On SW 2019, I have difficulty creating close folds on the inside edges of a sheet metal frame.
I start with a flat area of the frame, cut out in the inside corners, which I would like to fold. Except that below 3.8mm of cutting width, it blocks while the folds do not yet touch.
I tried with sketched fold, it blocks from the first fold.
By trying bent sheets on edges, it goes on 3 of the 4 edges, even if the folds overlap in the corners (and therefore the final flat area generated also overlaps). It does block with this function if I select the fourth edge.
I attach the images of the initial flat area and the type of folds desired.
FYI: Ep=2mm / Ri=2.67
Do you have a solution or ideas please? I'm a beginner in sheet metal work and I'm learning on the job, if it's not the best method don't hesitate ;)
No, indeed physically it's impossible (although with the "bent sheet metal on edge" function on 3 of the 4 edges, it doesn't pose a problem on the 3D, weird...).
But otherwise in the idea it's a bit like that, to bring them together in the corners to the limit of what is possible to draw physically on the initial flat area, with just a laser "incision" in the corners before folding.
On my images, my "incision" is 3.8mm wide, that's big for a laser! :D
If I go down the cutting width, the creases block and don't create.
The idea is to start with a frame and make a fold by editing the sketch of the fold to move it inwards and break the corners. Then, via an axis created earlier, a circular repetition must be made.
Thank you for your answer, I had done a test as you say, but the unfolded result is still quite openworked.
But you made me think of retouching the sketch of the fold, and I attach what gives the closest result to a simple cut line on the unfolded.
On the other hand, tinkering with the sketch of the fold like I did to have a unfolded that fits, it's not great, it makes you spend a lot of time finding the dimensions that fit well... That's why in this kind of case I start with a flat area, which I then fold with sketched folds.
I think it comes from your bending radius (too large unless it's wanted) which must be in your case more than twice the thickness if I can see correctly.
Since you're talking about laser, it's often better to make a small hole as a notch at the bottom of the 0.5 mm kerf.
I use "sketched folds" so I have a better command of corner cutting and notching because what SW offers has these limits.
Here is with a sketched crease but with a narrow laser cut with a hole at the end. The hole can be replaced by an ellipse, which facilitates bending and reduces the hole after bending.
After trying it, on your advice Zozo_mp, I attach the part that best meets what I was looking for, with a 0.5mm wide kerf and a 4x6mm ellipse. Despite everything, it leaves a nice hole.
Regarding the bending radius, it is 2.67mm (for 2mm thick sheet metal) when measured once bent, because I define the sheet metal parameters in each part, according to the sheet metal used. So the default settings in this room are the ones that I entered.
That's it for the 3D, and I'm waiting for the feasibility feedback because the real part is a little more complex. In talking with the subcontractor in question, he told me that we could surely work it out without notching at the bottom of the laser line and make sure to bring the folds together.
If I'm interested and I can, I'll post pictures of the tests on real parts.
I'm interested to see what your subcontractor will do to you because you always learn tricks because there are great fab tricks that don't always appear with regard to the finished part.
If you can attach a picture of the flat piece just before folding it would be great. ;-)
I too am curious to see the photos because I am in the field of cutting/folding; the only way I can see without having the 45° cutouts in the corners is to make the frame in 4 parts and to have the 4 corners in welds see PJ. In terms of soldering, it's almost identical, but in terms of material gain, that's where we win...
