to be able to create an e0tra wall by s#etching on its edge and then e0truding the profile, as, for e0ample, when multiple bends are re(uired. $o create an integral sensor brac#et, for e0ample, the dashboard shown below is entered by selecting the icon , +elect the desired attachment edge for Placement9 under Profile go to the 5ser $efined option and enter the s#etcher (s#etching on the M%D datum plane), specify the length as symmetrical about the s#etch plane. 5ther possibilities offered by this command include the ability to attach to a curved edge but to manufacture this type of feature would re(uire more sophisticated forming e(uipment than is available. Also, under the standard profiles are included various types of *safety edge- where material is folded to avoid sharp edges, but these are not considered relevant to the %D&. . 1D Part ! ) 4utput 5 Dra'ings and D6"7s Drawings must be produced to gain Design Approval. $he re(uirements are; 1. A general assembly drawing together with enough prints of rendered models to convey the operating principles of the design. 6. Dimensioned drawings for all components to be manufactured. %n the case of the chassis and other sheet metal parts these should comprise views of both the folded form and the flat pattern. !.1 Dra'ings +tart a new drawing and select *Empt+ ,ith &ormat-, browsing for a suitable C/8D border. 'hen in the drawing, add both *generic- and *folded- instances of the model 2 from 3M4 menu choose Properties and then $ra,in" 2odels. +elect )dd 2odel from the D3A'%.I M5D8)+ menu and insert chassis model twice, once in each instance. /se Set 2odel from the D3A'%.I M5D8)+ menu to determine which instance views are added from. As most features have been defined in the folded state, it is best to dimension these in the folded views. 5verall dimensions and the positions of the main groups of holes should be shown. %t is necessary to display centre,lines by selecting them from the dialogue bo0 accessed via the icon shown.
. 67 $he dialogue shown now appears and the right,hand tab will display centre,lines once the view(s) re(uired have been highlighted. 5nce the centre,lines are displayed manual dimensioning is much simpler as the centre,line itself may be used as a reference. Automatic dimensioning does not really wor# with sheet metal, so it is recommended that dimensions are inserted manually by selecting the icon shown. $he bo0 shown is displayed at this point and as a default the option *5n 8ntity- should be selected, although other options allow for the centre of circles or radii to be used etc. %t is not necessary to dimension every last hole as this information is contained in the D!" file. %t is permissible to use a note about symmetry to minimi@e the number of dimensions, provided the intention is unambiguous. .ote that, with sheet metal, it is not possible to rely upon the automatic dimensioning provided by &ro,8 and it is recommended to insert dimensions manually. %t is still necessary to produce flat views (from the flat instance of the model) but the only features which must be dimensioned on these are the bend lines (which must be scribed by hand in the wor#shop later).%t is acceptable to dimension to one side or the other of bends or even to their centre line, provided that dimensions appear stating the relationship between these. +uch dimensions may be shown once as *$J&%CA)- as in the e0ample below. . 61 3emember to alter any of the properties of a view, ?ighlight that view and on the 3M4 menu select *&roperties-. $his will bring the dialogue bo0 shown up. $he most useful page being *Kiew Display- which allows the display of a view to be loc#ed into a line drawing mode, either *?idden- or *.o ?idden- line display. !.2 D6" $he cutting machine re(uires a D!" file to be produced. +tart a new drawing file, choosing Empt+ ,ith &ormat, and select the format * 1bB steelB><70><7Bd0f.frm- or alalloyB67701<7. Attach the flat instance of the model and Add a $op Kiew at a scale of 1;1, ensuring that no notes or dimensions are displayed. ?ighlight the view and from the 3M4 menu select properties. 5pen the 6ie, $ispla+ page of the dialogue bo0 and change $ispla+ St+le to -o *idden and change Tan"ent Ed"es $ispla+ St+le to -one. $hese actions get rid of hidden detail and bend lines so that the view will be left with only cut lines displayed. Choose command *+ave a Copy- of the file and in the dialogue bo0 change "ile $ype to D!". %t is helpful to produce one D!" file for all components in 7.9mm steel and one (if applicable) for all components in 1.