GH

UNIGRAPHICS
SHEET METAL DESIGN

STUDENT GUIDE
March 2003
MT16020 - Unigraphics NX
EDS Inc.
Proprietary & Restricted Rights Notices
Copyright
Proprietary right of Unigraphics Solutions Inc., its subcontractors, or its suppliers are included in this
software, in the data, documentation, or firmware related thereto, and in information disclosed
therein. Neither this software, regardless of the form in which it exists, nor such data, information, or
firmware may be used or disclosed to others for any purpose except as specifically authorized in writing
by Unigraphics Solutions Inc. Recipient by accepting this document or utilizing this software agrees
that neither this document nor the information disclosed herein nor any part thereof shall be
reproduced or transferred to other documents or used or disclosed to others for manufacturing or any
other purpose except as specifically authorized in writing by Unigraphics Solutions Inc.
2003 Electronic Data Systems Corporation. All rights reserved.
Restricted Rights Legend
The commercial computer software and related documentation are provided with restricted rights.
Use, duplication or disclosure by the U.S. Government is subject to the protections and restrictions as
set forth in the Unigraphics Solutions Inc. commercial license for the software and/or documentation
as prescribed in DOD FAR 227-7202-3(a), or for Civilian Agencies, in FAR 27.404(b)(2)(i), and any
successor or similar regulation, as applicable. Unigraphics Solutions Inc., 10824 Hope Street, Cypress,
CA 90630.
Warranties and Liabilities
All warranties and limitations thereof given by Unigraphics Solutions Inc. are set forth in the license
agreement under which the software and/or documentation were provided. Nothing contained within
or implied by the language of this document shall be considered to be a modification of such warranties.
The information and the software that are the subject of this document are subject to change without
notice and should not be considered commitments by Unigraphics Solutions Inc.. Unigraphics
Solutions Inc. assumes no responsibility for any errors that may be contained within this document.
The software discussed within this document is furnished under separate license agreement and is
subject to use only in accordance with the licensing terms and conditions contained therein.
Trademarks
EDS, the EDS logo, UNIGRAPHICS SOLUTIONS, UNIGRAPHICS, GRIP, PARASOLID,

UG, UG/..., UG SOLUTIONS, iMAN are trademarks or registered trademarks of Electronic
Data Systems Corporation or its subsidiaries. All other logos or trademarks used herein are the
property of their respective owners.
Sheet Metal Design Student Guide Publication History:

Unigraphics NX . . . . . . . . . . . . . . . . . . . . March 2003
Table of Contents
Table of Contents
Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
Key Features of Sheet Metal Design . . . . . . . . . . . . . . . . . . . . . -2
Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3
Why do I need to know this? . . . . . . . . . . . . . . . . . . . . . . . . . -3
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4
Classroom System Information . . . . . . . . . . . . . . . . . . . . . . . -6
Class Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7
About Part File Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7
Class Part File Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7
Seed Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -8
Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9
Expressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -10
Layers and Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11
Unigraphics Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -13
Activity -1: Toolbars in Gateway Application . . . . . . . . . . . -15
Activity -2: Toolbars in Modeling Application . . . . . . . . . . -22
The Sheet Metal Feature Toolbar . . . . . . . . . . . . . . . . . . . . . . . . -29
Activity -3: Sheet Metal Toolbar in Modeling Application -31
Preferences and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Sheet Metal Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Global Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Reference Line Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Part Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Default Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Load Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Use Feature Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Check Standards on Create . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Enforce Creation State Editing . . . . . . . . . . . . . . . . . . . . . . . 1-6
Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Sequential Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Bracket Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Defining Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Checking Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Activity 1-1: Reviewing Preferences and Standards . . . . . . 1-11
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Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
The Flange Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Flange Profile Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Positioning Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Bend Allowance Formula (BAF) . . . . . . . . . . . . . . . . . . . . . . 2-8
Flip Bend Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Adjacent Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Parameter Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Reference Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Side Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Left and Right Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Butt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Global Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Confirm Upon Apply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Flange Instancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Activity 2-1: Creating Flanges . . . . . . . . . . . . . . . . . . . . . . . 2-20
Activity 2-2: Creating a Butt Joint . . . . . . . . . . . . . . . . . . . . 2-42
Miters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Miter Side Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Left and Right Miters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Simple Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Full Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Miter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Miter Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Miter Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Miter Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Flange Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Activity 2-3: Working with Miters . . . . . . . . . . . . . . . . . . . . 2-62
Sheet Metal Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

The Sheet Metal Corner Dialog . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Construction Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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Butt Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Parent Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Associate Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Simple Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Gap and Relief Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Full Miter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Multiple Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sheet Metal Corner Construction Tips . . . . . . . . . . . . . . . . . . . 3-10
Activity 3-1: Creating Sheet Metal Corners . . . . . . . . . . . . 3-11
Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
The Inset Flange Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Inset Flange Profile Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Inset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Use Expression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Outer Tangent Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inner Tangent Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Outer Mold Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
DIN Mold Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Inner Mold Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Relief Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Flange Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Left and Right Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Activity 4-1: Exploring Inset Flange Creation Techniques 4-11
Activity 4-2: Creating an Inset Flange . . . . . . . . . . . . . . . . 4-22
Sheet Metal Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

The Sheet Metal Bend Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Construction Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Base Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Application Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cylindrical Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Existing Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Application Curve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Flip Bend Direction Vector . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
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Flip Stationary Direction Vector . . . . . . . . . . . . . . . . . . . . . . 5-7

Bend Allowance Formula (BAF) . . . . . . . . . . . . . . . . . . . . . . 5-8
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Sheet Metal Bend Construction Tips . . . . . . . . . . . . . . . . . . . . . 5-9
Activity 5-1: Creating Sheet Metal Bends . . . . . . . . . . . . . 5-10
General Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

The General Flange Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Bend Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Spine String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Section Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Shaping Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Punch Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Add Tangent Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Parameters Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Reverse Bend Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Step Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Build to Sections Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Extend Start and Extend End . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Build to Faces Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Punch Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Adjacent Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Infer Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Infer Spine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
r Value and Area Preserve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Contour Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Mold Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Form Block Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Activity 6-1: General Flange Creation Methods . . . . . . . . . 6-26
Activity 6-2: Other General Flange Creation Methods . . 6-35
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Activity 6-3: Create a Gen. Flg. by the Punch Vector Method 6-43
Sheet Metal Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

The Sheet Metal Punch Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Placement Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Tool Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Lancing Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Direction Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Punch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Top Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Size Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Face Normal Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Flip Side Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Construction Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Activity 7-1: Creating Sheet Metal Punches . . . . . . . . . . . 7-14
Sheet Metal Solid Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

The Sheet Metal Solid Punch Dialog . . . . . . . . . . . . . . . . . . . . . 8-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Target Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Tool Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Transformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Pierce Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Create Auto Centroid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Edge Blend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Activity 8-1: Creating Sheet Metal Solid Punches . . . . . . 8-9
Sheet Metal Hole and Sheet Metal Slot . . . . . . . . . . . . . . . . . . . . . . 9-1

The Sheet Metal Hole Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Hole Positioning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Through Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Positioning Edge 1 & Positioning Edge 2 . . . . . . . . . . . . 9-5
Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
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Hole Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Size Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Face Normal Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Editing Sheet Metal Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Editing Hole Positional Parameters . . . . . . . . . . . . . . . . . . . . . . 9-9
Hole Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Activity 9-1: Creating Sheet Metal Holes . . . . . . . . . . . . . . 9-11
The Sheet Metal Slot Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Creation Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Orientation Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Size Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Slot Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Slot Positioning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Activity 9-2: Creating Sheet Metal Slots . . . . . . . . . . . . . . . 9-29
Sheet Metal Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Sheet Metal Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
The Sheet Metal Cutout Dialog . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Through Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Flip Discard Region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Activity 10-1: Creating Sheet Metal Cutouts . . . . . . . . . . . 10-9
Unbend/Rebend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Unbend/Rebend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Region Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Boundary Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
The Unbend/Rebend Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Bend Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Unbend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Rebend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
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Unbend to Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

Bend Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Adjacent Bend Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Global Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . 11-7
Activity 11-1: Creating Unbend and Rebend Features . . . 11-8
Activity 11-2: Creating Unbends from an Extrusion . . . . . 11-19
Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
The Bead Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Placement Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Centerline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Centerline Projection Vector . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Orientation Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Section Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Section Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Secondary Face Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
Target Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
Bead Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Bead Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Activity 12-1: Creating Beads . . . . . . . . . . . . . . . . . . . . . . . 12-18
Sheet Metal Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
The Sheet Metal Bridge Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Base Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Base Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Target Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Target Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Construction Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Flip Extension Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Construction Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Intersect Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Inside Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
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Distortion Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

Area Preserve and R Value . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
Construction Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Unite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Activity 13-1: Sheet Metal Bridge Creation . . . . . . . . . . . . 13-13
Multibend Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
The Multibend Bracket Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Tree List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Base Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Add Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Add Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Reverse Material Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Delete Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Inner Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
Intersection Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
Adjacent Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Sketch Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Editing Multibend Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Activity 14-1: Creating a Multibend Bracket . . . . . . . . . . . 14-10
Sheet Metal Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
The Sheet Metal Bracket Utility . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
The Sheet Metal Bracket Dialog . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Base Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Base Clearance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Reference Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Reference Clearance Points . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Reverse Material Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Clearance Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Material Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Bend Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Pad Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
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Flange Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Offset Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Chordal Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Linear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Add Rounded Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Create or Unite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Edit Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Normal to Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Between Circles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Along Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Drag Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Point Constructor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Creation of a Sheet Metal Cutout . . . . . . . . . . . . . . . . . . . . . 15-16
MultiĆflanged Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Editing Sheet Metal Brackets . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Bracket Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Activity 15-1: Bracket Creation . . . . . . . . . . . . . . . . . . . . . . 15-18
Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

The Flat Pattern Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Creating a Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Updating a Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Name and Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Traverse Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Unform and Form Sheet Metal Features . . . . . . . . . . . . . . . 16-6
Change Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Traverse Control Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Layout Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8
Area Preserving Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8
Distortion Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9
Projection Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9
Cutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-10
Additional Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-10
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11
Start Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11
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Orientation Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11

Activity 16-1: Creating a Simple Flat Pattern Drawing . . 16-12
Flat Pattern Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
Name and Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Chord and Angle Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Output Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Curve Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Bend Tangent Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Bend Center Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Auto Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Distortion Constraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Allow Multiple Flat Patterns . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Use Bend Allowance Formula . . . . . . . . . . . . . . . . . . . . . . . . 16-21
Geodesics Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
Flat Pattern Annotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
Edit Display Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
Text Callout Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-23
Flat Pattern Annotation Preferences . . . . . . . . . . . . . . . . . . . . . 16-24
Flat Pattern Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-25
Activity 16-2: Creating a Flat Pattern Drawing Assembly 16-27
Additional Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Sheet Metal Part in Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Part In Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Unform Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Form Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Add Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Add Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Delete Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Unform Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Form Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Execute Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Add Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Add Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Delete Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Bridge and Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
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Table of Contents
Flange and Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Process Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
General Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Surface Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Edge Constrains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Activity B-1: Creating a Process . . . . . . . . . . . . . . . . . . . . B-12
Working in Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22
Creating Process Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23
Sequential Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-24
Part Families . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-24
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-25
General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-25
Part Families Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Available Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Attribute Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Activity B-2: Generate Family Members for Model States B-28
Activity B-3: Adding Part in Process States to a Drawing B-32
Flat Pattern Additional Information . . . . . . . . . . . . . . . . . . . . . . . . C-1

Flat Pattern Woven Materials Options . . . . . . . . . . . . . . . . . . . . C-1
Warp Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Origin Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Grid Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Lock Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Activity C-1: Flat Patterns for NonĆSheet Metal Parts . . . C-6
Multibend Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Activity D-1: Creating a Multibend Bracket . . . . . . . . . . . D-2
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-1
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xii Sheet Metal Design

Student Guide
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Course Overview
Course Overview
The Sheet Metal Design course was developed to show the user how to employ
the sheet metal feature and design functions within Unigraphics to successfully
create and manipulate sheet metal parts.
The sheet metal design product supported within Unigraphics uses a

solidsĆbased, featureĆbased approach to defining sheet metal parts. From these
parts the user can create accurate manufacturing data such as flat pattern
definitions, forming tables, and bend sequence tables for downĆstream
applications.
This section contains the following activities:
Activity Page
-1 Toolbars in Gateway Application . . . . . . . . . . . . . . -15
-2 Toolbars in Modeling Application . . . . . . . . . . . . . -22
-3 Sheet Metal Toolbar in Modeling Application . . . -31
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Course Overview
Key Features of Sheet Metal Design
Some highlights of the sheet metal design product include:
FeatureĆspecific attributes and standards checking to ensure design for

manufacturability principles are met.
Associativity between sheet metal features and modeling features.
Dynamic model states (formed, intermediate, and unformed model
stages).
Multiple flat pattern generation, annotation, and update capabilities.
Part tailoring through the creation of userĆdefined features, such as
cutouts.
Preference settings for general and userĆdefined sheet metal
standards.
Information options to display bend sequence and forming tables.
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-2 Sheet Metal Design
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Course Overview
Course Objectives
After successfully completing this course, the student should be able to:
Create sheet metal parts using both modeling and sheet metal
features.
Set up default standards and creation preferences.
Effectively create and edit Flange, Inset Flange, Sheet Metal Bend,
General Flange, Sheet Metal Bridge, Bead, Sheet Metal Punch, Sheet
Metal Hole, Sheet Metal Slot, Sheet Metal Cutout and Sheet Metal
Bracket features. Sheet Metal Relief and Sheet Metal Strain features
will not be covered in this course. More information can be found on
these features using the Unigraphics onĆline documentation.
Recognize the benefits and limitations of sheet metal features.
Create and manipulate forming tables.
Create and edit sheet metal flat patterns.
Create and edit flat pattern display and callout annotations.
Recognize the effect of using sheet metal parts in Assembly
applications.
Why do I need to know this?
You may be wondering why specific sheet metal features were created
independent from modeling features. Sheet metal features are unique from
modeling features in that they contain applicationĆspecific data such as bend
allowance formula and other material property information. Sheet metal
features also have the ability to change their geometric representation with
respect to the formed state of the model.
Because of these characteristics, it is essential to the creation of a valid, usable

sheet metal part that you know when and how to use sheet metal features
during the construction of your part. Incorrect implementation or nonĆusage of
sheet metal features may result in inaccurate or unproducible flat pattern
definitions.
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Course Overview
Prerequisites
The Sheet Metal Design course is intended for users who have experience with
the basic Unigraphics functionality found in the Practical Applications (PAU),
Design Applications (DAU) and Drafting fundamental courses. In order to
ensure that the above course objectives are met, it is anticipated that you are
able to perform the following prerequisites prior to this course:
Log on, navigate through a directory structure, and create, open, close,
and save part files.
Manipulate the display of a model using views and layouts.
Organize the contents of a part file using layers.
Utilize the WCS to define points, vectors, planes, and coordinate
systems in model space.
Create and edit points, lines, arcs, fillets, and chamfers.
Create and edit primitive features.
Create and edit extruded and revolved bodies.
Create, edit, and position form features.
Create and edit datum planes and axes.
Apply the operational features blend, hollow, taper, offset, and
instance.
Create and edit simple/moderate sketches.
Create and edit drawings.
Work within an assembly file structure.
How to Use This Manual

It is important that you use the Student Manual in the sequence presented
because later lessons assume you have learned concepts and techniques taught
in an earlier lesson. If necessary, you can always refer to any previous activity
where a method or technique was originally taught.
The general format for lesson content is:

lecture
activity
project
summary
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Course Overview
The format of the activities is consistent throughout this manual. Steps are
labeled and specify what will be accomplished at any given point in the activity.
Below each step are action boxes which emphasize the individual actions that
must be taken to accomplish the step. As your knowledge of Unigraphics
increases, the action boxes will seem redundant as the step text becomes all that
is needed to accomplish a given task.
Step 1 Open part file xxx_topic_1.prt.
From the menu bar, select File.
Choose Open.
DoubleĆclick on the parts subĆdirectory.
Select the file xxx_topic_1.prt and choose OK.
While working through lesson activities, you will experience a higher degree of
comprehension if you read the CUE and Status lines .
It is recommended that students who prefer more detail from an Instructor Led
Course ask questions, confirm with restatement, and, more importantly, attend
and pay attention to the instruction as it is given.
Obviously, it is always necessary for students to consider the classroom situation

and be considerate of other students who may have greater or lesser needs for
instruction. Instructors cannot possibly meet the exact needs of every student.
At the start of each class day you will be expected to log onto your terminal and
start Unigraphics, being ready to follow the instructor's curriculum. At the end
of the day's class you should always quit Unigraphics and log off the terminal.
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Course Overview
Classroom System Information
Your instructor will provide you with the following items for working in the
classroom:
Student Login: Username:
Password:
Home Directory:
Parts Directory:
Instructor:
Date:
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Course Overview
Class Standards
The following standards will be used in this class. Standardization allows users
to work with others parts while predicting the organization of the part file. All
work should be performed in accordance with these standards.
About Part File Naming
In order to facilitate the identification of design models without requiring the

user to open a part file, the user community must establish standard names for
the various files associated with the part definition. The following is a sample
usage of a filenaming standard:
part name revision

(25 characters) (4 characters)
xxx_xxxxxxxxxxxx_xxxx_xxxx•prt
identifier configuration extension

(3 characters) (4 characters) (4 characters)
TIP Currently up to 128 characters are valid for file names. A four
character extension (.prt, for example) is automatically added to define
the file type. This means the maximum number of user defined
characters for the file name is actually 124.
Class Part File Naming
This course utilizes the following filenaming standard:
course identifier
(3 characters) part name
smd _ x x x x x x x x x x x x x x x x x x x x . p r t
extension
underscore delimiter (4 characters)
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Course Overview
Where the student is requested to save a part file for later use, the initials of
the student's given name, middle name, and surname replace the course
identifier smd" in the new filename with the remainder of the filename
matching the original.
Seed Part
Seed parts are an effective tool for establishing customer defaults or any
settings that are partĆdependent (saved with the part file). This may include
nonĆgeometric data such as:
Preferences
Commonly used expressions
Layer categories
UserĆdefined views and layouts
Part attributes
TIP Once a seed part is established, it should be writeĆprotected to avoid

accidental modification of the seed part.
A seed part file is available for use in this course. This file incorporate the
standards described above, and include the TFRĆTRI view as the default view.
smd_seedpart (Inches)
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Course Overview
Colors
The following colors are preset to indicate different object types:
Object Valid colors

Bodies
Solid Green
Sheet Yellow
Generating Curves (nonĆsketch)
Lines and Arcs Orange
Conics and Splines Blue
Sketches
Sketch Curves Cyan
Reference Curves Gray
Datum Features Aquamarine
Points and Coordinate Systems White
System Display Color White
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Expressions
The student will notice that there is a standard set of expressions resident in
each of the part files as follows:
Expression Name Intended Use

ANG DO NOT EDIT, this formula identifies the angle
for the JOGGLE
BR identifies outside bend relief
Delta DO NOT EDIT, this is a derived value
H identifies overall height
JOGGLE identifies a joggle offset value
L identifies overall length
R identifies inside bend radii
T identifies material thickness
W identifies overall width
These expressions could be entered by the user in each file or could be a

standard expression file that could be imported into the part file by the user.
Expression files that are valid for importing carry the file extension of .exp. The
total number of characters allowed in an expression is 132.
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Course Overview
Layers and Categories
The student will notice that there are standard layer assignments as well as
standard category names in each of the part files as follows:
Layers 1-100, Model Geometry (Category: MODEL)
Layers 1-14, Solid Geometry (Category: SOLIDS)
Layers 15-20, Linked Objects (Category: LINKED_OBJECTS)
Layers 21-40, Sketch Geometry (Category: SKETCHES)
Layers 41-60, Curve Geometry (Category: CURVES)
Layers 61-80, Reference Geometry (Category: DATUMS)
Layers 81-100, Sheet Bodies (Category: SHEET_BODIES)
Layers 101 - 120, Drafting Objects (Category: DRAFTING_OBJECTS)
Layers 101 - 110, Drawing Borders (Category: FORMATS)
Layers 121 - 130, Mechanism Tools (Category: MECHANISMS)
Layers 131 - 150, Finite Element Meshes and Engr. Tools (Category: CAE)
Layers 151 - 180, Manufacturing (Category: MANUFACTURING)
Layers 161-170, Flat Patterns (Category: FLAT_PATTERNS)
Layers 181 - 190, Quality Tools (Category: QUALITY_TOOLS)
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Course Overview
Platform Specific Dialog Variance (Windows vs Unix)
Most interaction with dialogs is the same on the Windows platform and the
Unix platform. The appearance of some of the controls is slightly different as
shown in the example below. Notice the variance in the display of the slider
bars, check boxes, option menus, etc.
Unix Windows
Graphics shown in this text are from a Windows workstation, some of the
dialogs at your classroom workstation may differ slightly from those shown.
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Course Overview
Unigraphics Interface
Unigraphics utilizes a toolbar interface which is customizable for each user.

Many of the options located under the Menu bar and various cascades can be
accessed by selecting an icon from the appropriate toolbar. It is the intent of
this course to emphasis ease of use". Lessons will introduce functions and
identify their location with respect to toolbars and icons. The session of
Unigraphics that will be initiated has an out of the box" interface, therefore
the Gateway and Modeling applications will be customized through an activity.
Control of Toolbar display may be accessed from one of 3 places:
Choose Tools"Customize from the main menu.

