OK, NX uses something called 'Tolerant Modeling' when it comes to stuff like sewing sheet bodies together, either into a solid or into a larger sheet body. If the adjoining edges of two sheet bodies do NOT match exactly BUT they're within the Modeling Tolerance, when they are sewn together the system will choose ONE of the edges as the NEW edge representing the 'seam' between what are now two faces of the new 'body', and the other edge will be permanently hidden. What this means is that theoretically there is STILL a gap between the faces since the actual shape of the sheet bodies have NOT been modified. However, NX will TREAT the body AS IF THERE WAS NO GAP for all downstream operations. This is why it's called
'TOLERANT Modeling' since the NX operations are 'tolerant' of this condition.
Now if the 'gap' between the sheet bodies is greater than the Modeling Tolerance and there were more than two sheet bodies being sewn together, you might get a result showing a single body but there could still be actual gaps between some of the sheets. To see if this is the case, after the sewing operation, go to...
Analysis -> Examine Geometry...
...and make sure that the 'Sheet Boundaries' check in toggled ON. When you hit the 'Examine Geometry' button look for highlighted 'edges'. Now if the only highlights edges are around the perimeter of the new sheet body, then that's OK. However, if you see some highlighted edges between faces of the new body then there are gaps, which probably meant that the mismatch between the original sheets bodies was greater than the 'Modeling Tolerance'. Now you can do one of two things, either use a larger modeing tolerance or try cleaning up the sheet bodies so that they match better. If you choose to increase the Modeling Tolerance be aware that eventually this could result in downstream problems if the hidden 'gaps' are so large that they are close to the size of whatever downstream operation that you're performing is based on. For example, if you're going at a blend or chamfer one of these edges sewn with a large modeling tolerance and the they are close to the size of the tolerance used they couls fail. The same holds true for toolpaths with small step-overs or FEM meshes with small element sizes.
Also note that once a feature which depends on the Modeling Tolerance is created, changing the default Modeling Tolerance will have NO effect whatsoever on any of these features when the model is subsequently updated. In order to change the Tolerance used by a feature you have to actually edit that feature and change the Tolerance parameter in the Feature's dialog.
Anyway, I hope that helps.
John R. Baker, P.E.
Product 'Evangelist'
Product Engineering Software
Siemens PLM Software Inc.
Industry Sector
Cypress, CA
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