<mm aluminium. Do this by attaching all relevant models to the drawing and selecting new model for each view. Take care that all scales are 8. +ubmit the D!" files via the bulletin boards accessed from the %D& website under *&roect H $eam "orums-. /pon logging in to this environment go to the "orum *+tudent submission of D!" files- and post your D!" files by pressing the button *.8' $5&%C-. "ill out the subect bo0 with your team number and place some te0t in the main space including team number and material(s) re(uired. Attach your D!" files by pressing the */pload attachment- button towards the bottom of the screen. 4rowse for the re(uired file(s) and press the *Add the file- button. 'hen complete press the -+ubmit- button below the message. .ote that there is a limit of : attached files per message. $ra,in" file appearance prior to creation of $<& file. Determine the order in which bends are to be e0ecuted 2 if in doubt see# advice from wor#shop technicians. $he cut sheet should have bend lines scribed upon it to show the start of each bend. 4e careful to scribe upon the side of material that will be uppermost (and therefore visible) in the bending machine. . 66 3 )ssembl+ 2odellin" 3. Parts 1ibrar+ %t is strongly recommended that the entire assembly is modelled before gaining design approval and starting manufacture. $o help with this, models of the standard component parts have been placed in the MD& library. $his is accessed, from the *5pen "ile- dialogue bo0, by changing directory to C/8D )ibrary and then selecting mdpBlib. $he library structure is shown below and it will be found that each section has a description of the contents. /se the &review facility offered by &ro,8 to see the file before opening it. .ote that some of the items have been pre,assembled to save time. Also note that the gears are shown as smooth drums of the pitch,circle,diameter. $o mesh the gears ensure that these circles are ust touching. ?owever to chec# the overall space envelope re(uired by a gear, Suppress the final cut and a new outer surface (coloured yellow) will be revealed. 'hen building up a large assembly, it is much easier to use sub,assemblies, rather than bringing loads of individual components into the top,level model. "or instance; assemble the motor, shaft e0tension and wheel (already done in the library), together with a suitable brac#et of your own devising, into a drive,unit assembly before inserting this into the overall robot, thus saving having to do everything twice and minimising the number of datum features that need to be displayed when positioning things. . 6: 8.2 Standard Brac1ets and other materials %n addition to the chassis, there will, probably, be a re(uirement for au0iliary brac#ets formed from sheet metal. $o save time, a small library of standard brac#ets has been compiled, which can be modified to individual re(uirements. .ote that from wherever library files are obtained, they are #ept as read,only. %t will be necessary to save a re,named copy to allow modification. $he types of brac#ets offered are shown below. $here are also short lengths of the bar and angle materials which may be used similarly. 8.% 0ssem$ly #ips 'hen placing parts in an assembly model, remember that when one or two constraints have been made then the part may be moved by hand (in the remaining degrees of freedom only) by holding Ctrl H Alt while using the MM4 for rotation and the 3M4 for translation. $here is nothing wrong with leaving a component partially constrained while other parts and features are arranged. %f it is re(uired to add a mounting hole to match a placed component, this can be done from within the assembly model by using the *Activate- facility. A typical procedure might be , %nsert a component into the assembly and place #nown constraints upon it. (e.g.; mounting surfaces and orientation of faces and edges). &osition the component by hand to roughly the right position in remaining plane(s). Activate the model to be cut (highlight and 3M4 menu). 5bserve little green diamond. Cut a hole to match that in placed component, possibly using concentric circles. &lace dimensions on cuts using references in chassis model alone. 