Choose View"Toolbars from the main menu.
Use the Third Mouse Button within the Unigraphics window, outside
the Graphics window.
The display of each toolbar, as well as each element of each toolbar, is user
customizable. To turn ON or OFF the display of a toolbar choose
Tools"Customize or click MB3 in the toolbar area and select Customize.
Placing a check in the box next to the toolbar name will instantly display the
toolbar in the graphics area.
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To turn ON or OFF the display of a toolbar element choose the Commands tab.
Placing a check in the box next to the toolbar command will instantly display
the command in the appropriate toolbar. Removing the check turns off the
display.
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Course Overview
Activity -1: Toolbars in Gateway Application
This activity will demonstrate working with toolbars to establish an efficient

working environment in the Gateway application.
Step 1 Open the part file smd_seedpart.
Choose the Open icon.
Step 2 Display the Standard toolbar in the Gateway Application.
Click Mouse Button 3 (MB3) in the toolbar area and choose

Customize.
Click MB3 within

toolbar area.
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The Customize dialog appears and shows the current toolbars

which are displayed.
Verify that the Standard toolbar is checked ON.
The Standard toolbar should be displayed on the screen docked

in the upper left corner under the Menu bar.
Choose Close to dismiss the Customize dialog.
Step 3 Display the View, Selection and Utility toolbars.
Click MB3 in the toolbar area and verify the View, Selection
and Utility toolbars are checked ON.
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Course Overview
The toolbars are displayed on the screen in an Docked state.

Remember that toolbars may be docked horizontally on the top
or bottom and vertically on the left or right. Locate the toolbars.
View
Selection
Utility
NOTE: Icons may vary for each

toolbar
Locate the Utility toolbar in the Unigraphics window, it may be

docked or undocked.
NOTE: Icons may vary.
Step 4 Move a docked toolbar.

Place the cursor on the handle portion of the Utility toolbar
and press and hold down MB1.
Select Here
Drag the toolbar such that it is aligned under the Standard

toolbar completely to the left side of the window.
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Release MB1.
The Utility toolbar remains docked to the Unigraphics window

in the proper position.
Select the View toolbar on the handle and drag the toolbar
such that it is aligned to the right of the Standard toolbar.
Locate Here
Select the Selection toolbar on the handle and drag the

toolbar such that it is aligned to the right of the Utility
toolbar.
Locate Here
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Course Overview
Step 5 Display the Application toolbar in the Gateway

Application.
Click MB3 in the toolbar area and check ON the Application

toolbar.
Click MB3 within

toolbar area.
Checked ON
Locate the Application toolbar in the Unigraphics window, it

may be docked or undocked.
NOTE: Icons may vary.
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Step 6 Customize the Application toolbar.
Click MB3 in the toolbar area and choose Customize.
Select the Commands tab and highlight Application in the

Toolbars column.
Select these
options
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Course Overview
A listing with the commands for the Application toolbar is

displayed. The commands displayed on the toolbar are checked
in the Commands column.
Scroll down to see all of the options in the Commands

column. Turn ON the Modeling, Drafting and Assemblies
commands and turn OFF all others options. Also, turn ON
the Separator above the Assemblies command.
Scroll
down
here
Note that the display of the toolbar changes immediately upon

selection of commands.
Locate the Application toolbar as shown below.
Locate here
These toolbar settings will be retained for the Gateway

application for the rest of the course.
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Course Overview
Activity -2: Toolbars in Modeling Application
This activity will establish toolbars in the Modeling application for use in
conjunction with sheet metal features.
Step 1 Enter the Modeling Application.
Select the Modeling icon in the Application toolbar.
Entering a different application will introduce a new set of

toolbars. The toolbars that were established in the Gateway
application may move and have different commands in them.
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Course Overview
Step 2 Display the common toolbars from the Gateway

application.
Click MB3 in the toolbar area and verify that the Standard,
View, Selection, Utility and Application toolbars are checked
ON. Turn OFF all other toolbars. Other toolbars will be
turned ON throughout the course as they are needed.
Dock the toolbars in similar locations as defined in the

Gateway application.
Step 3 Customize the toolbars.
Select the Commands tab and adjust the toolbars to match

the commands in the table below.
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Course Overview
Toolbars Standard View Selection Utility Application

Select
Work
New Refresh General Drafting
Layer
Objects
Select Layer
Open Fit Assemblies
Features Settings
Select
Save Zoom Separator Gateway
Components
Zoom WCS
Separator Separator
In/Out Dynamics
Commands Delete Rotate Type Filter Orient
Undo Pan Reset WCS
Separator Separator Separator
Wireframe
Information Select All
Settings
Shaded
Deselect All
Settings
Wireframe Separator
View Up One
Orientation Level
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Course Overview
Step 4 Display additional toolbars in the Modeling application.
Click MB3 in the toolbar area and turn ON the Form

Feature, Feature Operation, Edit Feature and Modeling
Toggles toolbars.
Form Feature
Feature Operation
Edit Feature
Modeling Toggles
NOTE: Icons may vary for each

toolbar
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Course Overview
Dock the toolbars horizontally or vertically in the locations

defined below.
Modeling
Feature Edit Feature Toggles
Operation
Form
Feature
Step 5 Customize the toolbars.
Select the Commands tab and adjust the toolbars to match

the commands in the following table.
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Course Overview
Form Feature Edit Modeling

Toolbars
Feature Operation Feature Toggles
Form
Edit Feature
Sketch Taper Feature
Parameters
Toolbar
Feature
Edit
Extruded Body Edge Blend Operation
Positioning
Toolbar
Edit
Revolved Body Edge Chamfer Move Feature Feature
Toolbar
Sheet Metal
Sweep along
Hollow Separator Feature
Guide
Toolbar
Instance Suppress
Separator
Feature Feature
Unsuppress
Hole Offset Face
Feature
Boss Separator Separator
Commands Delay Update
Pocket Trim Body
on Edit
Pad Separator Update
Slot Unite Separator
Feature
Groove Subtract
Playback
Separator Intersect
User Defined
Feature
Separator
Datum Plane
Datum Axis
Datum CSYS
Separator
Block
Cylinder
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Step 6 Leave the part open, it will be used again in the next
activity.
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Course Overview
The Sheet Metal Feature Toolbar
Within the Modeling application, sheet metal feature creation is accomplished

through the use of a dedicated toolbar. This arrangement permits the user to
remain within the modeling environment for the duration of the design process
and allows for the creation of sheet metal features which are associated to their
base model geometry.
One way to retrieve the Sheet Metal Feature toolbar it is to click MB3 in the
grey area next to any existing toolbar and selecting Sheet Metal Feature. In the
previous activity we turned on the Modeling Toggles toolbar and included the
icon for Sheet Metal Features. This icon can be conveniently selected to turn
ON and OFF the Sheet Metal Feature toolbar.
#1 Ć Click MB3 here
Sheet Metal
Feature toolbar
toggle
#2 Ć Click MB1 here
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Course Overview
Nineteen sheet metal features are currently available for use. They are shown
in the figure below. In addition, a Form/Unform button allows any or all of the
formable features (e.g. flange, inset flange, profile flange, general flange, or
smbend ) to change their formed or unformed state while remaining within the
Modeling application. Information and activities have been included in this
manual for all the sheet metal features except Sheet Metal Routed Relief, Sheet
Metal Strain and Metaform.
Inset Flange
Flange
Sheet Metal Hole

Profile Flange Sheet Metal Slot
Sheet Metal Cutout
Multibend Bracket
Sheet Metal Corner
General Flange Sheet Metal
Sheet Metal Bridge Solid Punch
Bead
Sheet Metal Punch
Sheet Metal Bend
Unbend/Rebend
Metaform
Form/Unform Sheet Metal Strain

Routed Relief
Sheet Metal Bracket
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Course Overview
Activity -3: Sheet Metal Toolbar in Modeling Application
This activity will turn ON the Sheet Metal Feature toolbar in the Modeling
application.
Step 1 Continue using the part file smd_seedpart and ensure the
Modeling application is turned ON.
Step 2 Turn ON the Sheet Metal Features toolbar.
Select the Sheet Metal Features icon in the Modeling Toggles

toolbar as shown below.
Click here
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Locate the toolbar as shown below.
Sheet Metal Feature
Step 3 Choose File"Close"All Parts, do not save.
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Preferences and Standards
Preferences and Standards ÏÏÏ

Lesson 1
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
PURPOSE Create sheet metal standards and preference defaults

to ensure design for manufacturability goals are
concurrent throughout the company, division and/or
department.
OBJECTIVES Upon completion of this lesson, you will be able to:
Set up the Sheet Metal Preferences dialog

Turn on the Sheet Metal Feature toolbar.
Retrieve the default standards file for sheet metal
design
Retrieve a part file's construction preferences and
determine its standards usage
This section contains the following activity:
Activity Page
1-1 Reviewing Preferences and Standards . . . . . . . . . . 1-11
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1-1
ÏÏÏ Sheet Metal Preferences

ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Before beginning your part development, it's a good practice to always set up
and verify your sheet metal default preferences. Attempting to change these
preferences in the middle, or after completion of your design may result in
unĆmanufacturable parts or inaccurate flat pattern definitions.
With the implementation of sheet metal features, provisions are available to

allow for the establishment of standard values applied at the time of the feature
creation. These standards are called part standards and feature standards, and
are contained in a Standards default file (ugsmd_def.std). Part standard
parameters are attributes or expressions used throughout the sheet metal
design process. They include characteristics like material type and thickness.
Feature standards are used to define the size of the feature, and vary for each
sheet metal feature. Typical feature standards are flange width, bend angle,
bend allowance formula, and diameter (for sheet metal holes).
While in the Modeling application, sheet metal part and feature standards can
be controlled through the Sheet Metal Preferences dialog accessed by selecting
Preferences→Sheet Metal (shown in the figure below). While in the Sheet
Metal Design application, you can also access the dialog from
Preferences→SMD General.
EDS Unigraphics NX
1-2 Sheet Metal Design
ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
All options are toggled ON for clarity
Global Parameters
The Sheet Metal Preferences dialog will allow you to set global parameters,
such as material thickness, bend radius, bend angle, and bend allowance
formula. This will reduce the number of parameters you need to enter while
creating sheet metal features. When you set any of these global parameters, all
of the sheet metal features that have these parameters will be created using the
global values. The widget for that parameter will not be available on the
feature's dialog. Default values and options for sheet metal feature dialogs are
contained within a Standards default file (ug_smd.def).
For example, if your company uses a standard bend allowance formula, enter
that formula on the Global Parameters dialog. When you open the Flange
dialog to create a flange, the Bend Allowance Formula button will no longer
appear on the dialog. The default Bend Allowance formula is also defined in
the ug_smd.def file.
If you want to turn off the Global Parameters for a single feature, you can
access Global Parameters from the individual feature's options dialog.
EDS
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Sheet Metal Design
Student Guide
1-3
ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ Reference Line Color
During the creation of flange geometry, you can create mold lines, form block
lines and/or contour lines for each Flange, Inset Flange and General Flange.
This option allows you to select the display color for these reference lines. With
this preference setting, you will have the capability to blank these lines by their
color designation before importing the flat pattern into a drawing.
Part Materials
The list of Part Materials displayed is derived from the Standards default file.
The material characteristic is a part attribute that is used to define feature
standards with respect to material qualities. Selecting a material type from the
displayed list will load the type into the Default Material field. Again,
userĆdefined material types can be added to the list by editing the Standards
default file.
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ÏÏÏ
ÏÏÏ
Default Material
ÏÏÏ
1
ÏÏÏ
The material type specified in this field will determine available feature
standard options like thickness, inside bend radii, and bend angles. The initial
default material type is assigned within the ug_smd.def file.
NOTE Although material type is a part standard, it is not used

for any calculations (e.g. mass) nor does changing this
attribute have any effect on the part's geometry. This
attribute is only used to define what feature standards are
available for a given parameter.
Load Standards
This button allows you to load a properly formatted standards file from a
specified directory. When selected, the system will prompt you to enter the
appropriate file for loading. This is a useful way to update available standard
options and values during working sessions.
Use Feature Standards
Toggling this preference option ON allows the user to select from a list of
standard values for specific feature parameters during the feature creation.
Toggling this option OFF forces the user to manually enter the feature
parameter values.
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Student Guide
1-5
ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ Check Standards on Create
NOTE This option is only active if a standards file is installed

under the Load Standards button and the Use Feature
Standards option is toggled ON.
When toggled ON, this option causes the system to check entered feature
parameters against feature standards. When OK or Apply is selected on the
sheet metal feature creation dialog, the system will compare entered values
against feature standard values. If the values do not match, a warning will
display. This warning lists the nonĆstandard parameters and will allow you to
continue or go back to the feature creation dialog. If there are multiple values
that are not standard, they will all be listed.
If you choose OK, the system will create the feature using the nonĆstandard
values. Selecting Back will allow you to return to the feature creation dialog
and correct the values for the nonĆconforming parameters.
Enforce Creation State Editing
This option is used to enable or disable the ability to edit the parameters or
position of a sheet metal hole, slot or cutout when the model is in a state other
than the original feature creation state.
EDS Unigraphics NX
ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Forming Method
This option allows you to control how new Straight Brake and Solid Punch
features are formed and unformed. The option can be set to Use Self-Forming
Features or Use Forming Operators.
If the option Use Forming Operations is checked, Straight Brake and Solid
Punch features you create will not be listed in the Form/Unform dialog. The
way to get these features to Form or Unform is to create Unbend and Rebend
features on their cylindrical faces. If the option Use Self-Forming Features is
checked, Straight Brake and Solid Punch features you create will be listed in
the Form/Unform dialog.
Sequential Processing
Toggle this option ON or OFF to control the processing of groups or items in
Part in Process. If it is processed sequentially then the selected item and
everything above it in the tree list will be formed. Non-sequential will only
form the selected object. Information on Part in Process can be found in the
Appendix.
Bracket Margin
The bracket margin is used in the Sheet Metal Bracket utility. During
construction of a bracket, the system creates a base pad that is trimmed to the
proper size. The original base pad's size is determined by the intersection curve
and the clearance distance dimension. The Bracket Margin value is a
percentage used to increase these dimensions. It only affects the size of the
original base pad and not the final bracket. You should increase this margin if
the Bracket outline curves do not lie entirely on the base pad.
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Student Guide
1-7
ÏÏÏ Defining Standards

ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Sheet Metal Design uses a Standards file named ugsmd_def.std to manage
material standards such as material types, BAFs, and thicknesses. This file also
manages feature standards for defining the size of each sheet metal feature. If a
sheet metal feature has standard values defined, it will have an active arrow
next to the input field. You can access the standard values by selecting the
arrow button. A list containing the standard values for that parameter will
appear. Selecting a value from this list will cause the system to insert it into the
parameter field.
Notice the arrow indicator is

highlighted. This means there is an
available list of standard values.
NOTE Remember, these selection arrows are only active if the

Use Feature Standards option is toggled ON in the Sheet
Metal Preferences dialog.
The ugsmd_def.std and ug_smd.def files are read when the Modeling or Sheet
Metal Design applications are first entered and every time you create sheet
metal features. The ugsmd_def.std file can be reloaded at any time by using the
Load Standards button on the Sheet Metal Preferences dialog.
Proper use of both standards files can ensure that only correct material
properties and feature standards are used per your design and manufacturing
specifications.
EDS Unigraphics NX
Checking Standards ÏÏÏ

ÏÏÏ
Within the Sheet Metal Design application, two methods are available to check
your part against the defined standards.
ÏÏÏ
1
ÏÏÏ
Two ways to
verify part
standards
You can use Information→Check Feature Standards to compare parameters of

a selected sheet metal feature against the feature standards. Or you can use
Information→Check Entire Part Standards to compare all sheet metal feature
parameters against the feature standards defined in the Standards file.
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Student Guide
1-9
ÏÏÏ Choosing the Check Feature Standards option brings up the Feature Selection
ÏÏÏ dialog. You can select one or more features from this dialog. With either check
ÏÏÏ
1
ÏÏÏ
option, an information window displays the results of the standards check.
A PASS is reported if the feature parameter value conforms to the established

standards list. A FAIL is reported if the value does not conform. If a feature
standard option was not implemented during the feature construction, or no
standards list for that parameter was loaded in the Standards file, the system
will return a Warning message.
EDS Unigraphics NX
Activity 1-1: Reviewing Preferences and Standards ÏÏÏ

ÏÏÏ
ÏÏÏ
1
ÏÏÏ
In this activity you will examine the Sheet Metal Preferences dialog and check a
part file's standards usage.
Step 1 Open and review a model's sheet metal preferences
Open the part smd_prefs.
Enter the Modeling application.
Step 2 Set your Preferences and load a standards file.
Check the default preferences by selecting

Preferences→Sheet Metal.
NOTE The directory containing the sheet metal design

Standards file is specified by an environment variable
(UGII_UGSMD_STDS_LIBRARY). See your instructor
if you need further information.
Set the default material to aluminum by selecting aluminum

in the Part Materials list.
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1-11
ÏÏÏ Ensure the Use Feature Standards option is turned OFF.

ÏÏÏ
ÏÏÏ
1
ÏÏÏ
NOTE The Check Standards on Create/Edit option is

automatically made unavailable if the Use Feature
Standards button is turned OFF.
Choose OK in the Sheet Metal Preferences dialog.
Step 3 Check a flange's feature creation parameters.
Choose the Edit Feature Parameters icon from the

Edit Feature toolbar.
Select FLANGE(2) from the Edit Parameters dialog.
Choose OK.
EDS Unigraphics NX
Notice that the feature standard arrows are not activated

ÏÏÏ
(they're grayed out).
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Standards are not selectable
Feature standards are not available for selection because the

Use Feature Standards option was toggled OFF in the Sheet
Choose Cancel.
Step 4 Enable feature standards.
Choose Preferences→Sheet Metal.
Toggle the Use Feature Standards option ON.
Choose OK.
Choose the Edit Feature Parameters icon again.
Select FLANGE(2) and OK.
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1-13
ÏÏÏ Now you can select the arrow to display a list of standard values
ÏÏÏ for that feature parameter.
ÏÏÏ
1
ÏÏÏ
Cancel out of the Flange dialog.
Step 5 Check feature standards.

To verify part features against specified standards you must first
enter the Sheet Metal Design application.
Choose Application→Sheet Metal→Design...
Choose Information→Check Feature Standards...
EDS Unigraphics NX
Select FLANGE(2) and OK.

