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using sheetmetal as folded boxes

using sheetmetal as folded boxes

using sheetmetal as folded boxes

(OP)
Is there any way to model "scored corners" in a sheetmetal part.  

This may not be the appropriate name so I will try to be a bit more clear.  I recently modeled (sloppily) a cardboard box packaging insert with a solid part.  What I really need is a flat version of the insert that I can dimension and send to a vendor.  I would love to make a sheetmetal part for this.  However, I don't know how to model the corners that this box will require.   The corners need to be prescored in the flat state and then folded opposite of the corner they are in to make a "tube-shape"  I have uploaded my model so that you can see the type of corner I am referring to.

It would seem that applications like this lend themselves to the sheetmetal parts, but I have never had this application come up before.

I guess the question becomes, at what point does this cease being sheetmetal and become origami?

http://multiterra.mooload.com/file.php?file=files/280406/1146229363/insert.SLDPRT

RE: using sheetmetal as folded boxes

I'm not an expert by any means either actual sheet metal fabrication or SW sheet metal functionality.  However, I don't think this part could be made by any standard sheet metal fabrication techniques since to actually form those tubes you have to bend all 4 corners simultaneously.  Easy to do by hand with pre-scored cardboard, but I daresay next to impossible with a piece of sheet metal.  Given that, I doubt the SW sheet metal functions would give an easy solution.

RE: using sheetmetal as folded boxes

(OP)
Thanks for the quick response.

handleman:  I agree, this would be tough with sheetmetal if not impossible, but I was curious to see if there was still a way to model it given the cardboard application.

CBL:
Thanks for the idea, I had thought of doing something similar, but was frustrated that in the flat state, I couldn't represent the fact that there should only be 2 cuts and 3 scores in the cardboard per feature.  Modeling the part in this way, implies the notch is not attached at both ends of the tube, so it wouldn't help much for making the drawing, but does make a nice 3D representation. (no sharp 90 bends)

Aside:
I know Pro/E allowed you to create special "form tools" which you could use to deform sheetmetal in specific applications.  Does SW employ a similar function?  Its been a while since even my Pro/E days, and I don't play with SW sheetmetal much.  If it is possible I wouldn't even know where to start.



RE: using sheetmetal as folded boxes

SW has lance features for sheet metal, but they do not flatten.

Flores
SW06 SP4.1

RE: using sheetmetal as folded boxes

I can't download files from work, so I haven't seen your model.  Can a picture be posted?

If you are only worried about the flat pattern, try making your model with very thin material thickness and use a very sharp bend radius.  I've designed cardboard packages with size E and F flute using this method to get the flat pattern to a vendor.

"Art without engineering is dreaming; Engineering without art is calculating."
Steven K. Roberts, Technomad
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RE: using sheetmetal as folded boxes

(OP)
Never tried posting a pic, but here goes.

RE: using sheetmetal as folded boxes

(OP)
on second thought, here's a closeup of the feature in question.

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