3esolve redundant dimensions and constraints as prompted (by deleting coincidences). $wea# dimensions to round numbers as re(uired. Accept cut feature if satisfactory. 3e,Activate assembly model (highlight top level of model tree and use 3M4 menu). 3eturn to definition of placement of partially constrained component and add constraint aligning mounting holes. *o,ever9 this techni;ue is not suitable for use ,ith instances of famil+ tables. 4f it is used to place holes in the folded instance of a chassis then all sorts of problems ,ill be experienced ,hen the "eneric model is examined9 from suppression of features to lost references. . 6> A safer method for folded components is to insert the mounting holes into the generic model without worrying about their e0act placement and then editing them in the assembly to bring them to the desired position. $he procedure is, therefore, amended as follows; %nsert appro0imate mounting features into chassis model. %nsert a component into the assembly and place #nown constraints upon it. (e.g.; mounting surfaces and orientation of faces and edges). &osition the component by hand to roughly the right position in remaining plane(s). 8dit holes to match those in placed component. $wea# dimensions to round numbers as re(uired. 3eturn to definition of placement of partially constrained component and add constraints aligning mounting holes. 8.! Mechanisms 'hen assembling the elements of a mechanism 'onnections dashboard is used, rather than the static 'onstraints. $he model can rapidly become over,complicated unless some simple golden rules are observed. 'hen placing an item use either 'onstraints or 'onnections page of dashboard, never both at the same time. +ee# to minimi@e the number of connections used to describe a mechanism. Avoid placing individual components into a dynamic assembly. 4uild up sub,assemblies of components which are statically fi0ed to each other and then combine these with dynamic connections in a higher level assembly which defines the mechanism. %n the e0ample shown below, a lifting arm is mounted on the chassis and driven by a pneumatic cylinder. . 6< $he recommended approach is , 1. 4uild up the chassis assembly, with relevant mounting brac#ets. 6. Create the lifting arm assembly (by attaching component parts with static constraints). :. +tart a new assembly and insert chassis, fi0ed to main assembly frame of reference by using default location button on right hand side of constraints dialogue bo0. >. %nsert lifting arm assembly by selecting the dynamic connections dialogue and using a Pin oint. <. Ma#e a copy of the pneumatic actuator from C/8D )ibrary and insert this copy into the assembly with a pin connection at one end and a simple cylinder at the other (to avoid redundant a0ial restraint). . 6= Inde* "/.C$%5. 38"838.C8 .5$8+ 2 - =ettin" Started +tarting with +olid Model 6.1 8ntering sheet metal application and creating shell +M$ Conversion 6.6 Defining sheet metal features 3ipping 6.6.1 Deciding which edges are discontinuous and which bent 4end Definition 6.6.6 Kalues of bend radii for materials used in %D& "lat &attern 6.6.: Development of model as cut from sheet, before being bent 3eliefs 6.6.> Adding corner reliefs and slots for ease of manufacture Adding ?oles and Cut,outs 6.: /se of "latL"olded models "amily $able 6.> Allowing flat and folded instances to be used independently % - 2odification Techni;ues +imple Modification of Dimensions :.1 Modification of original e0trusion H pitfalls Modification of 'alls :.6 80tends wall uniformly over entire length of edge .on,/niform e0tension of 'alls :.: Allows e0tension over part of edge and to varying lengths Adding 'alls with 4ends :.> Attaching new bent wall An Alternative Approach :.< Cutting away unwanted material Copying :.= Adding multiple new features by *copy and paste- method $abs 3e(uiring 4end 3elief :.9 Adding e0tra folded tabs and managing relief of material in corners 4ent $abs from "lat 4ac#ground :.C Adding bent walls to flat material, including relief Create "lange 'all :.D 80trusion of wall with several integral bends ( - Output Drawings >.1 Drawings and Dimensioning D!" >.6 &roducing files for cutting 3 - )ssembl+ Component )ibrary <.1 )ocation and use of library of standard parts 4rac#ets <.6 .otes on use of standard brac#ets Assembly $ips <.: +ome guidance on alignment of components Mechanisms <.> Assembly with dynamic connections . 69