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Warnings were issued for WIDTH and LENGTH because no

default standards were loaded into the ugsmd_def.std file for
these parameters.
Step 6 Choose File"Exit in the Information window and close

your part.
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Sheet Metal Design
Student Guide
1-15
ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
SUMMARY Use standards and preference defaults to

maintain design for manufacturability goals
throughout your company, division or
department.
In this lesson you:

Turned on the Sheet Metal Feature icons
Set up the SMD Preferences dialog
Retrieved the default standards file
Determined a part file's standards usage
Compared the Modeling environment to the
Sheet Metal environment
EDS Unigraphics NX
Flange
Flange
Lesson 2
PURPOSE Create and edit sheet metal flanges using the Flange
sheet metal feature
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Create and edit flanges

Add taper angles and mitered corners to flanges
Create expressions to customize flange creation
methods
Add and properly locate modeling features on
flanges
Activity Page
2-1 Creating Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-2 Creating a Butt Joint . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-3 Working with Miters . . . . . . . . . . . . . . . . . . . . . . . . 2-62
EDS
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2-1
Flange
Flange
The sheet metal Flange feature allows for the parametric control and creation
of a straightĆbrake flange along a planar placement face. Because parameters
are used in the creation of all sheet metal features, they can be parametrically
edited like any other modeling feature using the Edit Feature Parameters icon.
ÏÏÏ
ÏÏÏ
2
Upon selecting Insert→Sheet Metal Feature→Flange, or the Flange icon
from the Sheet Metal Feature toolbar, the Flange dialog is displayed and the
ÏÏÏ
ÏÏÏ
system prompts you to choose a bend edge. To edit a Flange, use Edit→Feature
or the Edit Feature toolbar.
TIP The edge selected on a thickness face represents the

bend side of the flange.
Select this Bend

Edge
Select this Bend

Edge
EDS Unigraphics NX
Flange
The Flange Dialog
Flange Profile
Inputs
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Flange Profile Inputs
These inputs can be manually loaded or a standard value can be chosen from an
active arrow button inside the parameter field. Remember, these arrow buttons
are only active if the Use Feature Standards option is toggled ON in the Sheet
Any grayed out input field will derive their values from internal system
information. The status of these input fields (active or inactive) can be
controlled through the Options icon.
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2-3
Flange
Width
Initially, the Width type is set to Infer Width and is inferred from the
highlighted face. The width is measured by the actual length of the bend edge.
In addition, when this option is set to Infer Width, the Width parameter is
grayed out and not available.
The flange parameter value can be switched to the Width Expression condition
which allows for a specific value or valid expression to be manually entered into
the parameter field.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Width
Expression
Inferred
Width
NOTE When the Width option is set to Width Expression, the

Positioning Method is set to Manual. The Positioning Method
can be set back to Automatic, if desired.
EDS Unigraphics NX
Flange
Positioning Method
There are two methods for positioning a flange on a planar face: automatically
and manually. If flange positioning is set to Automatic, the system will line up
the flange with the planar placement face, and will create a parallel distance set
to zero and vertical positioning dimensions. If you select a Manual position
option you will be prompted to provide positioning dimensions. The Manual
position option is best used for flanges with userĆspecified widths.
NOTE The system will always initially locate the flange against the
edge of the face which was associated with the bend direction ÏÏÏ
ÏÏÏ
2
vector.
ÏÏÏ
ÏÏÏ
Perpendicular or Under Constrained
Horizontal
Horizontal combined with Vertical
Fully Constrained
Line onto Line or Parallel @ a Distance
combined with
Perpendicular or Horizontal
Over Constrained
Line onto Line or Line onto Line or Parallel @ a Distance

Parallel @ a Distance (Horizontal combined with
Reference) Line onto Line or Parallel @ a Distance
Examples of positioning dimensions used to

manually locate a feature
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2-5
Flange
Length
The length of the flange can be defined in one of three ways. The figure below
depicts the three methods for measuring length . The default length type is set
to Tangent Length.
Bend Area
Lengths are measured
ÏÏÏ
ÏÏÏ
2
parallel with the web of
the flange
Contour
ÏÏÏ
ÏÏÏ Web
Area
Tangent
Length
Length
Contour / DIN
Tangent
Tangent
Bend Angles < 90 DIN
Contour
Bend Angles > 90
NOTE To create a flange with no web area you must use Tangent
Length and set the length equal to zero. If a length of zero is
used for Contour Length the system will generate a warning
message.
EDS Unigraphics NX
Flange
Angle
Angle represents the angle of the flange in the formed state. This angle can be
set to specify a bend angle or an included angle. The default angle type is Bend
Angle.
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2
ÏÏÏ
ÏÏÏ
Bend Angle Included Angle
NOTE The maximum angular value is limited by the selfĆintersection

of the flange bend segment with the attachment body.
Maximum bend angle limited

by selfĆintersection.
Bend
Angle
NOTE The Angle field is removed from the dialog if the Global
Parameters option of Use Global Angle is toggled ON inside
Preferences"Sheet Metal.
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Student Guide
2-7
Flange
Radius
Radius is the radial value of the cylindrical surface representing the bent
portion of the flange. Either the inside or the outside radius value can be
specified. The default radius type is Inside Radius.
NOTE The Outside radius value must be greater than the thickness of
the part or the system will issue an error message.
ÏÏÏ
ÏÏÏ
2
NOTE The Radius field is removed from the dialog if the Global
Parameters option of Use Global Bend Radius is toggled ON
ÏÏÏ
ÏÏÏ
inside Preferences"Sheet Metal.
Bend Allowance Formula (BAF)
When you click on the Bend Allowance Formula button, the following dialog
will appear:
The BAF originally loaded in the Sheet Metal Preferences dialog will
automatically be loaded as the flange default Bend Allowance Formula. A new
BAF can be selected from the Bend Allowance Formulae list box, or a
userĆspecified formula can be directly entered into the BAF field.
NOTE The Bend Allowance Formula button is removed from the

dialog if the Global Parameters option of Use Global is toggled
ON inside Preferences"Sheet Metal.
EDS Unigraphics NX
Flange
Flip Bend Direction
When you select a bend edge during the initial flange creation process, the
system automatically selects a bend direction for the flange. This direction is
displayed on the graphics screen as a vector located against the left edge of the
highlighted face. The Flip Bend Direction icon allows you to flip the vector
direction, thereby reversing the bend direction and left edge of the flange.
ÏÏÏ
ÏÏÏ
2
Adjacent Face
ÏÏÏ
ÏÏÏ
When you select a Bend Edge during the initial flange creation process, the
system automatically selects one of the two faces next to the Bend Edge. By
selecting the Adjacent Face icon, you can toggle between the two faces.
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Student Guide
2-9
Flange
Options
Selecting the Options icon within the Flange dialog activates the Options
dialog. Within this dialog, there are three tabs which access various options
used to derive feature parameters, side options and the use of global
parameters.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
NOTE The Options dialog may be accessed repeatedly, and

parameters changed, throughout the flange creation process.
EDS Unigraphics NX
Flange
Parameter Options
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Thickness
Initially, the value for the thickness is inferred from the highlighted face. The
thickness is measured perpendicular to the selected bend edge. In the Options
dialog, under the Parameters Options tab, this is the Infer Thickness from Edge
condition.
The thickness condition can be switched to the use an expression condition by

turning OFF the Infer Thickness from Edge option, which allows for a specific
value or valid expression to be manually entered into the parameter field.
NOTE The Standard arrow may also be selected to specify a thickness

if the Use Feature Standards option is turned ON in the Sheet
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2-11
Flange
Reference Lines
Contour lines, mold lines and form block lines can be generated for each flange
so that other features, such as holes or slots, can be positioned from these
reference lines.
The mold line of a flange is represented by the intersection of the base plane of
ÏÏÏ
ÏÏÏ
2
the part with a plane parallel to the placement face and tangent to the farthest
point of the flange bend face. Mold lines may only be created for flanges with
ÏÏÏ
ÏÏÏ
bend angles greater than 90 degrees.
Base Plane
Mold line
Plane parallel to the

placement face.
Contour lines are defined by the intersection of the base plane with the plane of
the web, and can be created for flanges with bend angles from 1 to 135 degrees.
Form block lines are similar to a contour lines except that they apply to the
inner surfaces of the Flange. Form block lines can only be applied to Flanges
whose angles have an absolute value less than 135 degrees.
EDS Unigraphics NX
Flange
NOTE Because reference lines are statically positioned relative to the

base feature and the flange in the formed state only, reference
lines should be used to position features on the base faces
adjacent to the flange, and not the flange itself.
Contour line Mold line
ÏÏÏ
ÏÏÏ
2
Contour line
Flange (Typ)
ÏÏÏ
ÏÏÏ
Form block line
These reference lines may be generated separately, together, or not at all

during the flange creation stage and, because they are associated to the flange,
they will update if the flange parameters change.
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2-13
Flange
Side Options
Left and Right Settings
The Left and Right settings include None, Taper, Simple Miter, Full Miter and
Butt. None is the default and produces simple straight and square sides on the
flange.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Taper
Tapers can be added to each side of your flange, and can have parametric
values independent from each other. That is, the right side of the flange can
have a taper value which is different from the left.
The left and right side designation of a flange is governed by a front view, bent
down orientation. Positive angular taper values cause the flange to be trimmed
inward along the length of the flange. Negative angular values taper the flange
outward.
Right side
of flange
Left side
of flange
Negatively Positively
Straight Flange
Tapered Flange Tapered Flange
EDS Unigraphics NX
Flange
Tapers can be implemented in three different ways: along the bend of the
flange, along the web of the flange, and along the total length of the flange. A
totally tapered flange has angular values in both the Bend and the Web input
fields. Independent tapers can be specified for the bend area and web of a
totally tapered flange.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
WebĆtapered BendĆtapered Totally Tapered
Flange Flange Flange
When Taper is selected, text fields will appear below the Left or Right Settings
columns in the Options dialog. These text fields allow input of a Bend Taper
Angle and/or a Web Taper Angle.
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Flange
Miter
When Simple Miter is selected, text fields will appear below the Left or Right
Settings columns in the Options dialog. These text fields allow input of a Miter
Angle, Phase or Relief. These options will be discussed later in this lesson.
When Full Miter is selected, text fields will appear below the Left or Right
Settings columns in the Options dialog. These text fields allow input of a Miter
Angle or Miter Phase. These options will be discussed later in this lesson.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Butt
Butt adds an extension to the side or sides of a flange so the web portions of the
flanges butt" up against each other. This option is ideal for flanges which meet
at a common corner and are bent at 90 degree angles. In earlier versions this
was accomplished using a Pad feature or an extrusion.
NOTE For flanges that meet at a common corner and are not bent at
90 degrees use the Sheet Metal Corner feature. The Sheet
Metal Corner feature will be discussed later in the course.
When Butt Joint is selected, a text field will appear in the Left or Right Side
Parameters window in the Flange dialog. These text fields allow input of a Butt
Length extension.
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Flange
ÏÏÏ
ÏÏÏ
2
Butt Joint
ÏÏÏ
ÏÏÏ
Butt Joint
Global Preferences
You can toggle the Global Parameters ON and OFF here. Global Parameters
are selectable only if the options are ON in the Sheet Metal Preferences.
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2-17
Flange
Confirm Upon Apply
Checking the Confirm Upon Apply button will add a chance for the user to
verify their selection before creating the flange.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
EDS Unigraphics NX
Flange
Flange Instancing
It is possible to create instances of a straight brake flange by using the
Insert→Feature Operation→Instance function. However, like all other
instances, the resultant flanges are directly linked to the master, or parent,
flange. Thus, trying to form or unform any one of the instances will cause all
instances, plus the master, to form or unform.
Flanges and Inset Flanges are currently the only Sheet Metal Features that can
be instanced. Sheet metal features such as SMHOLE and SMCUTOUT can be
ÏÏÏ
added to the master flange before or after instancing has occurred. However, in
neither case will the added feature be reflected in the resultant flange
instances. These features have distortion characteristics which are dependent ÏÏÏ
2
on the original placement face. Trying to instance these features would cause
inaccurate deformation profiles for each instance.
ÏÏÏ
ÏÏÏ
Sheet metal features can be individually added to each flange instance if
necessary. Any properly located Modeling Feature, such as Holes, Bosses, Slots,
Pockets, or Pads can be instanced with the underlying flange.
Flange parameters and instance array parameters can be edited in the normal
manner using the Edit Feature Parameters icon.
NOTE Modeling Holes and Slots can be instanced then converted to

Sheet Metal Features. This will be covered later in the course.
Master Flange
Flange
Flange Instancing instances
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Flange
Activity 2-1: Creating Flanges
In this activity you will create and edit sheet metal flanges. You'll also attach
other model features to the created flanges.
Step 1 Open the part smd_flange. Save this part as xxx_flange

ÏÏÏ
ÏÏÏ
2
where xxx are your initials.
ÏÏÏ
ÏÏÏ Step 2 Set up your default preferences.
Ensure you're in the Modeling application.
Open the Sheet Metal Preferences dialog.
Choose Global Parameters.
Toggle ON Use Global Thickness.
Set the Thickness option to Use Expression.
Enter .080 for the Thickness.
Confirm your settings and choose OK.
Select aluminum in the Part Materials window.
EDS Unigraphics NX
Flange
Toggle ON Use Feature Standards.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Choose OK again to accept the preference settings.
TIP A seed partfile can be created which already

contains your company's sheet metal preferences
such as bend angle formulas and inside radius
standards. Use of this seed file would ensure
accurate initial design parameters are employed
from the beginning of the design effort.
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2-21
Flange
Step 3 Create the body of the part.
Choose the Extruded Body icon from the Form Feature
toolbar.
Select the sketch in the graphics window.
Choose MB2.
ÏÏÏ
ÏÏÏ
2
Accept the default extrusion method of Direction _Distance
by choosing MB2.
ÏÏÏ
ÏÏÏ Choose MB2 to accept and create the extrusion vector.
Ensure vector is
pointing up.
Enter a Start Distance of 0 and an End Distance of .080
EDS Unigraphics NX
Flange
Choose MB2.
Select Cancel in the Extruded Body dialog.
For clarity, make the SKETCHES and DATUMS layers

invisible.
Step 4 Create the first flange.
Choose the Flange icon. ÏÏÏ

ÏÏÏ
2
Notice that the message in the Cue Line is prompting you to
select the Bend Edge of the Flange. ÏÏÏ
ÏÏÏ
Select the top back edge of the part.
Select this edge
TIP The edge you select determines the initial bend

direction of the flange.
A vector arrow will appear in the corner of the part to indicate

the bend direction of the flange.
LEFT
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Flange
TIP You can change the vector direction at any time

while you're creating the flange by selecting the Flip
Bend Direction button in the Flange dialog.
Notice in the Flange dialog the Width field is grayed out.
ÏÏÏ
ÏÏÏ
2 The Width parameter
ÏÏÏ
ÏÏÏ
input field is grayed
out.
The Width input field was initially set to Infer Width. For now
we'll accept the default values.
Ensure the Tangent Length is set to 2.00 .
Change the Bend Angle to 90.
Choose the standards arrow for the Inside Radius field.
Notice the available values, these values are stored in the

default file ugsmd_def.std.
EDS Unigraphics NX
Flange
From the Standard Values list choose 0.125 and then MB2.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Leave the remaining parameters at their default values, and
create the flange by selecting OK.
Your part should look like this:
Step 5 Create a tapered flange.
Choose the Flange icon.
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2-25
Flange
Select the bottom back edge of the part.
Select this edge
ÏÏÏ
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2
ÏÏÏ
ÏÏÏ
The flange bend direction vector should be pointing down.
Change the flange bend direction by choosing the Flip Bend
Direction icon.
Choose the Options icon.
Choose the Side Options tab.
EDS Unigraphics NX
Flange
Change the Left Settings to Taper.
Insert 45 into the Web Taper field.
Set Left Setting to Taper
ÏÏÏ
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2
ÏÏÏ
ÏÏÏ
Choose OK.
Now you'll use the thickness and bend radius parameters to

define the length of the flange.
Change the length option from Tangent Length to Contour

Length.
Change the Contour Length value to the mathematical

expression: 2.00+.08+.125
Set to Contour Length
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2-27
Flange
TIP Expressions can be created for flange parameters

such as R for bend radius or T for flange thickness.
These expressions can then be inserted into any
parameter input field.
Choose OK to create the flange.
Your part should look like this:
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Step 6 Create a flange tab.
EDS Unigraphics NX
Flange
Select the top back edge of the new flange for the Bend
Edge. The flange direction vector should be pointing away
from the body of the part.
Select this edge
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Change the length option from Contour Length to Tangent

Length.
In the Side Options tab, verify the Left Settings is set to

None.
Also verify the Right Settings is set to Taper.
Insert 45 into the Bend Taper field.
If necessary, change the Web Taper to 0.
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2-29
Flange
Your Options dialog should look like this:
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Choose OK.
Insert a Tangent Length value of .80
Your Flange dialog should look like this:
EDS Unigraphics NX
Flange
Choose OK to create the tab.
ÏÏÏ
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2
ÏÏÏ
ÏÏÏ
Step 7 Create a custom width flange.
Select the top far edge of the straight flange for the Bend
Edge.
Select this edge
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2-31
Flange
In the Side Options tab, change the Right Settings option to

None.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Choose OK.
Change the width option from Infer Width to Width

Expression.
Change the Width value in the Flange dialog to .50
EDS Unigraphics NX
Flange
Verify the Positioning option is set to Manual.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Choose OK.
Because a manual positioning method was selected, you are

prompted to provide positioning dimensions.
CAUTION It is imperative that the flange location is sufficiently

specified by constraining at least two edges of the flange. Insufficiently
constrained flanges may fail to position properly when the part is
unformed.
Choose the Line onto Line positioning icon.
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Flange
Select the target edge, then the flange tool edge as shown.
Select this edge for

both the target edge
and tool edge.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ Choose the Perpendicular icon from the Positioning dialog.
Select the target edge, then the flange tool edge as shown.
TIP You may have to zoom up on the area to grab your target
and tool edges.
Select this edge for

both the target edge
and tool edge.
Enter 1.0 into the Create Expression text field.
EDS Unigraphics NX
Flange
Choose OK.
An error message is displayed, warning you that the tool body

was positioned outside of the target body.
ÏÏÏ
ÏÏÏ
2
When overlapping edges are used as positioning edges, a
negative value must be supplied in order to move the feature in
the desired direction.
ÏÏÏ
ÏÏÏ
Choose OK inside the message window.
Repeat this step except this time use Ć1.0 instead of 1.0 for
the Perpendicular dimension.
TIP The flange parameters should already be set up with

the previous inputs.
Your part should look like this when you're finished:
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2-35
Flange
Step 8 Edit a Flange feature.
Ensure the Selection toolbar is set to Select Features.
Select Features
ÏÏÏ
ÏÏÏ
2
In the graphics window, double-click on the center flange.
ÏÏÏ
ÏÏÏ
Choose this flange
Change the Width parameter to .80
Choose OK.
In the graphics window, select the center flange again.
Place the cursor over the flange and select MB3.
Choose Edit Positioning from the Pop-Up window.
Choose Edit Dimension Value.
Select the Perpendicular dimension and change the value

from -1.0 to 0.
EDS Unigraphics NX
Flange
Choose MB2 three times. The flange will update to the new
dimension and location specifications.
ÏÏÏ
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2
ÏÏÏ
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Step 9 Add a pad to the flange.
Choose the Pad icon.
Choose MB2 to accept the Rectangular default.
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2-37
Flange
Select the far side of the straight flange as the placement

face.
Select the
thickness" face.
ÏÏÏ
ÏÏÏ
2 Select this front edge
ÏÏÏ
ÏÏÏ
as the horizontal
reference.
Hint: Select the

lower side of the
midpoint of the edge
to help position the
feature.
Select the front edge of the face as the horizontal reference.
Insert the following Rectangular Pad parameters:
Length = 1.00
Width = .08
Height = .25
Choose OK.
EDS Unigraphics NX
Flange
Position the pad .50 inches horizontally and 0 inches

vertically from the edges of the base flange. (Hint: Use Line
onto Line and Perpendicular)
ÏÏÏ
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2
ÏÏÏ
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Step 10 Add a stiffening flange.
Select the inside edge of the pad as the Bend Edge. The
flange direction vector should be pointing to the right.
Set the Tangent Length to 0 .
Notice the Width input field is selectable. The system retains

the length of the placement face from the prior step. You can
correct the width to 1.00 or.....
Change the width option back to Infer Width.
Notice the Width input field is now grayed out.
Verify the Positioning option is set to Automatic.
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2-39
Flange
Tab Stiffening
flange
ÏÏÏ
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2
ÏÏÏ
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Step 11 Add blends.
Using the blend feature, add .25 inch blends to the tab
corners.
Add .125 inch blends to the inside edges of the stiffening

flange.
EDS Unigraphics NX
Flange
When you're finished, your part should look like this:
2X R .125 4X R .25
ÏÏÏ
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2
ÏÏÏ
ÏÏÏ
Step 12 Choose File"Close"Save and Close.
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2-41
Flange
Activity 2-2: Creating a Butt Joint
In this activity you'll start with a seed partfile and create a formable box with
butt jointed flanges.
Step 1 Open the partfile smd_seedpart. Save this part as

ÏÏÏ
ÏÏÏ
2
xxx_buttjoint where xxx are your initials.
ÏÏÏ
ÏÏÏ Step 2 Change the default variables of the seedpart.
Ensure you are in the Modeling application.
Select Tools→Expression...
Choose the T variable and change the value to .060.
Choose the R variable and change the value to 1/16.
Choose the L variable and change the value to 6.00.
Choose the W variable and change the value to 4.00.
Choose the H variable and change the value to 2.00.
Select OK.
Step 3 Change the default material for the part.
Choose Preferences→Sheet Metal
EDS Unigraphics NX
Flange
Enter T for the Thickness.
Toggle ON Use Global Bend Radius.
Enter R for the Bend Radius.
ÏÏÏ
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2
ÏÏÏ
ÏÏÏ
Confirm your settings and choose OK.
Step 4 Create the base feature.
Choose the Block icon.
Notice the default block option is set to Origin, Edge

Lengths. The base feature will be created using this option.
Enter the following parameters:
Length (XC) = L-2*T-2*R

Width (YC) = W
Height (ZC) = T
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2-43
Flange
Choose MB2 to create the block at the default 0,0,0 location

and Fit the part to the graphics display.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ Step 5 Create a flange with edge extensions using the Butt Joint
option.
Since the part you will build is made from aluminum, you will use a different
BAF than the default formula.
Choose the Bend Allowance Formula button and choose the

formula from the list that uses the .40 factor.
NOTE The Bend Allowance formula could also be set in the Global
Parameters section of the Sheet Metal Preferences dialog.
EDS Unigraphics NX
Flange
Choose OK.
Change the Length option from Tangent Length to Contour

Length.
Change the Contour Length to 2.00
Change the Bend Angle to 90.
Notice there is no Radius field. This is because we toggled

ON Use Global Bend Radius in the Sheet Metal
preferences.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
In the Side Options tab, choose the Butt option for the Left
and Right Settings.
Insert R+T into the Butt Length field for both sides.
Your Options dialog should look like this:
Choose OK.
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Flange
Select the upper front edge of the Block as the Bend Edge.
ÏÏÏ
ÏÏÏ
2
Choose this edge
as the Bend Edge.
ÏÏÏ
ÏÏÏ
Choose OK.
EDS Unigraphics NX
Flange
Step 6 Create bend reliefs on the back corners of the part.
Choose the Pocket icon.
Choose Rectangular.
Select the top face of the Block as the Placement Face and
the back edge as the Horizontal Reference.
ÏÏÏ
ÏÏÏ
2
Choose this edge
ÏÏÏ
ÏÏÏ
as the Horizontal
Reference.
Choose this face as the

Placement Face.
Insert the following parameters:
X Length = BR-T-R
Y Length = BR-T-R
Z Length = T
Choose OK.
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2-47
Flange
Select the upper back edge of the Block for the target
edge/datum.
Select the upper back edge of the Tool Solid for the tool
edge.
Select this edge as

the target
edge/datum.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Select this edge
as the tool edge.
Choose the Point onto Line icon from the Positioning dialog.
Select the upper left edge of the Block for the target
edge/datum.
Select the upper left edge of the Tool Solid for the tool edge.
Select this edge as

the target
edge/datum.
Select this edge

as the tool edge.
Repeat the process for the other back corner.
EDS Unigraphics NX
Flange
ÏÏÏ
ÏÏÏ
2
Step 7 Create side flanges to close the front corners using the
ÏÏÏ
ÏÏÏ
Butt Length option.
Select the upper right edge of the Block as the Bend Edge.
Check to see if the RH face of the block is highlighted. If the

top of the block is highlighted, choose the Adjacent Face
icon in the Flange dialog (the arrow should point up).
Select this edge as

the Bend Edge.
This face should

be highlighted.
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2-49
Flange
For better parameterization of our part we will link the contour

length to that of the front flange.
Choose Information→Feature
Select Flange(1)
Choose OK.
In the Information Window locate and record the pX" value

for the Length of the Flange feature where X" is a integer.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Close the Information Window.

Enter the following values in the Flange creation dialog:
Contour Length = p5 (From the previous Information

window.)
Bend Angle = 90
EDS Unigraphics NX
Flange
In the Side Options tab, choose the Butt option for the Left
and Right Settings.
Enter the following Butt Length values in the appropriate
fields:
Left Butt Length = BR-T-R
Right Butt Length = R-.001
Choose OK.
Turn ON Confirm Upon Apply.

Choose Apply.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ

If the flange appears correct accept the results by selecting

OK.
ÏÏÏ
Repeat the process for the upper left edge of the Block using
the same values. Ensure the Butt Length's are put on the
correct sides of the flange. The R-.001 butt length should be
towards the front.
Step 8 Create joggles on the back edges of the Block and the two
flanges.
If necessary, choose the Flange icon.
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2-51
Flange
Select the upper back edge of the Block as the Bend Edge.
Check to see if the back face of the block is highlighted (the

arrow will point up). If the top of the block is highlighted,
choose the Adjacent Face button in the Flange dialog.
Select this edge as

the Bend Edge.
ÏÏÏ
ÏÏÏ
2
This back face should
be highlighted.
ÏÏÏ
ÏÏÏ
In the Side Options tab, set both the Left and Right Settings
back to None.
Choose OK.
Change the length option from Contour Length to Tangent

Length.
EDS Unigraphics NX
Flange
Enter the following values:
Tangent Length = 0
Bend Angle = ANG
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Choose Apply and check the flange to see if it appears

correct before accepting the results.
Repeat the previous steps for the Right and Left flanges
using the same parameters and using the inside edges as the
Bend Edges.
Step 9 Continue creating the joggles using the Flange option.
Choose the Flange icon if the dialog is not open.
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2-53
Flange
Select the bottom edge of the back flange created in the last
step as the Bend Edge.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ Select this edge as
the Bend Edge.
Enter the following values:
Tangent Length = .500

Bend Angle = ANG
Repeat the previous steps for the Right and Left flanges
using the same parameters and using the outside edges of
the joggle flanges as the Bend Edges.
EDS Unigraphics NX
Flange
Your part should resemble the one below.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Step 10 Unform the part to test its integrity.
Choose the Form/Unform icon.
Choose the Unform All button.
Look over the part to see if anything obvious has changed. If

it looks okay, reform your part.
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2-55
Flange
Miters
NonĆlinear tapers can be added to the flange bend face to provide a mitered
corner in the formed state of the flange. Like regular tapers, right side mitered
values can be different than left side values.
Miter Side Options
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Left and Right Miters
Flange miter parameters are set within the Side Options tab in the Options
dialog, and can be specified as Simple Miter or Full Miter.
When Simple or Full Miter is selected, text fields will appear below the Left or
Right Settings columns in the Options dialog. These text fields allow input of a
Miter Angle, Miter Phase or Miter Relief.
EDS Unigraphics NX
Flange
Simple Miter
A Simple Miter type allows you to create a mitered corner where only the
inside bend edges of the flange meet.
Perpendicular
sides
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Relief
Simple Mitered Flange with a Relief
Full Miter
A Full Miter type allows you to create a fully closed mitered corner between
two flanges in the formed state. Both the outside and inside edges of the
adjacent flanges meet. A miter relief radius is not available, nor is it required,
with the full miter condition.
Flange end
faces meet
Full Mitered Flange
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Flange
Miter Parameters
The Flange dialog contains three miter parameter input fields for each side of
the flange. Depending on the miter type specified under the Options button,
two or all three of these parameters will be activated to accept input values.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Full
Simple Miter
Miter
EDS Unigraphics NX
Flange
Miter Angle
This parameter defines the angle of the mitered corner in the formed state of
the flange as viewed from an orientation normal to the adjacent highlighted
face. This angle is typically half of the desired corner angle.
Miter Angle = Angle/2
ÏÏÏ
ÏÏÏ
2
120 deg ref
Angle
ÏÏÏ
ÏÏÏ
60 deg
Thickness
30 deg
Miter Angle
NOTE Keep in mind the issue of positive miter vs. negative miter. In
the above figure, you would enter a negative 30 degrees for the
miter angle. A positive 30 degree miter would reverse the
miter such that the flanges would not meet at the corners.
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2-59
Flange
Miter Phase
The Miter Phase is usually employed when you are creating additional flanges
on existing flanges. The value of a miter phase is typically equivalent to the sum
of the bend angles of the base flanges. This parameter enables the creation of
tapered flanges which retain the orientation of a mitered cut from one flange to
the next.
Mitered edge retains

orientation from one flange to
the next.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Simple Miter Flanges with 455 and 905 Phase Angles
Mitered edge suitable

for a weld joint.
Simple Miter Flange with 905 Phase Angle
Miter Relief
This option allows you to apply a relief radius to the beginning of the simple
miter. The sides of the flange are perpendicular to the top and bottom faces of
the flange. In NX1 this value can now be zero between the first set of adjacent
flanges originating from a common corner.
Gap (e.g. .001) = Miter Relief
Miter Relief
EDS Unigraphics NX
Flange
Flange Construction Tips
To ensure the viability of a part, there are a few design requirements which
should be followed when creating sheet metal flanges:
Due to the positionally dynamic nature of flange features, it is

important to sufficiently position flanges by constraining at least two
edges of the flange. Insufficiently constrained flanges can fail to
position properly if their base attachment feature changes.
Note that after being unformed, the bend area of a flange is no longer
ÏÏÏ
ÏÏÏ
cylindrical, but is planar. Therefore, datum axes should not be created
2
ÏÏÏ
through the axis of a flange's cylindrical bend area in the formed state.
The only type of features which may be placed on the cylindrical bend ÏÏÏ
area of a flange are Sheet Metal Punch, Sheet Metal Hole, Sheet Metal
Slot, or Sheet Metal Cutout. Any other feature placed on the bend will
give unpredictable results during forming and unforming.
When using instance sets on flange features, it is important to fully
constrain the feature placement using positioning dimensions. It is a
good practice to unform the flange after creating the instance to test
its integrity.
A dependency is created between adjacent flanges if the Thickness
parameter is set to Infer From Edge for each flange. To break this
associativity, you must change the Thickness parameter to Use
Expression.
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2-61
Flange
Activity 2-3: Working with Miters
In this activity you'll start with a seed partfile and create a picture frame with
simple mitered corners.
Step 1 Open the partfile smd_seedpart.

ÏÏÏ
ÏÏÏ
2
Expressions have already been created for the thickness (T) and
ÏÏÏ
ÏÏÏ
inside bend radius (R) values. For this activity, we need to
change the inside bend radius value.
Select Tools→Expression in the Modeling application.
Choose the R variable and change the value to .125 and

choose OK.
Step 2 Create the base of the frame.
Rotate the WCS about the +XC axis 90 degrees.
If necessary, select the Origin, Edge Lengths icon.
Length (XC) = 6
Width (YC) = 8
Height (ZC) = T
Choose OK to create the block at the default 0,0,0 location

and Fit the part to the graphics display.
EDS Unigraphics NX
Flange
Step 3 Add a cutout to the center of the frame using the pocket
feature.
Before adding a pocket, it's good modeling practice to create
reference datums as positional aids for locating added features.
Create center datum planes using opposing faces of the

edges of the frame.
Choose the Rectangular option.

ÏÏÏ
ÏÏÏ
2
Select the front face as the placement face and the bottom
ÏÏÏ
ÏÏÏ
edge as the horizontal reference. Accept these selections if
necessary.
Select this face as

the placement face.
Select this edge as

the horizontal
reference.
X Length = 4.5
Y Length = 6.5
Z Length = T
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Flange
Choose OK.
Using the Line onto Line and Point onto Line positioning
methods, center the pocket in the middle of the frame using
the reference datum planes.
Move the reference datum planes to layer 61.
Step 4 Create a beveled edge around the frame using mitered

ÏÏÏ
ÏÏÏ
2
flanges.
ÏÏÏ
ÏÏÏ Choose the Flange icon.
Select the back right edge as the Bend Edge so that the
flange will bend behind the part.
Select this edge as

the Bend Edge.
In the Flange dialog, choose the Options icon.
EDS Unigraphics NX
Flange
Change the Left Side and Right Side options from None to
Simple Miter.
In this design, the angular value of the corner to be mitered is

90 degrees. Therefore, the miter angle for each side of the
adjacent flange is one half the total angular value, or 45 degrees.
But, because the miter needs to expand outward, a negative
angular value (Ć45) must be specified.
ÏÏÏ
ÏÏÏ
2
(Flange) ÏÏÏ
ÏÏÏ
(Frame)
(Flange)
Also in this activity we will add a Miter Relief on both sides of a

common corner. This will represent a gap similar to what would
be created during the manufacturing process. A value of zero
could be used if so desired.
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Flange
Set the miter parameters to the following values:
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Choose OK.
Set the flange parameters to the following values:
Choose Apply to create the flange.
EDS Unigraphics NX
Flange
Rotate your part to see the mitered edges of the flange.
Mitered
edge
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Mitered
edge
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2-67
Flange
Create three more flanges with the same flange parameter

values on the remaining edge faces of the frame.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Step 5 Create the sides of the frame.
Select the inside edge of one of the mitered flanges as the

Bend Edge. Your flange bend direction vector should be
pointing behind the frame body.
Because you are adding a mitered flange to the end of another
mitered flange, you must now provide a Miter Phase value in
order to maintain a constant miter orientation through both
flanges. Since you're creating a flange on only one base flange,
the Miter Phase value is equal to the bend angle of the base
flange (45 degrees).
In the Flange dialog, choose the Options icon.
EDS Unigraphics NX
Flange
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
NOTE A miter relief is not necessary again since it will be carried

over from the base flange. Insert a 0 value into this field to
avoid adding an additional relief.
Choose OK in the Options dialog.
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Flange
Repeat the flange creation on the other flange edge faces to

complete the sides of the frame.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Step 6 Add a flange to three sides on the back of the frame.

These flanges will guide the picture into the frame.
EDS Unigraphics NX
Flange
Again, select the inside edge of the long rightĆhand mitered

flange to derive the Bend Edge.
ÏÏÏ
ÏÏÏ
2
Select the inside
edge of this flange
ÏÏÏ
ÏÏÏ
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2-71
Flange
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
NOTE The Miter Phase value is now the sum of both bend angles of
the base flanges (45 degrees + 45 degrees).
TIP Use expression p" values for better parameterization.
Change the Bend Angle to 90 .
Repeat this step on the top and far side flanges to create the
guide edge on three sides of the frame.
EDS Unigraphics NX
Flange
Your part should resemble the one below.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
NOTE You can also create this part using full mitered flanges.
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Flange
Unform the part to test its integrity.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Step 7 Choose File"Close"All Parts, do not save.
EDS Unigraphics NX
Flange
SUMMARY Flanges are a basic feature to sheet metal parts;
ÏÏÏ
upon which you can build simple to
ÏÏÏ
complicated sheet metal parts.
2
In this lesson you: ÏÏÏ
ÏÏÏ
Created simple sheet metal flanges
Created tapered and custom width sheet
metal flanges
Created buttjoints
Created simple and full mitered corners
Edited flange features
Applied these functions to create a bracket,
a box, and a picture frame.
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2-75
Flange
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
EDS Unigraphics NX
Sheet Metal Corner
Sheet Metal Corner

Lesson 3
PURPOSE This lesson will teach you how to create various

associative corner types on formed straight-break
sheet metal flange features.
Create corner geometry using butt, full miter,

simpler miter and machinery types.
ÏÏÏ
ÏÏÏ
This section contains the following activity: ÏÏÏ
3
ÏÏÏ
Activity Page
3-1 Creating Sheet Metal Corners . . . . . . . . . . . . . . . . 3-11
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3-1
Sheet Metal Corner
The Sheet Metal Corner Dialog

The Sheet Metal Corner feature allows you to create various corner fill"
geometry. Unlike some of the functionality inside the Sheet Metal Flange
feature, a Corner feature is added as a separate feature after flanges are
created.
In order for the Corner feature to be applied between two adjacent flanges, the
two adjacent flanges must share a common starting edge.
Common
starting edge
ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ The Butt Joint option has more flexibility in that the two adjacent sides do not
have to be created using Sheet Metal flange features (e.g. Hollow operation
used to create a sheet metal type part). Currently the Miter and Machinery
corner features can only be applied to corners which are made from Sheet
Metal Flange type features. If the corner is not comprised of two Sheet Metal
Flange type features in this scenario, the system will display the following
message.
You can access the Sheet Metal Bend dialog by choosing Insert→Sheet Metal
Feature→Corner or the Sheet Metal Corner icon in the Sheet Metal

Feature toolbar. To edit a Sheet Metal Bend, use Edit→Feature or the Edit
Feature toolbar.
EDS Unigraphics NX
Sheet Metal Corner
Construction Methods
The sheet metal Corner feature has a series of construction type icons available
to create corner geometry. There are four selections available in the Corner
feature, Butt Joint, Machinery, Simple Miter and Full Miter. The dialog is
dynamic and changes based upon the Corner type selected.
Machinery
ÏÏÏ
ÏÏÏ
Butt Joint ÏÏÏ
3
ÏÏÏ
Full Miter
Simple Miter
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3-3
Sheet Metal Corner
Butt Joint
The butt joint option works very similarly to the butt joint option within the
Flange feature. The advantage of using a Butt Joint within Sheet Metal Corner
dialog is the ease and added associativity you gain. The user has the option to
specify an Overlap or Gap value between the adjacent flanges which create the
corner.
Parent Flange
The flange whose edge or face you selected for creating the corner. A 1 is
displayed on the top bend face of this flange.
Associate Flange
ÏÏÏ The flange that shares a common edge with the parent flange. A 2 is displayed
ÏÏÏ on the top bend face of this flange.
ÏÏÏ
3
ÏÏÏ Switch Parent
The Switch Parent option allows the user the ability to change the Parent flange
which originates the Overlap.
1 2 2 1
Switch Parent changes where the

Overlap originates from
EDS Unigraphics NX
Sheet Metal Corner
Overlap
The distance of the parent flange over the associate flange along the direction
of the parent flange side face normal. Overlap can be a negative value. Negative
overlap value cannot exceed the computed length of the parent butt joint. To
switch the Overlap to the other flange use the Switch Parent option.
Gap
The distance between two flanges along the direction of associate flange side
face normal. The system will only allow the corner to be created with a valid
Gap value, in which case the Apply button will be inactive until a valid value is
entered.
NOTE If no Overlap is specified (zero) there must be a Gap (e.g.

.001) specified to prevent a Non-Manifold solid error
(Similar to the Simple Miter function of the Flange
feature).
ÏÏÏ
ÏÏÏ
NOTE It is not possible to have a zero Gap because the surface
to surface contact would yield incorrect Flat Pattern ÏÏÏ
3
ÏÏÏ
results.
Gap
Overlap
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Sheet Metal Corner
Machinery
The machinery option yields a condition that is typical in thinner gauge

materials. The appearance of the Machinery corner in the formed state
represents a smashed" condition which is intended to depict the results of
forming two adjacent flanges simultaneously during the manufacturing process.
In the unformed state the intersecting corners of the two adjacent flanges are
filled in with material and a bisecting edge is shown.
NOTE It is called machinery corner because a corner like this is

typically filed by the machinist to remove a bur that is
created after the forming process.
ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Unformed machinery
corner results
EDS Unigraphics NX
Sheet Metal Corner
Simple Miter
The simple miter option works very similarly to the simple miter option within
the Flange feature. The advantage of using a simple miter within Sheet Metal
Corner dialog is the ease and added associativity you gain. The user does not
have to supply miter angle or miter phase because the feature calculates the
values based on the adjacent flanges on the corner it is being applied to.
The adjacent flanges must have the same bend angles or the following message
will appear.
Gap and Relief Radius
ÏÏÏ
Using the Gap option will define the distance between the two adjacent flange
ÏÏÏ
ÏÏÏ
inside edges. If Relief Radius is selected, the relief radius applied on parent and 3
ÏÏÏ
associate sides at the common edge will be equal to the value specified. In the
case of Relief Radius, the distance or gap between parent and associate Miter
bodies will be less than the value of Relief Radius. In NX1 this value can be
zero or greater for either option.
Relief Radius
Gap
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Sheet Metal Corner
Full Miter
The full miter option works very similarly to the full miter option within the
Flange feature. The advantage of using a full miter within Sheet Metal Corner
dialog is the ease and added associativity you gain. The user does not have to
supply miter angle or miter phase because the feature calculates the values
based on the adjacent flanges on the corner it is being applied to.
ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
EDS Unigraphics NX
Sheet Metal Corner
Multiple Steps
The Multiple Steps option is available for both the Simple and Full Miter
options and allows the user to select a corner which has several flanges stacked
on one another. Again, the bend angle of the flanges must be equal to the
corresponding adjacent flange section.
ÏÏÏ
ÏÏÏ
NOTE The adjacent flanges cannot intersect one another at any
point before applying the simple miter. If they intersect
the following messages will appear. ÏÏÏ
3
ÏÏÏ
NOTE If there is a different number of flange segments on the

adjacent side, the corner feature will only be created
where there is an adjacent side to match up to.
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3-9
Sheet Metal Corner
Sheet Metal Corner Construction Tips
should be followed when creating sheet metal corners:
Editing Sheet Metal Corners uses the same dialog as for creation.
Sheet Metal Corner can be edited no matter what state its flanges are
in. You cannot change type of Sheet Metal Corner in Edit mode.
You cannot form or unform the sheet metal corner feature by itself.
You can however, form and unform the two flanges individually that
flank the corner and the corner will follow those flanges.
Butt Joint and Machinery Corners cannot be created between flanges
with a zero web length. If selected the following message will appear:
ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Machinery Corners cannot be created between adjacent flanges if
taper options already exist on the flanges.
No Corners can be created between adjacent flanges if miter or butt

options already exist on the flanges.
Corners cannot be created if the bend angles of the adjacent flanges

are less than .5 degrees or greater than or equal to 180 degrees.
Corners cannot be created for flanges in an intermediate state.
EDS Unigraphics NX
Sheet Metal Corner
Activity 3-1: Creating Sheet Metal Corners
In this activity you will use different corner options to create different fill
conditions of the part shown below.
Step 1 Open part smd_corner and start the Modeling ÏÏÏ

application. ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Step 2 Check the expressions.
Choose Tools"Expression.
Notice there are expressions in the list for thickness (T) and
bend radius (R).
Choose Cancel in the Expressions dialog.
Step 3 Create a butt joint corner.
Choose the Sheet Metal Corner icon.
If necessary, choose the Butt Joint icon.
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Sheet Metal Corner
Select the left flange edge in the corner area shown below.
Select this flange
NOTE The side that is picked is defined as the Parent Flange

and is identified by a number 1.
ÏÏÏ Enter a value of T in the Overlap field.
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Enter a value of .010 in the Gap field.
Turn ON Confirm Upon Apply.
Before choosing Apply look at the graphics screen and

identify the Parent Flange (1) and the Associate Flange (2).
Choose Apply.
Notice the Overlap comes from the Parent Flange (1).
Choose Back.
Choose the Switch Parent button and choose Apply.
Notice the Overlap now comes from the opposite flange,

which has been switched to the Parent Flange (1).
Choose OK to accept your results.
If necessary, choose the Sheet Metal Corner icon again.
EDS Unigraphics NX
Sheet Metal Corner
Select the right flange edge in the corner area shown below.
Part has been rotated 905 for clarity
Select this flange
Change the Overlap value to 0 .
Continue to use the same value for the Gap field.
Choose Apply.
ÏÏÏ

ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Step 4 Edit a flange to see the associativity.
Choose Edit"Feature"Parameters or choose the Edit
Parameters icon.
Select FLANGE(13) from the list and choose OK.
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Sheet Metal Corner
Change the Bend Angle to 60 .
Choose OK twice to update the model.
Shade and Rotate your model to see the changes.
Notice both SM_CORNER features have updated and have

maintained the overlap and gaps defined in the previous
steps.
Step 5 Create a simple and full mitered corner
Choose the Sheet Metal Corner icon.
Choose the Simple Miter icon.
ÏÏÏ
ÏÏÏ Ensure the Gap is set to .010 .
ÏÏÏ
3
ÏÏÏ Toggle ON the Multiple Steps option.
Select either side of the flange corner shown below.
Select either side
The Multiple Steps option selects all of the flange edges

after selecting the first edge.
EDS Unigraphics NX
Sheet Metal Corner
Choose Apply.
Choose the Full Miter icon.

ÏÏÏ
ÏÏÏ
Select either side
ÏÏÏ
3
ÏÏÏ
Choose Apply and then OK to accept your results.
Shade and Rotate your model to see the difference between

the Simple and Full Miters.
Step 6 Create a machinery corner.
If necessary, choose the Sheet Metal Corner icon again.
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Sheet Metal Corner
Choose the Machinery icon.
Select either side
Choose OK to create the Machinery corner.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Step 7 Inspect your part.
Shade and Rotate your model to see the difference between

all of the corners.
Unform your part using the Form/Unform icon.
EDS Unigraphics NX
Sheet Metal Corner
ÏÏÏ
Inspect the different results in each corner area. ÏÏÏ
ÏÏÏ

3
Step 8 Close your part. Do not save.

ÏÏÏ
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3-17
Sheet Metal Corner
SUMMARY The Sheet Metal Corner application provides

you with the ability to fill in the corners of
adjacent flange features using various options.
In this lesson you created:

Various Sheet Metal Corners
Edited flange geometry to see the effects on
ÏÏÏ a corner feature
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Unformed the part to see the results of a
corner in the flat condition
EDS Unigraphics NX
Inset Flange
Inset Flange
Lesson 4
PURPOSE Create and edit sheet metal inset flanges using the
Inset Flange feature.
Create and edit inset flanges.

Recognize the six different methods to define the
inset distance of the flange into the body of the
part.
Position an inset flange properly.
Activity Page
4-1 Exploring Inset Flange Creation Techniques . . . . 4-11
4-2 Creating an Inset Flange . . . . . . . . . . . . . . . . . . . . 4-22 ÏÏÏ
ÏÏÏ
4
ÏÏÏ
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4-1
Inset Flange
Inset Flange
Inset flanges fit and form like regular flanges, but have the added function of
being able to control a setback distance.
The Inset Flange feature allows you to create inset flanges on a planar
placement face while controlling its inset and relief characteristics . The Inset
Flange feature always removes material from the target body to create the
flange.
Upon selecting Insert→Sheet Metal Feature→Inset Flange or the Inset Flange
icon from the Sheet Metal Feature toolbar, the Inset Flange dialog is
displayed and the system prompts you to choose a bend edge. To edit an Inset
Flange, use Edit→Feature or the Edit Feature toolbar.
TIP The edge selected on a thickness face represents the

bend side of the flange.
ÏÏÏ
ÏÏÏ
4 Select this Bend Edge
ÏÏÏ
EDS Unigraphics NX
Inset Flange
The Inset Flange Dialog
Inset Flange
Profile Inputs
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Inset Flange Profile Inputs
Just like the Flange dialog, these inputs can be manually loaded or a standard
value can be chosen from an active arrow button inside the parameter field.
Remember, these arrow buttons are only active if the Use Feature Standards
option is toggled ON in the Sheet Metal Preferences dialog.
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4-3
Inset Flange
The Inset Flange dialog has additional feature options to specify the
characteristics of the inset condition. The Thickness, Length, Angle and Radius
inputs as well as the Flip Bend Direction, Adjacent Face and Options icons
function in the same manner as described in the Flange lesson.
Any grayed out input field will derive their values from internal system
information. The status of these input fields (active or inactive) can be
controlled through the Options icon.
The Options dialog also contains specific inset flange feature options under the
Relief Options tab such as Flange Width, and Left and Right Relief options.
Inset
The Inset field contains the value of the distance the flange is offset into the
body of the part. This distance may be either a userĆspecified or calculated
value. The calculated inset value depends on the specified thickness, angle and
radius values given in their respective fields when the inset is set to an option
other than Use Expression.
NOTE This field is only active if the Inset option is set to Use
Expression.
Inset using the

Outer Mold Line
ÏÏÏ
ÏÏÏ
Inset using the
4 Inner Mold Line
ÏÏÏ Inset
Inset of
UserĆDefined
value ( >zero )
NOTE Pressing Enter or Return while any text edit box is

highlighted will cause the system to create the flange.
EDS Unigraphics NX
Inset Flange
Use Expression
With this inset method, the Inset field within the Inset Flange dialog becomes
active and you may insert any value or valid UG expression. The value will then
be used as the distance with which to offset the base of the flange from the
attachment face. Using a given value or expression for the flange inset yields
the same inset regardless of the thickness, angle or radius.
Outer Tangent Line
The Outer Tangent Line option adjusts the base of the flange so that the outer
bend tangent line of the fully formed flange is coplanar with the attachment
face plane.
Inset Inset
Attachment
Flange Face
base
Outer bend tangent
line is coplanar with
attachment face
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
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Inset Flange
Inner Tangent Line
This option adjusts the base of the flange so that the bend tangent line on the
inner surface of the fully formed flange is coplanar with the attachment face.
Inset Inset
Attachment
Face
Flange
base
Inner bend tangent
line is coplanar with
attachment face
Outer Mold Line
The mold line, also know in the Flange feature as the bend contour line, is the
line created by the intersection of the surface of the formed flange with the
surface of the target body.
The Outer Mold Line option adjusts the base of the flange so the outer flange
surfaces resides in the same plane as the upper edge of the attachment face.
Upper surface of
flange is coplanar Inset
Inset
with upper edge of
attachment face.
ÏÏÏ Flange
ÏÏÏ
base
4
ÏÏÏ
EDS Unigraphics NX
Inset Flange
DIN Mold Line
This option is based on the calculation methods used in the Deutsches Institut
für Normung (DIN) Standard 6935. The calculated inset value is the same as
the Outer Mold Line value up to a bend angle of 90 degrees. The inset value
calculated at 90 degrees is retained for bend angles greater than 90 degrees.
Inset remains
unchanged for
bend angles
greater than
90°
Inset Inset
Attachment
Face
Flange
base
Inner Mold Line
The Inner Mold Line option adjusts the base of the flange so that the mold line
of the inner flange surface and inner body surface reside on the lower edge of
the attachment face.
Inset Inset
ÏÏÏ
Flange
base
ÏÏÏ
4
ÏÏÏ
Lower surface of
flange is coplanar
with lower edge of
attachment face.
NOTE Regardless of the method used, the calculated inset of the

flange base into the target body must be greater than zero
or an error will be generated.
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4-7
Inset Flange
Options
Selecting the Options icon within the Inset Flange dialog activates the Options
dialog. Within this dialog, there are four tabs which access various options used
to derive feature parameters, side options, the use of global parameters and
relief options. The parameter options, side options and global parameters act
the same as described in the Flange lesson.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
NOTE The Options dialog may be accessed repeatedly, and

parameters changed, throughout the creation process.
EDS Unigraphics NX
Inset Flange
Relief Options
Flange Width
The width of an inset flange is either the width of the flange itself or the sum of
the base width of the flange plus the widths of the right and left reliefs. This
option is only selectable if the Width option in the Inset Flange dialog is set to
Width Expression. You have the option to choose either method to measure the
width of the inset flange. This applies to both normal and tapered flanges.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Excludes Excludes
Reliefs Reliefs
or or
Includes Reliefs Includes Reliefs
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Inset Flange
Left and Right Relief
Three different types of bend relief may be specified: None, Rectangular, or

Obround. When a relief type other than None is selected, text fields will appear
below the Left or Right Relief columns in the Options dialog. These text fields
allow input of a value which represent the width of the rectangular relief or the
diameter of an obround relief. A typical manufacturing recommendation is to
set this value greater than or equal to the material thickness, however any value
greater than zero is acceptable. The Bend Relief value can be individually set
for the left and right side of the flange.
No relief
(ripped edge)
Rectangular Obround
relief relief
The relief is aligned with the base of the flange, and the width of the relief is
ÏÏÏ measured perpendicular to the flange side face.
ÏÏÏ
4
ÏÏÏ Relief Width
Relief
Control points Control points Width
located at base located at base
of flange. of flange.
EDS Unigraphics NX
Inset Flange
Activity 4-1: Exploring Inset Flange Creation Techniques
In this activity you'll create a two piece box using inset flanges and
parametrically controlled dimensions. Rather than mathematically accounting
for the use of regular flanges, two different inset flange creation techniques will
be used to control the interface between the box pieces.
Step 1 Open the part smd_insetflg2 and save it as xxx_insetflg2,

where xxx represents your initials.
Check for part specific expressions by selecting

Tools→Expression. Notice that expressions have been
created for the bend radius (R), height (H), length (L),
thickness (T), and width (W). You'll use these expressions to
control the parametric definition of your box.
Choose Cancel to close the dialog.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
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Inset Flange
Step 2 Create the base of the box.

In order to control the outside dimensions of your part, you
must account for the flange bend radius and part thickness for
each flange added to the body of the part.
T T
R R
R T
If necessary, choose the Origin, Edge Lengths icon.
Length (XC) = W-R-2*T

Width (YC) = L-2*T
Height (ZC) = T
ÏÏÏ
ÏÏÏ
4 Choose OK to create the block at the default 0,0,0 location
ÏÏÏ and Fit the part to the graphics display.
EDS Unigraphics NX
Inset Flange
Step 3 Create relief cutouts.
Select the upper surface of the block as the placement face

and accept.
Select the near edge of the placement face as the horizontal

reference.
Select this face

as the placement
face
Select this edge

as the horizontal
reference edge
X Length = R
Y Length = R
Z Length = T
Choose OK.
ÏÏÏ
ÏÏÏ
4
Using the Line onto Line and Point onto Line positioning
methods, locate the pocket in the nearest front corner of the
ÏÏÏ
block.
Choose OK to create the pocket.
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Inset Flange
Repeat this step to create a pocket in the opposite front

corner of the block. When you're finished, your part should
look like this:
Step 4 Create the side of the box.
Select the upper edge of the near face as the Bend Edge so
that the flange directional vector points up.
Select this edge

as the Bend Edge
ÏÏÏ
ÏÏÏ
4
ÏÏÏ Ensure the Width option is set to Infer Width.
Change the Length option to Tangent Length.
Change the Left and Right Settings to None.
EDS Unigraphics NX
Inset Flange
Choose OK to accept the change.
Change the following flange parameters:
Tangent Length = H-R-T

Inside Radius = R
Ensure the Positioning method is set to Automatic.
Step 5 Change the color of the part to facilitate the creation of

the other half of the box.
Change the Selection toolbar setting to Select General

Objects and change the Filter option to Solid Body.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Select General Objects Filter to Solid Body
In the graphics window, select the solid body.
Place the cursor over the part and select MB3.
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Inset Flange
Select Edit Display... from the Pop-Up window.
Choose the Color option and change it to Blue.
Choose OK to apply the change and close the dialog.
Step 6 Create the opposite side of the box.
Length (XC) = T
Width (YC) = L-2*R-2*T
Height (ZC) = H
Change the Point Method to Point Constructor.

ÏÏÏ
ÏÏÏ
4 Enter the following:
ÏÏÏ

XC = -T (NOTE: remember the minus sign!)

YC = R
ZC = 0
Choose OK twice to create the solid.
Fit the view.
EDS Unigraphics NX
Inset Flange
Step 7 Create the edges of the box.
Select the inside edge of the left face of the new block as the
Bend Edge.
Select this edge

as the Bend Edge
Change the Tangent Length to Contour Length.
Set the Contour Length equal to W and the Inside Radius

equal to R .
Create another flange with the same parameters on the other
ÏÏÏ
side of the block.
When finished, your box should look like this: ÏÏÏ

4
ÏÏÏ
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Inset Flange
Step 8 Now you can create tabs without adjusting the part size
by using the Inset Flange feature.
Choose the Inset Flange icon.
Select the inside edge of the left flange as the Bend Edge.
Select this edge
Ensure the Width option is set to Infer Width.
Change the Contour Length to Tangent Length.
Change the Inset option to Inner Mold Line.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ Choose the Options icon.
Choose the Relief Options tab.
Ensure the Left and Right Reliefs are set to None.
Choose OK to accept the changes.
In the Inset Flange dialog, set the Tangent Length equal to

.500 and the Inside Radius equal to R .
EDS Unigraphics NX
Inset Flange
Select Apply to create the flange.
Create another inset flange on the opposite edge of the box.

Your part should look like this when you're finished:
Step 9 Create a recessed flange on the face of the part.
TIP Blanking the green portion of the part will help with
the selection process in this step. (Ctrl+B)
If necessary, choose the Inset Flange icon.
Select the upper edge of the back face as the Bend Edge so
that the flange directional vector points up.
ÏÏÏ
ÏÏÏ
4
Select the upper edge to
place the inset flange. ÏÏÏ
Change the Inset option to Outer Mold Line.
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Inset Flange
Change the Left and Right Reliefs to Rectangular.
In the text fields below the Left and Right Relief enter a
value of R .
Ensure the Tangent Length is still .500 and the Inside Radius
is R .
Unblank and shade the part to review the geometry.
BEFORE AFTER
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
EDS Unigraphics NX
Inset Flange
Check the outside length, width and height of the part to

verify the dimensions. Why is the overall width off by .100
inches?
The Why" Some times when creating sheet metal parts which fit together you will
find that the parts may be off in size. You will also find in most cases the
parts are off by either a material thickness or bend radius value. It is a
good practice to occasionally measure the overall size after creating
flanges to see if you are capturing your design intent".
How Does it Work?
Depending on which type of flange you use you will get different
results.
The flange feature always adds length to the part so it is
necessary to accommodate the base feature's size.
The inset flange feature has options that can be set to
accommodate inset distances. It is common to use a
combination of the two type of flanges to get a part that
correctly represents your needs.
Using Tools→Expression or Edit"Feature, edit the length,

width or height to correct the size of the parts.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
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Inset Flange
Activity 4-2: Creating an Inset Flange
In this activity you'll create an inset flange and apply proper positioning
constraints.
Step 1 Open or change your displayed part to xxx_buttjoint,

NOTE If a finished part was not saved in the last lesson, you may
use smd_insetflg1 to complete this activity.
Step 2 Unform only the front flange. This step is done for clarity.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Step 3 Add an inset flange.
Choose the Inset Flange icon.
EDS Unigraphics NX
Inset Flange
Select the inside edge of the right flange as the Bend Edge.
Select the edge such that the flange will form toward the
inside of the part. Accept your choice, if necessary.
Select this edge as the

Bend Edge
Before modifying any inset flange parameters, it's a good idea to

first establish the inset condition.
Change the Width option to Width Expression. ÏÏÏ
ÏÏÏ

4
Change the Inset option to DIN Mold Line. ÏÏÏ
Change the Flange Width option to Excludes Reliefs.
Change the Left and Right Reliefs to Obround.
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4-23
Inset Flange
In the text fields below the Left and Right Relief enter a
value of T .
Choose the Global Preferences tab.
Turn OFF the Radius option.
In the Inset Flange dialog insert the following values:
Width Expression = 1.375

ÏÏÏ Bend Angle = 90

ÏÏÏ

4
ÏÏÏ
Inside Radius = R
Ensure the Positioning option is set to Manual.
Notice that the inset flange cutout is currently located against

the end of the flange.
EDS Unigraphics NX
Inset Flange
Select the edge used as the Bend Edge for the target edge.
Select the outside vertical line of the sketch for the Sketch
line.
Select this line

as the Sketch line
Select this edge

as the target edge
Choose the Perpendicular icon from the Positioning dialog.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
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4-25
Inset Flange
Select the bottom tangent edge of the attachment face as the

target edge.
Select the bottom horizontal line of the sketch as the Sketch

line.
Select this line

as the Sketch line
Select this edge
as the target edge
Enter a value of (2-1.375)/2-R-T in the Create Expression

dialog.
ÏÏÏ Choose OK to create the flange.

ÏÏÏ

4
ÏÏÏ
EDS Unigraphics NX
Inset Flange
Repeat Step 3 to create an inset flange on the opposite

flange. This time, while using the Perpendicular placement
function, enclose the entire expression in parentheses and
add a minus sign as follows: -((2-1.375)/2-R-T).
Step 4 Verify your part.
Again, choose the Form/Unform icon.
Choose the Unform All button. Your part should unform to

its flat pattern state.
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Step 5 Reform, save and close your part.
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4-27
Inset Flange
SUMMARY The Inset Flange feature has built in

functionality to allow for adjustable inset of the
placement face and also the ability to apply left
and/or right reliefs to the sides of the inset
flange.
In this lesson you:

Created and edited an inset flange
Positioned an inset flange properly
ÏÏÏ
ÏÏÏ
4
ÏÏÏ
EDS Unigraphics NX
Sheet Metal Bend
Sheet Metal Bend

Lesson 5
PURPOSE This lesson will teach you how to create and edit
formable bend geometry from existing flat patterns.
Create bend geometry using a bend centerline,

bend tangent line, contour line or mold line.
Activity Page
5-1 Creating Sheet Metal Bends . . . . . . . . . . . . . . . . . 5-10
ÏÏÏ
ÏÏÏ
5
ÏÏÏ
ÏÏÏ
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5-1
Sheet Metal Bend
The Sheet Metal Bend Dialog
The Sheet Metal Bend feature allows you to create formable sheet metal solid
models from non-sheet metal feature geometry. One example would be where
2D geometry has been extruded into a part which resembles a sheet metal
model. The various Sheet Metal Bend methods replace material in the solid
body with a formable region that has the ability to be unformed and reformed.
You can access the Sheet Metal Bend dialog by choosing Insert→Sheet Metal
Feature→Bend or choosing the Sheet Metal Bend icon in the Sheet Metal
Feature toolbar. To edit a Sheet Metal Bend, use Edit→Feature or the Edit
Feature toolbar.
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EDS Unigraphics NX
Sheet Metal Bend
Construction Methods
The sheet metal Bend feature uses a selection steps type of dialog to create and
edit the bend geometry and positioning parameters. There are four selections
available in the Bend feature, Base Face, Application Curve, Cylindrical Face
and Existing Edge.
Base Face
Select one face of the part on which to place the bend feature. This option is
followed by the selection of an Application Curve.
Application Curve
The application curves must be a line located on or at a distance to the

placement face. If they do not extend to the end of the face, the curve will be
extended to the end of the face. This step goes along with the selection of a
Base Face.
Application curve
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Sheet Metal Bend
Cylindrical Face
Cylindrical Face allows you convert a blended" edge that represents the
outside radius of a bend into a formable feature . Use this feature in cases
where it may be easier to create a 2D profile (sketch) with filleted corners and
an extrusion to make the model. Only modeled bends that need to be unformed
should be converted into a SM_Bend feature. Each modeled bend must be
converted individually before they can be recognized as formable features and
unformed.
The radius and angle is taken directly from the face selected. A Bend
Allowance Formula may also be chosen for application to each bend.
Sketch
Extruded
Cylindrical
Face Bend and
Unformed
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Sheet Metal Bend
Existing Edge
Existing Edge allows you convert a sharp" edge that represents the outside
edge of a bend into a formable feature . Use this feature in cases where it may
be easier to create a 2D profile with sharp corners and extrude it . Each sharp
corner must be converted individually before they can be recognized as
formable features and unformed.
Sketch
Extruded
Existing Edge
method applied
to each sharp
corner
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Sheet Metal Bend
Angle
Angle represents the angle of the bend. This angle can be set to specify a bend
angle or an included angle. The default angle type is Bend. This option is only
available when using the Base Face and Application Curve method.
Bend Angle Included Angle
NOTE The maximum angular value is limited by the

selfĆintersection of the flange bend segment with the
attachment body.
Maximum bend angle limited

by selfĆintersection.
Bend
Angle
NOTE The Angle field is removed from the dialog if the Global
Parameters option of Use Global Angle is toggled ON
inside Preferences"Sheet Metal.
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Sheet Metal Bend
Radius
Radius is the radial value of the cylindrical surface representing the bend.
Either the inside or the outside value can be specified. The default radius type
is Inside. This option is available when using either the Base Face and
Application Curve method or the Existing Edge method.
NOTE The Outside radius value must be greater than the

thickness of the part or the system will issue an error
message.
NOTE The Radius field is removed from the dialog if the

Global Parameters option of Use Global Bend Radius is
toggled ON inside Preferences"Sheet Metal.
Application Curve Type
The application curve type options allow you to specify how the Application
Curve you select will be applied to the bend.
Flip Bend Direction Vector

When you select an application curve while creating a bend, the system
automatically determines the bend direction. This direction is displayed on the
graphics screen as a vector located at the midpoint of the application curve. The
Flip Bend Direction Vector button allows you to flip the vector direction,
thereby reversing the bend direction.
Flip Stationary Direction Vector

When selecting an application curve, an outside cylindrical face (using the
Cylindrical Face method) or an outer existing edge (using the Existing Edge
method) , the system also determines the stationary side of the bend. This
direction is displayed on the graphics screen as a vector located at the midpoint
of the curve or edge. The Flip Stationary Direction Vector button allows you to
flip the vector direction, thereby reversing the stationary side of the bend.
NOTE Care should be taken to ensure the correct Stationary

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Side and Bend Direction Vectors are displayed.
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Sheet Metal Bend
Bend Allowance Formula (BAF)
When you click on the Bend Allowance Formula button, The following dialog
will appear:
The BAF originally loaded in the SMD General Preferences dialog will
automatically be loaded as the default Bend Allowance Formula. A new BAF
can be selected from the Bend Allowance Formulae list, or a userĆspecified
formula can be directly entered into the BAF field.
NOTE The Bend Allowance Formula button is removed from the

dialog if the Global Parameters option of Use Global is
toggled ON inside Preferences"Sheet Metal.
Options
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EDS Unigraphics NX
Sheet Metal Bend
Sheet Metal Bend Construction Tips
should be followed when creating sheet metal bends:
The SMBend forms and unforms in the same manner as the flange
feature and allows other SMD features to be applied to it.
Currently it is not possible to create a bend if there is a hole in the
bend area. This restriction will be removed in the future. In the below
example, apply the cutout after the bend feature has been applied.
Hole in bend area
Apply bend without hole
Create hole using

SM Cutout feature
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Sheet Metal Bend
Activity 5-1: Creating Sheet Metal Bends
In this activity you will use different bend construction techniques to form
different flanges from an existing flat pattern.
Step 1 Retrieve the part and start the Modeling application.
Open the part smd_seedpart. Save the part as xxx_bend.
Make layer 110 selectable.
Choose File"Import"Part from the menu bar.
Turn OFF the Create named group option.
Change the Layer mode to Original layers.
Choose OK.
Select smd_bend from the parts folder and choose OK.
Ensure the destination point for the import is set to 0, 0, 0.

This will import a flat pattern.
Choose OK.
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Cancel the Point Constructor dialog.
EDS Unigraphics NX
Sheet Metal Bend
Fit the display and make sure you're in the Modeling

application.
Step 2 Extrude the flat pattern.
Choose the Extruded Body icon.
Choose the Chain Curves option.
Select one of the outside profile curves as the Start of the

section string.
Select one of the outside profile

curves as the Start of the section
string.
Click MB2 to complete the chain.
Choose OK.
Select each circle in the flat pattern.
Choose OK.
Choose the Direction _Distance option.
If the extrusion vector is pointing upward choose OK in the

Vector Constructor dialog, otherwise choose Cycle Vector
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Direction to flip the vector direction. ÏÏÏ
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Sheet Metal Bend
Start Distance = 0
End Distance = T
First Offset = 0
Second Offset = 0
Taper Angle = 0
Choose OK.
Step 3 Check the expressions and standards
Choose Tools"Expression. Notice there are duplicate

expressions in the list.
The Why" When the flat pattern part was imported the expressions in that file
where carried over. If there are duplicate expression names the system
assigns a prime (`) and a number to the duplicate expressions. We don't
need many of the expressions in the list so we will delete the unused
expressions.
Choose Cancel in the Expressions dialog.
Choose File"Utilities"Part Cleanup...
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Toggle ON the Delete Unused Expressions option.
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Choose OK.
EDS Unigraphics NX
Sheet Metal Bend
Choose Tools→Expression. Notice the duplicate expressions

are gone.
In the Expression dialog create the expression:
R=.06 (press Enter to store the expression)
Choose OK.
Choose Preferences"Sheet Metal...
Enter R for the Bend Radius.
Toggle ON Use Global for the Bend Allowance Formula and

select the BAF that uses the 0.40 factor.
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Confirm your settings and choose OK. ÏÏÏ
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Sheet Metal Bend
Step 4 Create the bend areas.
Choose the Sheet Metal Bend icon.

Select the top surface as the base face.
Click MB2.
Select the bend centerline shown below as the application
curve:
Choose this line as Choose the top surface as the base face.
the application curve.
Ensure the Bend Angle is set to 90 .

Ensure the Stationary vector points towards the middle of
the part. If necessary, choose the Flip Stationary SideVector
button to flip the stationary side.
Choose Apply.
NOTE If your part contains flanges on multiple sides we

recommend that you start on the outside of the part and
work inward. If your part has a stacked set of flanges (one
side to the other) start at the ends and work towards to
the stationary section (middle). This ensures that your
stationary arrow points towards the same region for each
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bend section.
Repeat this process for all centerlines. Be sure to pick the
5
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base face surrounding each bend centerline.
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EDS Unigraphics NX
Sheet Metal Bend
When complete, your model should look as shown below:
The previous actions have replaced sections of the solid part

with formable geometry that represents the bends. Next, we will
form and then unform the flanges to check their integrity.
Step 5 Form and Unform your part to test its integrity.
Choose the Form All option.
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Sheet Metal Bend
Unform the part using the Unform All button.
Step 6 Change the size of the part.

To change the size of the part we must edit the curves. The
curves drive the extrusion and dictate where the bend centerline
exists, therefore the curves are the parent geometry for the part.
Replace the view to the Top view.
Choose Edit"Curve"Stretch...
or choose the Stretch icon.
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EDS Unigraphics NX
Sheet Metal Bend
Drag a rectangle around the top portion of the flat pattern as

shown below.
Enter 1.00 in the Delta YC field.
Choose OK.
Notice the solid went through an update process. The

extrusion and the bend features where updated according to
the stretch operation.
Repeat the same stretch steps for the three other sides
making them all 1.00 inch longer. Make sure you use the
correct XC or YC direction and positive or negative value.
Step 7 Reform and inspect the changes. ÏÏÏ

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5
Replace the view to the TFR-TRI view (MB3). ÏÏÏ
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Sheet Metal Bend
Choose the Form All option.
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EDS Unigraphics NX
Sheet Metal Bend
SUMMARY The Sheet Metal Bend application provides

you with the opportunity to develop flanged 3D
parts from flat patterns.
In this lesson you created:

Sheet Metal Bends
Edited curve geometry to see the effects on a
bend feature
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Sheet Metal Bend
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EDS Unigraphics NX
General Flange
General Flange ÏÏÏ

Lesson 6
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6
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PURPOSE Create contoured sheet metal flanges using the

General Flange sheet metal feature.
Create and edit a General Flange using the

Parameter Method
Create and edit a General Flange using the Build
to Sections Method
Create and edit a General Flange using the Build
to Faces Method
Create and edit a General Flange using the Punch
Vector Method
Activity Page
6-1 General Flange Creation Methods . . . . . . . . . . . . 6-26
6-2 Other General Flange Creation Methods . . . . . . 6-35
6-3 Create a Gen. Flg. by the Punch Vector Method . 6-43
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General Flange
ÏÏÏ The General Flange Dialog

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6
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Parameters Build to Sections
Build to Faces
Punch Vector
This portion of
the window will
change per the
method selected
The General Flange feature was developed to enable the creation of formed
flanges along contoured (nonĆlinear) edges of a part. These flanges may be
created either as sheet bodies or as solid bodies, depending on the application.
EDS Unigraphics NX
General Flange
The General Flange dialog is accessed from Insert→Sheet Metal

ÏÏÏ
ÏÏÏ
Feature→General Flange or from the General Flange icon in the Sheet
Metal Feature toolbar. To edit a General Flange, use Edit→Feature or the Edit
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Feature toolbar.
General Flange is a selection steps type of dialog, the Selection Step icons will
highlight as you progress through the general flange creation process. You may
also select any icon at any time to specify, or reĆspecify, information for that
step of the process. Only the Selection Steps needed for each method will
appear for each method used. See the figure below.
NOTE Like the Flange dialog, the General Flange dialog can
resolve mathematical expressions. Also, it can create
expressions on the fly". You can enter a new expression
into the appropriate window. The system will resolve the
expression into its numeric value upon creation of the
flange.
Parameters Method Build to Sections Method
Bend
Edges Spine Section
String Strings
Build to Faces Method Punch Vector Method
Shaping Punch
Faces Vector
TIP Flange parametric inputs such as bend angle and web length can
be inserted at any time during the creation process. These values
can be defined before or after the bend edge(s) is/are selected.
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General Flange
ÏÏÏ
ÏÏÏ Bend Edges
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6
ÏÏÏ To create a General Flange, you must first select a bend edge or a set of bend
edges (a bend string) that will become the start edge of the General Flange.
The bend string must have the following criteria:
All edges must be from the same solid body.

They must be G1 continuous (tangentially joined edges).
The faces that own the edges must be G1 continuous (tangentially
joined faces).
When you select the bend edge, the system will highlight the attachment face
upon which the General Flange will be built. The bend direction will be
displayed as a temporary vector. Also, the start of the bend edge is designated
using temporary text display. It is important to differentiate between the start
and end of the bend edged, especially when defining law functions and also
when extending section curves.
You must select edges (not curves). The system will filter your selections to
ensure these criteria are met. It is acceptable to select bend edges that form a
closed loop. You may set the selection Filter to choose All Edges, Solid Edges,
or Sheet Edges.
You may have the system automatically select all tangent edges by turning on
the Add Tangent Edges toggle. The system selects these edges after you select a
seed edge. As the model changes, the system will guarantee that all tangent
edges are selected. This toggle is only enabled while in the Bend String
selection step.
When you select a bend string, you implicitly select a set of tangent faces. Since
each edge is surrounded by, at most, two faces; there are no more than two sets
of tangent faces that could be used to construct the General Flange. The
General Flange will be built tangent to the unhighlighted face. The highlighted
face is the target attachment face. The system infers the tangent faces to be
those that yield the smaller thickness. You may change this inference by
pressing the Adjacent Faces button. If you have selected edges from a sheet
body, the Adjacent Faces option is not needed.
EDS Unigraphics NX
General Flange
ÏÏÏ
Spine String ÏÏÏ
The Spine function is an optional step that allows you to select a curve which
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the system will use to govern the construction of the general flange. The spine
curve geometry is related back to the general flange through specific points
along the spine. At these points, perpendicular section planes are temporarily
constructed, then used to shape the general flange geometry.
Spine curves may be as simple as straight lines, or they may be as complex as a

twisted spline. Either way, when you select curves or edges for your spine curve,
they must be G1 continuous. To avoid potential construction failures, it is
recommended that spine curves be constructed as very fair curves. The
complexity of the general flange is reflected by the complexity of the spine.
Any G1 curve may be chosen as a spine curve, but the spine should be selected
carefully to achieve good results. Usually, the spine should follow the general
direction of the bend edge and have as little curvature as possible. A good
strategy is to start with the bend edge and smooth out places where the
curvature is excessive. It should be kept in mind that the spine controls not only
the shape of the creation state, but the distortion to other states when the
Along Sections distortion algorithm is used. If the spine has too much
curvature, nearby sections of the flange will be far from parallel and may cause
self-intersecting surfaces. In general, the larger the flange, the gentler the
spine needs to be.
If the spine string is shorter than the bend edge (or vice versa), the General
Flange will be truncated to the shorter curve/edge. If an independent spine
curve is not selected, the bend edge is used as the spine.
If you do not select a spine, you may set the Infer Spine toggle on the Options
dialog. This will enable the system to generate a spine that is suitable for the
input data you have selected.
The system evaluates all law functions (e.g., plus, angle, radius, and length)
using this spine string.
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General Flange
ÏÏÏ Refer to the figure below. Both General Flanges have curved bend edges. The
ÏÏÏ General Flange on the left was created using a curved spine (identical to the
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bend edge). The General Flange on the right has a linear spine. Note how the
shape of the General Flange has changed.
Spine curve
Bend Edge
Bend Edge
Unformed general Unformed general

flange created without flange created with a
a spine curve spine curve
Section Strings
The Section Curves selection step is only available when using the Build to
Sections method. You may select curves or edges that define the shape of the
General Flange top face.
Shaping Faces
Use the Shaping Faces selection when you are using the Build to Faces method.
You may select faces from solid bodies or sheet bodies that define the shape of
the General Flange top face.
EDS Unigraphics NX
General Flange
ÏÏÏ
Punch Vector ÏÏÏ
This selection step is used in Punch Vector method. It brings up the standard
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vector selection method.
Depending on the vector selection method, a vector is inferred from the

selected geometry. The vector is displayed temporarily.
Among the vector selection methods are: Inferred Vector, Between Two Points,
At Angle, Edge/Curve Vector, Face Normal, Plane Normal, Datum Axis, XC
Axis, YC Axis, ZC Axis, and Vector Constructor.
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General Flange
ÏÏÏ Parameters
ÏÏÏ
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6
ÏÏÏ Add Tangent Edges
When in the Bend String selection step, the Add Tangent Edges toggle is
enabled. If you set this option, the system will automatically select all edges that
are tangent to your current selections. The system will maintain this setting so
the set of tangent edges can be re-evaluated whenever the model updates.
Thickness
If you have selected bend edges from a solid body, the system will produce a
General Flange with the given thickness.
If you turn ON Infer Thickness (from the Options dialog), the system will build
the General Flange using the thickness derived from the target geometry. The
thickness will be associative to the target geometry ć if the thickness of the
target body changes, the General Flange thickness will automatically change.
Note that the system assumes uniform thickness.
You can control the thickness of the General Flange by turning OFF the Infer
Thickness toggle (from the Options dialog) and entering a valid expression into
the Thickness field. This field is only available if Infer Thickness is OFF. The
default thickness is the inferred material thickness. You cannot enter a negative
thickness. If you specify a thickness for the General Flange, the system will
create an expression to maintain that value.
If the thickness is greater than any bend outer radius, the General Flange will
not be thickened. You will be warned and the feature will be created as a sheet
body.
The thickness direction is inferred from the target faces. The system will always
thicken the General Flange such that the attachment face of the General
Flange aligns with the faces adjacent to the target faces.
EDS Unigraphics NX
General Flange
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Parameters Method ÏÏÏ
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Parameters
When using the Parameters method, you must enter the parameters that define
the plus, bends, and webs. These parameters may be defined using constant
values or by defining laws. You may define parameters for up to 12 bend/web
combinations, called Steps. All these values can be defined in two ways:
Constant ć Enter any valid expression to define a constant value (i.e.,

it yields a constant value as it is evaluated along the spine). An
expression will be created for each constant value you supply.
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General Flange
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Law Controlled – This brings up the Law Curve dialog, which can be used to
define a value that changes along the length of the spine.
Reverse Bend Direction
Upon selecting the bend string, the system displays a vector that defines the
direction of a positive bend angle. Toggle Flip Bend Direction to cause the
General Flange to build in the opposite direction. By default, the bend
direction will be normal to the tangent face.
Flange
Plus Extension
Bend Edge
Top View
Plus
The Plus lets you extend the tangent faces before attaching the bend. This
extension will follow a direction normal to the tangent face. This field is only
available in the Bend Edges selection step. Specify the plus as either a constant
or law controlled value. The Plus must be greater than or equal to zero. A Plus
value can only be entered for Step 1 when creating multiple stepped flanges.
EDS Unigraphics NX
General Flange
Step Data
ÏÏÏ
The Step Data field lets you define bend and web parameters for each step. The ÏÏÏ
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6
delete steps. Set the menu to a step number (Step 1, Step 2, etc.) and the bend ÏÏÏ
option menu contains settings for all defined steps as well as fields to add and
and web parameter fields are populated with the values for that step. Select the
Add option to add a new step following the current step. The bend and web
parameter fields are populated with default values. The maximum number of
steps is 12. Select the Delete option to delete the current step. There must be at
least one step.
Radius
The Radius field controls the bend radius of the current step. Specify the radius
as either a constant or law controlled value. You may define either the Inner or
Outer radius. The outer radius must be greater than the thickness, or the
thicken operation will fail and the General Flange will be created as a sheet
body. The minimum allowable radius is the modeling tolerance.
CAUTION If you are working with a solid part, it's important to make
sure you insert the correct bend radius value for the selected bend edge.
If you specify an internal radius value but select the outside bend edge of
the target face, the resultant flange will not reflect the correct bend
geometry.
Angle
The Angle field defines the bend angle in degrees. Specify the angle as either a
constant or law controlled value. A positive value bends the General Flange in
the direction of the displayed bend vector. The angle may have any value
between -360° and 360° , but not zero, plus or minus the model's angle
tolerance (as set in the Preferences→Modeling dialog under the Modeling
Application). The bend angle should not allow a self intersection between the
general flange bend segment and the target body.
Length
The length of the general flange is defined as the length of the extension from
the edge of the bend to the end of the flange. It is equivalent to the Tangent
Length of a regular flange feature. The length can be specified using a constant
or law controlled value. The length can be zero or any value greater than zero.
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General Flange
ÏÏÏ
ÏÏÏ Build to Sections Method
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Build to Sections
Section Curves
The General Flange can be defined using section strings. The section strings
must be created with Modeling tools. The General Flange dialog does not
support section string creation.
The section curves must have the following criteria:
Each section must consist of an arbitrary number of curves and edges

that comprise an open, tangentially joined (G1) string.
One end of each section must touch the bend edge. The section must
be tangent to the target face at this point.
Strings can have a different number of curves in the string.
It is acceptable to end a string with an arc.
NOTE There is builtĆin functionality which allows you to drag a

window around the section strings without having to
select them manually. In most cases, the system will figure
out the order.
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General Flange
Extend Start and Extend End

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When section curves are not defined at the spine ends, the Extend Start and
Extend End toggles determine how the General Flange will be interpreted at
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the spine ends. If either toggle is ON, the General Flange will maintain a
constant section from the last defined section to the spine start/end. If it is OFF,
the General Flange will only be created between the extreme section curves. If
there is only one section string, the General Flange is always extended to
spine/bend ends.
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General Flange
ÏÏÏ
ÏÏÏ Build to Faces Method
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Build to Faces
Shaping Faces
You can build a General Flange by specifying shaping faces that define its top
face. The faces can come from either solid bodies or sheet bodies.
The shaping faces must meet the following criteria:
They must not be from the body of the target faces.

They must be G1 (tangent) with the target faces at the bend edge.
To select all G1 faces in the Shaping Faces selection step, set the Filter to G1
Faces, then select a seed face and drag a selection rectangle around the
remaining faces.
The General Flange top face is approximated by taking sections normal to the
spine through the shaping faces. The Tolerance field defines the section
sampling along the spine. The Minimum Number of Sample Points provides a
means of generating more sections along linear spine curves. Set these values
on the Options dialog. If a shaping face contains a hole or some other void, the
cross section curve that is generated will end at that void.
You will get the best results if you only choose G1 continuous faces from a
single body.
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General Flange
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Punch Vector Method ÏÏÏ
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Punch Vector
Punch Vector
Defining a General Flange using a Punch Vector is similar to using Parameters

method, however, the first bend angle is determined from a user-specified
vector. Select Punch Vector to bring up the standard vector selection method.
The other fields are identical to the Parameters method. The system displays
the punch vector to indicate the bend direction (similar to the bend direction
vector in Parameters method). You must select a punch vector ć there is no
default. The punch vector will be associative to the selected reference geometry
(if any).
The spine will be projected to a plane that is normal to the punch vector prior
to construction. This is necessary to generate the proper section curves.
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General Flange
ÏÏÏ Since the first bend angle is a function of the punch vector, the Angle field (for
ÏÏÏ the first step only) is the angle with respect to the punch vector. The angle can
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be between ć360° and +360° . The default angle of zero makes the web parallel
to the punch vector. Angles for other steps are relative to the previous step, as
in Parameters method.
Bend Allowance Formula
You can choose a Bend Allowance Formula by pressing this button. The Bend
Allowance Formula dialog is displayed below. You can select the Bend
Allowance Formula (BAF) from the list or you can enter the BAF in the text
field.
If Use Global is turned ON in global parameters for Bend Allowance Formula,

this option will be removed from the General Flange dialog.
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General Flange
Adjacent Faces ÏÏÏ

ÏÏÏ
When you select the bend edge(s), there are two adjacent faces available if ÏÏÏ
6
ÏÏÏ
you're working with a solid body and only one adjacent face if you're working
with a sheet body.
Solid bodies Sheet Body
Selected Bend Edge
For solid bodies, the system measures the distance from each face to its
opposite face. The shorter distance is assumed to be the thickness and the
related faces become the sheet metal surface. The remaining faces are assumed
to be the target attachment faces. The target attachment faces are highlighted
when you select the bend edges. If the wrong faces are highlighted, simply press
the Adjacent Faces button.
This option is not available if you have selected edges from sheet bodies.
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Sheet Metal Design
Student Guide
6-17
General Flange
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ Options
Infer Thickness
Set this option if you want the system to infer the thickness of the General
Flange from the selected geometry. The system will sample the thickness at one
point on the tangent faces. It will assume uniform thickness.
If this toggle is turned OFF, you can enter a valid expression in the Thickness
field shown on the main dialog.
If Use Global Thickness is turned ON in global parameters, this option will be

grayed out (as shown above).
EDS Unigraphics NX
General Flange
ÏÏÏ
ÏÏÏ
Infer Spine ÏÏÏ
6
ÏÏÏ
The Infer Spine option enables the system to generate a spine that will be
usable for the given input data. The spine will be created internally only ć it will
not be saved. If the user has explicitly selected a spine, the system will attempt
to use it as is, regardless of this setting of this toggle. If the spine does not
match the input data, (e.g., section curves are not normal to the spine), the
feature will give an error and the General Flange will not build.
The system will create this curve using various approaches:

Bend edges that have a high degree of concavity can be problematic,
since they can often yield self-intersecting surfaces. Infer Spine will
attempt to generate a spine by smoothing out the bend edge. Note that
this will change the shape of the General Flange by making it spread
out more. This technique is used by all construction methods, except
Build to Sections. (See the figure below)
If the creation method is Build to Sections, the Infer Spine option will
cause the system to generate a spine that is normal to all selected
section curves.
If the creation method is Punch Vector the system will project the bend
edge to a plane that is normal to the punch vector. It will further apply
the smoothing algorithms to reduce the amount of concavity.
The Infer Spine setting will be used in all states of the General Flange (formed,
unformed, or intermediate).
The figure below shows a General Flange with a concave bend edge. The spine
has been adjusted as shown.
Original Spine
Adjusted Spine
Spine Adjustment
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6-19
General Flange
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ r Value and Area Preserve
The r value is the average strain ration or normal anistropic property of the
material formed. Higher r values represent a higher resistance to thinning when
the material is stretched, or resistance to thickening when the material is
compressed. This will affect how the General Flange is mapped to other states.
Selecting the Area Preserve button is equivalent to specifying an infinite r value.

The default value of 1.0 corresponds to a homogeneous material.
Distortion
When the general flange is placed in any formed or unformed state, the
material will distort. The flange profile will always remain fixed along the bend
edge, but outer edge distortion can be controlled by selecting either the Along
Section or BiĆdirectional distortion options.
Along Section Ć this option calculates a distortion which is constrained
to be along sections normal to the governing spine. (Note that this is
the bend edge when a specific spine string is not selected during flange
creation). The end edges of the flange remain normal to the governing
spine while the far edge distorts.
BiĆdirectional Ć this option causes a spreading type of behavior by
allowing the flange to distort on all three outer edges as it is unformed.
NOTE Regardless of the selected distortion method, additional

deformation constraints may be placed on the flange
when creating unforming sequences. This topic will be
addressed in the Forming and Process Tables lesson.
EDS Unigraphics NX
General Flange
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Formed
Unformed Along Unformed

Sections BiĆdirectional
Distortion Algorithms
Tolerance
The construction of the general flange feature involves an approximation

process, which is controlled by the Tolerance option. The default value is the
distance tolerance found under the modeling preferences.
Note that unrealistically small tolerance values may produce excessively

complex geometry or a failure to construct the General Flange. It may be
necessary to experiment with various tolerances to determine the best value for
any particular General Flange.
A General Flange is built by creating section curves that are normal to the bend
edge (or spine) at points that are determined by the Tolerance field. Since this
would give a small number of sampled points along linear segments, the
Minimum Number of Sampled Points field can be used to increase the density
of these points. An example of its use is when using Build to Faces along a
linear bend edge. The faces may have details that require a larger number of
sections than the bend edge curvature would yield.
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Student Guide
6-21
General Flange
ÏÏÏ Reference Lines
ÏÏÏ
ÏÏÏ
Mold Line
6
ÏÏÏ
Contour Line Form Block Line
Contour Lines
You can request the system to create Contour lines for certain General Flanges.
The contour line is defined as the intersection of surfaces extended from the
tangent face and the web of the first step. You can only generate contour lines
for the first step of General Flanges created using Parameters Method or Punch
Vector Method. Contour lines can only be applied to General Flanges whose
angles have an absolute value less than 135°.
Mold Lines
You can request the system to create Mold lines for certain General Flanges.
The mold line is defined as the intersection of surfaces extended from the
tangent face and a surface normal to the tangent face and tangent to the bend
face. You can only generate mold lines for the first step of General Flanges
created using Parameters method or Punch Vector method. Mold lines can only
be applied to General Flanges whose angles have an absolute value greater
than 90°.
EDS Unigraphics NX
General Flange
Reference Lines (cont'd)

ÏÏÏ
Mold Line ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Contour Line Form Block Line

Form Block Lines
You can request the system to create Form Block lines for certain General
Flanges. The form block line is similar to the contour line, however it applies to
the inner surfaces of the flange. You can only generate form block lines for the
first step of General Flanges created using Parameters method or Punch Vector
method. Form block lines can only be applied to General Flanges whose angles
have an absolute value less than 135°.
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6-23
General Flange
ÏÏÏ Construction Tips

ÏÏÏ
ÏÏÏ
6
ÏÏÏ
The following tips will help you to successfully create a general flange:
The system may fail to boolean the general flange to the target body. If
this happens, a warning will be generated and a standalone feature will
be created. If this happens, it is suggested that you work with a sheet
body first, then thicken it. In simpler cases, check all of your values to
make sure they are realistic.
Make sure the section curves are tangent to the target face and in a
plane normal to the spine.
The flange creation may fail if the governing spine curve is too severe.
At any given concave point on the flange, the bend radius must be less
than the radius of curvature of the edge or a selfĆintersection will
occur and the flange will fail to create.
Bend Radius of General Flange

Note: Bend Radius of
Material General Flange (R1) is
Convex Thickness larger than radius (R2) of
portion
concave portion of Bend
of Bend SelfĆ
Edge
Edge Intersection
R1 = 1.15 R1 = 1.15
General Flange
Bend Radius = R1 R2 = 1.11
Concave portion of
Bend Edge
The system will not allow the selection of a spine curve which contains
discontinuities (such as sharp corners). The system will generate a
warning message to deselect invalid curves.
Although the system can reĆsort the sequence of selection picks, it is
suggested that you pick a contiguous string of curves or edges when
selecting the bend edge or spine.
EDS Unigraphics NX
General Flange
Remember to load and activate your user standards if you wish to

ÏÏÏ
standardize the feature's parametric options.
ÏÏÏ
Some text fields within the General Flange dialog (e.g. law options),
do not support expressions or mathematical statements (e.g. 1/2 or
ÏÏÏ
6
ÏÏÏ
p10).
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6-25
General Flange
ÏÏÏ Activity 6-1: General Flange Creation Methods

ÏÏÏ
ÏÏÏ
6
ÏÏÏ
In this activity you will create general flanges using a variety of creation
methods.
Step 1 Open the part smd_genflg. Save this part as xxx_genflg

Step 2 Create a stepped general flange.

Choose the General Flange icon.

Notice that the Bend Edges selection step is highlighted and you
are prompted to select continuous edges.
Select the top edge of the spline curve in the graphics
window.
Select this edge

of the part
NOTE You can reselect any selection step icon at any time in the
creation process to correct that steps associated input.
Use the <Shift> MB1 combination to deselect unwanted
geometry.
EDS Unigraphics NX
General Flange
Change the Angle to 45

ÏÏÏ
ÏÏÏ
TIP Double click inside the input field to highlight and
replace the existing value.
ÏÏÏ
6
ÏÏÏ
Change the Length to .50
Choose the Step Data button and select the Add option.
Notice that the Step Data now displays Step 2.

Change the Angle to -60
Change the Length to .20
Toggle Confirm Upon Apply ON and then choose Apply.
Rotate and inspect your model; if the results appear correct,
choose OK. Otherwise, choose the Back button and flip the
bend direction or edit the parameters as necessary.
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General Flange
ÏÏÏ Step 3 See how a spine can be used to affect the flange geometry.
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
If you are not in the wireframe mode, choose the Wireframe
icon.
Make layer 41 selectable. Resize the graphics image if

necessary.
Choose the Edit Feature Parameters icon.
Select the general flange either from the Feature Selection

list, or from the graphics window.
Choose OK.
Choose the Spine String icon in the General Flange

dialog.
Change the Filter option to Curve.
Select the orange curve in the graphics window .
Choose OK twice to complete the edit.
EDS Unigraphics NX
General Flange
The flange is now limited by the length of the spine curve at one
ÏÏÏ
end and by the edge of the part at the other end. The taper
ÏÏÏ
characteristic of the flange is derived from section plane cuts
normal to the spine curve. ÏÏÏ
6
ÏÏÏ
Step 4 Create a Law Controlled general flange.
Make layer 1 your work layer. Make layer 82 selectable and

all the other layers invisible.
Using the sheet body, make an extruded solid .08 inches

thick.
Make layer 82 invisible.
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General Flange
ÏÏÏ Select the front edge of the top face as the bend edge.
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Select this edge as

the Bend Edge
Set the Plus to .20
Change the Radius from Constant to Law Controlled.
EDS Unigraphics NX
General Flange
Choose Linear from the Law Curve dialog.

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Change the Start Value to .50 and the End Value to .15
Choose OK.
Change the bend Angle back to 90
Change the web Length from Constant to Law Controlled.
Again, choose the Linear option.
Leave the Start Value at 1.0 and set the End Value to .50
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General Flange
ÏÏÏ Choose OK.

ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Ensure the Confirm Upon Apply button is ON.
Choose Apply to create the flange. Rotate the part to

examine the flange geometry. Accept the results if they
appear as the in figure below.
Plus
Law Controlled
Web
Law Controlled
Bend Radius
EDS Unigraphics NX
General Flange
Step 5 Review the unformed shape.

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Select the general flange from the graphics window.
Choose the Unform Selected Features button from the

Form/Unform dialog.
Orient the view to the Right view.
Review the flange profile. Notice the spike at the outer edge of
the part?
Spike in the
flange profile.
Because the Distortion option was set to Along Section, the far
edge of the unformed flange will buckle to accommodate the
material compression occurring in this area.
For reference, extract edge curves from the outer edges of

the flange using the Insert→Curve Operation→Extract
function.
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General Flange
ÏÏÏ Step 6 Change the flange distortion control.

ÏÏÏ
ÏÏÏ
6
ÏÏÏ Choose the Edit Feature Parameters icon and select
the general flange feature.
Choose OK.
Within the General Flange Options dialog, change the

Distortion option from Along Section to BiĆdirectional.
Choose OK until the general flange updates. (Watch the

status line. This should be 3Ć4 clicks with your mouse
button.)
Your unformed flange should now reflect a smooth outer edge.

The ends of the flange have shifted outward to compensate for
the material distortion.
EDS Unigraphics NX
General Flange
Activity 6-2: Other General Flange Creation Methods ÏÏÏ

ÏÏÏ
ÏÏÏ
6
ÏÏÏ
In this activity you will learn how to use section strings and faces to create
general flanges.
Step 1 Create a general flange using a single section string.
Open the part smd_genflg2.
Change the method to Build to Sections.
Select the bottom left fillet edge, the bottom back edge and
the bottom right fillet edge as the bend edges.
Select the bottom edges.
Click MB2 twice to skip the Spine String selection step.
At the Section Strings step, select the orange section curves.

Accept your selections, if necessary.
Choose the Options button.
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General Flange
ÏÏÏ Ensure the Distortion option is set to BiĆDirectional.

ÏÏÏ
ÏÏÏ
6
ÏÏÏ
NOTE The system automatically determines the part thickness,
because Infer Thickness is toggled ON, and inserts the
value into the Thickness field.
Choose OK twice to create the general flange.
Step 2 Create a flange using two sets of section curves.

Select the bottom left edge as the bend edge.
Select this bottom edge.
At the Section Strings step, select all of the orange section

curves (Remember to select the first string under the edges
of the last flange created). Accept your selections, if
necessary.
TIP You can drag a window around the curves you wish
to select.
EDS Unigraphics NX
General Flange
Choose OK to create the general flange.

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Step 4 Create a general flange using the Build to Faces method.
This is a model of three sheet bodies. They represent legacy

data imported into your file. You will use the Build to Faces
option to create a formable General Flange based on these
existing faces.
Choose Insert→Form Feature→Thicken Sheet...
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Sheet Metal Design
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General Flange
ÏÏÏ Enter .125 for the First Offset.

ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Select the planer sheet body .
Select this face
Choose OK.
EDS Unigraphics NX
General Flange
ÏÏÏ
Choose the General Flange icon. ÏÏÏ

ÏÏÏ
6
Choose the Options button and change the Distortion option ÏÏÏ
back to Along Sections.
Choose OK.
Change the method to Build to Faces and the Filter to

Solid Edge.
Select the bottom front edge of the solid body as the Bend
Edge.
Select this bottom edge.
Choose MB2 to advance to the next selection step.
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6-39
General Flange
ÏÏÏ Select the bottom back edge of the solid body as the Spine.
ÏÏÏ (Change the filter to Solid Edge.)
ÏÏÏ
6
ÏÏÏ
Select this bottom

back edge.
Change the Filter to Any Face.
Select the remaining faces as the Shaping Faces.
Select these faces.
EDS Unigraphics NX
General Flange
Choose OK.
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Step 5 Examine your part.
Choose the Top view icon and then the Trimetric view
icon.
Choose the Form All button to reform your part.
Step 6 Edit the Shaping Faces that created the General Flange
and see the associativity between the two.
Make layer 50 selectable. This will show the spline used to

create the nonĆplanar face.
Change the view to top by selecting the Top view icon.
Choose Edit→Curve→Parameters...
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6-41
General Flange
ÏÏÏ Select the spline.

ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Choose the Edit Pole button.
Place your cursor over any interior pole, click and hold MB1
to move the pole to a new location (within a reasonable
distance from its origin). Repeat for other interior poles as
desired.
Choose OK three times and watch your part update.
Shade your image and inspect the part.
Unform your part.
Again, look at your part using the Top view Trimetric view
icons.)
Form your part.
EDS Unigraphics NX
General Flange
Activity 6-3: Create a Gen. Flg. by the Punch Vector ÏÏÏ

ÏÏÏ
Method ÏÏÏ
6
ÏÏÏ
Step 1 Create a general flange using the Punch Vector method.
Change the Method to Punch Vector and if necessary,

set the Filter to Solid Edge.
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6-43
General Flange
ÏÏÏ Select the top edge of the hole in the solid body as the Bend
ÏÏÏ Edge.
ÏÏÏ
6
ÏÏÏ Select this top edge
Choose MB2 twice to advance to the Punch Vector selection
step.
Select the Punch Vector in the diagram.
Select this vector
Change the Plus factor to 0 .
Change the Radius to .09 .
Change the Length to .50 .
EDS Unigraphics NX
General Flange
Toggle ON the Confirm Upon Apply button (if it is not ON

ÏÏÏ
already).
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Choose Apply to create the flange. Rotate the part to

examine the flange geometry.
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6-45
General Flange
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Accept the results if they appear as the in figure above.
Step 2 Edit the expression used to orient the Punch Vector and
see its association to the General Flange.
Choose Tools→Expression...
Choose the angle variable and change the value to 15 .
EDS Unigraphics NX
General Flange
Choose OK.
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Step 3 Examine your part.
Change the view orientation using the Top view icon
and then the Trimetric view icon.
EDS
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6-47
General Flange
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
SUMMARY The General Flange application enables you to

create formed flanges along contoured
(nonĆlinear) edges of a part.
In this lesson you:

Created and edited a general flange using
the Parameter method.
Created a general flange using the Build to
Section Curves method.
the Build to Faces Method.
the Punch Vector method.
EDS Unigraphics NX
Sheet Metal Punch
Sheet Metal Punch

Lesson 7
PURPOSE Create and edit sheet metal punch objects using the
Sheet Metal Punch feature.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Create a Sheet Metal Punch.
Activity Page
7-1 Creating Sheet Metal Punches . . . . . . . . . . . . . . . 7-14
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7-1
Sheet Metal Punch
The Sheet Metal Punch Dialog
The Sheet Metal Punch feature allows you to create userĆdefined emboss, coin
and lance operations across multiple, adjacent placement faces, including the
formable bend surface of a flange. Open and closed profiles intersecting the
periphery of the part are also available.
You can access the Sheet Metal Punch dialog from Insert→Sheet Metal
ÏÏÏ
Feature→Punch or from the Sheet Metal Punch icon in the Sheet Metal
ÏÏÏ
7
Feature toolbar. To edit a Sheet Metal Punch, use Edit→Feature or the Edit
ÏÏÏ
ÏÏÏ
Feature toolbar.
The Sheet Metal Punch dialog steps you through the process of placing and
creating the punch feature. As with all selection step type of dialogs, you can
jump to any step of the process and make adjustments before completing the
creation of the feature. However, all steps must have their required inputs
specified before you will be allowed to create the feature.
Size
Parameters
EDS Unigraphics NX
Sheet Metal Punch
Selection Steps
Placement Face
Like other sheet metal features, a placement face must be selected for the
location of the Sheet Metal Punch feature. The Placement Face defines
whether the outline curves will be projected onto the top or bottom of the
target body. By default, the top of the punch follows the contours of the ÏÏÏ
ÏÏÏ
7
placement face and any adjacent faces onto which the punch outline projects.
ÏÏÏ
ÏÏÏ
The placement outline curves (see figure below) are projected onto any
adjacent faces, if necessary. This way, only a single placement face need be
selected. A punch feature may also cross formable faces (also shown below).
Adjacent faces
Placement face
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7-3
Sheet Metal Punch
Placement Outline
The placement outline is a set of curves which define the profile of the punch
on the placement face. The profile may be open or closed; however, if it is
open", it must intersect the periphery of the part. Also, the curves must be
contiguous, but sharp corners are allowed.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Open profiles crossing the periphery
If the curves are not created on the placement face, the system will project
them onto the face along the specified punch direction vector. To avoid possible
projection errors, it is suggested that the curves be created on the placement
face.
The outline curves are associated to the punch feature. Like other sheet metal
features, you should place the model in the original creation state (formed or
unformed) before editing the outline curves. The punch will not update its
profile until the part is placed in the original creation state.
EDS Unigraphics NX
Sheet Metal Punch
Tool Center
Tool Center allows you to select a point to indicate the center of the punch (e.g.
the index point). This point can be on or off of the placement face. By default
the Auto Centroid option is ON within the Options dialog, in which case, this
step is grayed out.
NOTE If the Auto Centroid option is not used, the point used
for the Tool Center must be created prior to entering the
Sheet Metal Punch operation.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
The punch direction vector will be established from this point. In the case of a
nonĆplanar placement face, the reverse face normal" vector is calculated at
this point after being projected onto the placement face.
Lancing Curves
Lancing Curves allows you to select a curve or set of curves to indicate where
the punch will be ripped" away from the adjacent curves. These lanced curves
are part of the placement outline curves and should be included in the
Placement Outline selection step.
NOTE This option is only available if the Punch Type is set to

Lance.
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7-5
Sheet Metal Punch
When selecting the lancing curve(s), the system will automatically select any
curves that are tangent to the one(s) selected. When the string comes to a sharp
corner the selection process stops.
ÏÏÏ
ÏÏÏ
7
Lancing curves on both
sides.When selecting a
ÏÏÏ
ÏÏÏ
curve, all tangent curves
will also be selected.
Lancing curves on two sides
Lancing curve
Lancing curve on one side
EDS Unigraphics NX
Sheet Metal Punch
Direction Vector
Direction Vector will bring up the Vector Method option. Use this option to
choose a punch direction other than the default or flipped default directions. It
allows you to specify the direction along which the outline curves and the actual
punch feature will be applied to the part.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Punch Type
V18 has added the option to choose between Embossed, Coin or Lance punch
types, with the default set to Emboss. Coin punches are used to create stamped
shapes. Coin acts similar to an extrude and subtract function. Lance allows the
definition of ripped edges (see Lancing Curves).
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7-7
Sheet Metal Punch
Top Type
By default, the top of a punched feature will follow the contour of the
placement face. This is the Offset setting for the Top Type.
If the Top Type is set to Flat, the top of the punch will be a surface which is
perpendicular to the punch direction vector.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Offset Top Type Flat Top Type
If the punch outline is compromised of a closed, circular profile, the additional

option of applying a Round or ConeĆshaped top will be available. Round and
Cone top types require a closed, circular profile and can only be placed on a
single, planar placement face.
EDS Unigraphics NX
Sheet Metal Punch
Size Parameters
There are five geometric parameters which define the Sheet Metal Punch
feature. They are Depth, Die Radius, Taper Angle, Punch Radius and Cone
Depth.
ÏÏÏ
ÏÏÏ
7
The Depth parameter is the distance which the punch extends beyond the ÏÏÏ
ÏÏÏ
surface of the part, as measured along the punch vector. If the Depth is less
than or equal to the Punch Radius, you will create a Dimple. The depth can be
less than the material thickness, however the die and punch radius values must
be considered when do this.
The Die Radius, or Blend Radius, is the value of the blend between the face on
the opposite side of the placement face and the sides of the punch. This is a
fixed value resulting in a constantĆradius blend.
The Taper Angle is a constant angle measured from the punch direction vector
to the side faces of the punch.
The Punch Radius, or Top Radius, is the blend radius between the inner sides
of the punch and the punch top, or it is the value of the inside radius of any
closed, circular emboss (e.g. a dimple or cone type top).
Taper Angle
Punch Radius
Depth
Die Radius
Offset Punch with Taper Angle
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Sheet Metal Punch
The fifth parameter, Cone Depth, is the height of the cone portion of a punch
as measured from the base of the cone to the top of the punch feature. This
option is only available if the Top Type is set to Cone.
Punch Radius
Die Radius
Depth
ÏÏÏ
ÏÏÏ
7
Cone Depth
ÏÏÏ
ÏÏÏ Cone Top Punch with no Taper Angle
Taper Angle
Depth
Die Radius
Round Top Punch with Taper Angle
Circle defines
Spherical Radius
Die Radius Only Depth
Dimple
EDS Unigraphics NX
Sheet Metal Punch
Face Normal Direction
When Face Normal Direction is toggled ON, the axis of the Sheet Metal Punch
will align normal to the placement face. If you prefer to define a specific vector
for this axis, turn this toggle OFF and use the Direction Vector selection step to
define a new vector.
Flip Side Vector

ÏÏÏ
ÏÏÏ
7
The side vector points to the region, on either side of the placement outline, to
be punched (area that will be displaced). Using this button, you can flip this
vector to change the region you want to punch.
ÏÏÏ
ÏÏÏ
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7-11
Sheet Metal Punch
Options
Options allows you to assign the Placement Outline as either the Inside or the
Outside of the punch perimeter. The punch outline either shows the Inside
surface of the punch or the Outside surface of the punch.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Inside Outside
Placement Outline Placement Placement
Auto Centroid Creation: When ON this option will create an automatic tool
center point (centroid) based on a 2D analysis of the placement outline curves.
The default setting is ON.
If the profile curves do not lie on the placement face(s), neither will the
centroid. It will be projected to the placement face internally along the punch
vector.
Flanged Cutout: When ON this option will create a flanged cutout (drawn
cutout or flanged hole) in lieu of the emboss or coin punch. The default setting
is OFF.
Flange Cutout
EDS Unigraphics NX
Sheet Metal Punch
Construction Tips
Do not place Round top or Cone top punches on the bend surface of a
flange feature. The formable nature of the flange produces distortion
within the punch feature which will lead to Boolean errors during the
forming or unforming process.
When using sketches to define the placement outline, it is
recommended that you create a separate sketch for each punch
feature. This will ensure that edits made to a sketch will not
accidentally affect a nonĆintended feature.
If using splines for the placement outline, the resultant punch faces ÏÏÏ
ÏÏÏ
7
will be comprised in some areas of trimmed BĆsurfaces. This may
present minor difficulties while attempting to dimension the feature,
or a section cut of the feature.
ÏÏÏ
ÏÏÏ
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7-13
Sheet Metal Punch
Activity 7-1: Creating Sheet Metal Punches
In this activity you will create the base of a sheet metal housing while practicing
several different Sheet Metal Punch creation techniques.
ÏÏÏ
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7
ÏÏÏ
ÏÏÏ
Step 1 Create the body of the part.
Open the smd_seedpart and save it as xxx_punch, where xxx

are your initials. Ensure you are in the Modeling application.
Change the bend radius and thickness expressions to the

following values (Tools→Expression):
R = 3/32
T = .080
EDS Unigraphics NX
Sheet Metal Punch
Create a 14 x 4 x T inch block as your base feature and locate

it at (XYZ=0,0,0).
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7
ÏÏÏ
ÏÏÏ
Step 2 Create sheet metal flanges.
Create a bent up flange with the following parameters on the
back edge of the block:
Bend Angle = 30
Inside Radius = R
Create a bent down flange on the end of the existing flange
using the following parameters:
Tangent Length = 5.50
Bend Angle = 30
Inside Radius = R
Your part should look like this when you're through:
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Sheet Metal Punch
Change the work layer to 2 .
Create a bend up flange on the front face of the part. Use

the following parameters:

Bend Angle = 90
Inside Radius = .35
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7
Reference Lines = Contour (Under the Options icon)
ÏÏÏ
ÏÏÏ NOTE You'll use the contour line to position future features.
Flange Contour
Line
EDS Unigraphics NX
Sheet Metal Punch
Step 3 Create sheet metal punches on the flange feature.
Create and locate two separate 1.00" diameter circles on the

upper face of the flange web surface (Recommend creating a
sketch on layer 21).
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7
ÏÏÏ
ÏÏÏ
Choose the Sheet Metal Punch icon.
Select the top face of the flange web as the Placement Face.
Select one of the circles as the Placement Outline curve.
Adjust the follow:
Placement Outline = Inside

Auto Centroid Creation = ON
Flanged Cutout = OFF
Change the Top Type to Flat.
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Sheet Metal Punch
Enter the following size parameters:
Depth = .125
Die Radius = .02
Taper Angle = 0
Punch Radius =.02
Choose Apply to create the punch feature.
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7
Create another punch with the same parameters using the
ÏÏÏ
ÏÏÏ
other 1.00" diameter circle. Your part should look like this
when you're through:
Punch placement curves and tool centers invisible for clarity
EDS Unigraphics NX
Sheet Metal Punch
Step 4 Edit a Sheet Metal Punch feature.

Create and position the following outline curve on the top
face of the part.
TIP You can create a sketch to contain and position the

curves (use work layer 22).
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7
ÏÏÏ
ÏÏÏ
Using the curves, create a Sheet Metal Punch feature with

the following parameters:
Top Type = Flat
Depth = .21
Die Radius = R
Taper Angle = 30
Punch Radius = R
NOTE Unlike other modeling operations, you must select each

sketch curve individually until the entire profile is
highlighted or drag a selection box around the entire
profile.
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Sheet Metal Punch
Ensure the Side Vector is pointing inward from the outline, if

not choose Flip Side Vector.
Choose OK to create the punch.
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7
ÏÏÏ
ÏÏÏ
Punch placement curves and tool center invisible for clarity
Stretch your curves or edit your sketch and change the length
of the rectangle from 4.00 to 5.00 .
If you used a sketch, choose the Update Model icon or
simply exit the sketch using the Finish Sketch icon.
EDS Unigraphics NX
Sheet Metal Punch
Step 5 Use the Flanged Cutout option to create a Flanged Hole.

Make two circles to use as the outlines for a flanged cutout
(sketch on layer 23). Create and locate them as shown below.
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7
ÏÏÏ
ÏÏÏ
Use Flange Contour Line Use Flange Contour Line
TIP If using a sketch, use the contour line, as shown, to

locate the circles.
Ensure the Placement Outline is set to Inside.
Toggle ON the Flanged Cutout option.
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Sheet Metal Punch
Choose OK.
Select the bottom face of the original block as the Placement

Face.
Select one circle and create a Sheet Metal Punch feature

with the following parameters:
Depth = .125
ÏÏÏ

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7
Die Radius = .02
ÏÏÏ
ÏÏÏ
Taper Angle = 0
NOTE A punch radius is not necessary since the floor of the

punch will be pierced by the flanged cutout option.
Choose Apply to create the punch.
Repeat the steps for the other circle.
Unform your model to test its integrity.
Step 6 Create a punch that crosses the periphery of the part.
Reform the part.
EDS Unigraphics NX
Sheet Metal Punch
Create and locate the curve profile shown below (use work
layer 24).
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7
ÏÏÏ
ÏÏÏ
Use Flange Contour Line

locate the curves.
Toggle OFF the Flanged Cutout option.
Choose OK.
Select the top face of the base block as the Placement Face.
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Sheet Metal Punch
Select the curves and create a Sheet Metal Punch feature

with the following parameters:
Depth = .25
Die Radius = R
Taper Angle = 45
Punch Radius = R
ÏÏÏ
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7
Ensure the side vector is pointing towards the center of the
outline. If necessary, choose Flip Side Vector.
ÏÏÏ
ÏÏÏ Choose OK to create the punch.
EDS Unigraphics NX
Sheet Metal Punch
Step 7 Create a lanced punch.
Create and locate the curve profile shown below (use work
layer 25).
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7
ÏÏÏ
ÏÏÏ
Use Flange
Contour Line

locate the curves.
Change the Punch Type to Lance.
Select the top face of the base block as the Placement Face.
Select the three curves as the Placement Outline.
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Sheet Metal Punch
Select the vertical line as the Lancing Curve.
Depth = .25
Die Radius = R
Taper Angle = 45
ÏÏÏ

ÏÏÏ
7 Punch Radius = R
ÏÏÏ
ÏÏÏ Ensure the side vector is pointing towards the center of the
outline. If necessary, choose Flip Side Vector.
Choose OK to create the punch.
Make layer 1 your work layer and all other layers invisible.
Shade and rotate your model to examine the various

punches.
EDS Unigraphics NX
Sheet Metal Punch
SUMMARY The Sheet Metal Punch application allows you

ÏÏÏ
ÏÏÏ
7
to create embossed and coined features on
sheet metal parts.
ÏÏÏ
ÏÏÏ
In this lesson you:
Applied the Sheet Metal Punch function
using the emboss option.
Applied Auto Centroid and Flanged cutout
functionality.
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7-27
Sheet Metal Punch
ÏÏÏ
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7
ÏÏÏ
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EDS Unigraphics NX
Sheet Metal Solid Punch

Lesson 8
PURPOSE Create and edit sheet metal punch objects using the
Sheet Metal Solid Punch feature.
Create a Sheet Metal Solid Punch.
ÏÏÏ
ÏÏÏ
Activity Page ÏÏÏ
8
ÏÏÏ
8-1 Creating Sheet Metal Solid Punches . . . . . . . . . . 8-9
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8-1
The Sheet Metal Solid Punch Dialog

Similar in results to the Sheet Metal Punch, the Sheet Metal Solid Punch
feature embosses the shape of a solid tool onto a target sheet metal body. The
solid tool body may cross multiple, adjacent placement faces, including the
formable bend surface of a flange. Solid punches that intersect the periphery of
the part are also valid.
The Sheet Metal Solid Punch's advantage over the Sheet Metal Punch feature
is that you have direct control of what you want the punch to look like based
upon how you model the tool body.
You can access the Sheet Metal Solid Punch dialog from Insert→Sheet Metal
Feature→Solid Punch or from the Sheet Metal Solid Punch icon in the
Sheet Metal Feature toolbar. To edit a Sheet Metal Solid Punch, use
Edit→Feature or the Edit Feature toolbar.
The Sheet Metal Solid Punch dialog steps you through the definition of a target
ÏÏÏ face, tool body (which depicts the punch), transformation (optional) and
ÏÏÏ
selection of pierce faces (optional). As with all selection step type of dialogs,
you can jump to any step of the process and make adjustments before
ÏÏÏ
8
ÏÏÏ
completing the creation of the feature. However, some steps must have their
required inputs specified before you will be allowed to create the feature.
EDS Unigraphics NX
Selection Steps
Target Face
Like other sheet metal features, a target face must be selected for the location
of the Sheet Metal Solid Punch feature. The Target Face defines the direction
in which the punch will be applied to the target body. By default, the solid
punch is applied using the reverse face normals of the target face (see figure
below).
Tool Body
ÏÏÏ
ÏÏÏ
Placement face
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8
ÏÏÏ
Placement face
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Tool Body
The tool body is a solid body which defines the shape of the punch applied to
the target body. Create a solid tool body using any desired modeling technique.
The tool body may also intersect the periphery of the part (see figure below).
ÏÏÏ
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8
ÏÏÏ
Tool Body crossing the periphery
NOTE Currently only punch" type tools can be selected. The

ability to select a die" tool will be available in upcoming
releases.
EDS Unigraphics NX
Transformation
Place the tool body at the desired emboss depth so that it intersects with the
target sheet metal body. Alternately, you can reposition a copy of the tool body
so that it intersects with the target body by selecting the Transformation step.
When selected, you will be prompted to select a CSYS/point on the tool body
(From) and a CSYS/point on the target body (To). The Solid Punch will
transform a copy of the tool body to align the CSYS's. This step is only
necessary if you wish to move a copy of the tool body from its created location.
Pierce Faces
This optional step allows selection of face(s) on the tool body that will be
pierced. These pierced faces allow you to create features such as louvers.
ÏÏÏ
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8
ÏÏÏ
Pierce face
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NOTE Faces which would create openings, such as holes, cannot

be selected because it would cause the tool body to be
split into multiple pieces. If the pierce face(s) selected
cause this condition the following message appears.
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8
ÏÏÏ
EDS Unigraphics NX
Options
The Options dialog allows access to various creation aids.
Thickness
This option allows you to choose from Infer from Target (default) or Use
ÏÏÏ
Expression. If Use Expression is chosen the Thickness field in the main Solid
ÏÏÏ
Punch dialog will become active for input.
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8
ÏÏÏ
Create Auto Centroid
When ON this option will create an automatic tool center point (centroid)
based on a 3D analysis of the tool body. The default setting is ON.
Edge Blend
When ON this option will create edge blends for the inside and outside edges
created as a result of the boolean between the target and tool bodies. The blend
features are created immediately after the solid punch feature and can be
independently edited or deleted. The default setting is ON.
NOTE It is not necessary to enter a value for both Inner and

Outer Radius. If a value is entered in either field, the
system will calculate the opposing radius by taking the
thickness of the target body into consideration.
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8-7
Construction Tips
You may find it easier to create the Solid Punch in place where it is to
be applied to the target body, otherwise you will need to create
additional objects (CSYS or points) which would be used in the
Transformation step.
Solid Punch features may be instanced after creation. If the Edge
Blend option is turned ON and the blends are desired in the arrayed
copies, you must first group the Solid Punch and the two Edge Blends
together. Doing this will ensure all duplicate features have the edge
blends applied as well.
Consider building a library of standard" punches to be used at your
company. Communicate with your manufacturing group to find the
off the shelf" punches and build a tool body to reflect those punches.
Doing so can significantly cut costs during manufacturing by not
requiring special tooling to be built.
ÏÏÏ
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8
ÏÏÏ
EDS Unigraphics NX
Activity 8-1: Creating Sheet Metal Solid Punches
In this activity you will apply several different Sheet Metal Solid Punch features
using various creation techniques.
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8
ÏÏÏ
Step 1 Open the part smd_solid_punch and save it as
xxx_solid_punch, where xxx are your initials. Ensure you
are in the Modeling application.
Step 2 Create a gusset using Solid Punch.
Shade a rotate the part to better understand how the tool

body will be applied to the part.
Turn OFF the Shading and orient the view to Trimetric.
Choose the Sheet Metal Solid Punch icon.
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Select the outside bend face as the Target Face.
Bend outer
face
Choose MB2 to advance to Tool Body.
Select the green solid as the tool body and accept if

necessary.
ÏÏÏ Turn OFF the Create Auto Centroid option.
ÏÏÏ
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8
ÏÏÏ
Ensure Edge Blend is toggled ON.
In the Inner Radius field, enter a value of R and choose OK.
Ensure Blank the tool body is toggled ON and choose Apply.
Step 3 Create an instance of the gusset.
Open the Model Navigator.
EDS Unigraphics NX
Using the Ctrl key, select the SOLID_PUNCH and the two
BLEND features below the Solid Punch.
With all three features highlighted, place your cursor over

one of the features and press MB3.
Choose Group...
The Sets of Features dialog becomes available.
At the top of the dialog, enter GUSSET for the Feature Set
Name.
At the bottom of the dialog turn ON the Hide Feature Set

Members and choose OK.
Notice the three features have been replace by a single

feature named GUSSET.
ÏÏÏ
ÏÏÏ
Choose the Instance icon.
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8
ÏÏÏ
Choose Rectangular Array.
Select the GUSSET feature from the list and choose OK.
Enter the Parameters for the Instance as shown below:
Method General
Number Along XC 1
XC Offset 0
Number Along YC 2
YC Offset 5
Choose OK.
Step 4 Create a Louver using the pierce faces option.
Make layer 3 selectable and 2 invisible.
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8-11

Select the top face as the Target face.
Choose MB2 to advance to Tool body.

necessary.
Choose the Pierce faces icon.
ÏÏÏ Select the flat front face as the Pierce face as choose OK.
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8
ÏÏÏ
Pierce face
Shade and rotate to examine the solid punch.
Step 5 Create an instance of the louver.
EDS Unigraphics NX
Using the Ctrl key, select the SOLID_PUNCH and the two
BLEND features below the Solid Punch.
Create a group named LOUVER and Hide the Feature Set

Members.
Choose the Instance icon.
Choose Rectangular Array.
Select the LOUVER feature from the list and choose OK.
Method General
Number Along XC 1
XC Offset 0
Number Along YC 6
YC Offset 1 ÏÏÏ
ÏÏÏ
Choose OK. ÏÏÏ
8
ÏÏÏ
Step 6 Create a rectangular solid punch.
Make layer 4 selectable and 3 invisible.

Select the bottom face as the Target face.
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8-13

necessary.
Choose Apply to create the Solid Punch.
Shade and rotate to examine the solid punch.
Step 7 Create a solid punch and use transformation to locate it.
Make layers 5 and 10 selectable and 4 invisible.
Notice the CSYS associated to the conical punch tool body

and the CSYS located on the target body.
ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ
Select the bottom face as the Target face.
EDS Unigraphics NX
Select the green solid as the tool body.
Since the tool body does not intersect the target body the
following message appears.
Choose OK to the warning message.
Choose MB2 to advance to Transformation.
The Cue line prompts you to select a from" csys/point and a

to" csys/point.
Choose the CSYS on the Tool body (green solid) as the ÏÏÏ
FROM CSYS. ÏÏÏ
Choose the CSYS on the Target body as the TO CSYS.
ÏÏÏ
8
ÏÏÏ
Choose Apply to create the solid punch.
NOTE A copy of the tool body was transformed into place to

create the solid punch. This is done for every solid punch
feature, even if the location of the punch tool is already
defined. Unblanking the tool will reveal the original tool
body.
Choose Edit→Blank→Unblank All of Part.
Make layers 5 and 10 invisible.
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8-15
SUMMARY The Sheet Metal Solid Punch allows you to

create embossed and features on sheet metal
parts.
In this lesson you:

Applied the Sheet Metal Solid Punch
function using the punch option.
ÏÏÏ Applied pierce face functionality.

ÏÏÏ
ÏÏÏ
8
ÏÏÏ
Created rectangular arrays of grouped
features.
EDS Unigraphics NX
Sheet Metal Hole and Sheet Metal Slot

Lesson 9
PURPOSE To see the advantage to creating hole features in a

sheet metal part using the Sheet Metal Hole feature.
As well as to create slots on formable features using
the Sheet Metal Slot feature.
Create and edit holes in both a formed and

unformed sheet metal part.
Create a hole through multiple sheet thicknesses
Locate a sheet metal hole using an expression
Create and orient a Sheet Metal Slot
Activity Page
ÏÏÏ
ÏÏÏ
9
9-1 Creating Sheet Metal Holes . . . . . . . . . . . . . . . . . . 9-11
9-2 Creating Sheet Metal Slots . . . . . . . . . . . . . . . . . . . 9-29 ÏÏÏ
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9-1
The Sheet Metal Hole Dialog

The Sheet Metal Hole feature enables you to place a hole on any type of face.
When placed on a flange, the Sheet Metal Hole features are capable of forming
and unforming with the flange. Sheet Metal Holes may completely or partially
cross one or more bend areas, and can be used to create simple bend reliefs.
Sheet Metal Holes will distort when the state of the sheet metal part changes
from the original creation state.
You can access the Sheet Metal Hole dialog from Insert→Sheet Metal
Feature→Hole or by selecting the Sheet Metal Hole icon from the Sheet
Metal Feature toolbar. To edit a Sheet Metal Hole, use Edit→Feature or the
Edit Feature toolbar.
Positioning
Creation Method
Selection
Steps
Hole Types
Size
Parameters
ÏÏÏ
ÏÏÏ
9
ÏÏÏ
Hole Positioning Methods

The Sheet Metal Hole feature has the unique ability to be located on a
placement face using two different positioning methods. Like the Modeling
Hole feature, you can use positioning dimensions to locate the hole center point
from other features of the part.
EDS Unigraphics NX
To use the positioning method, the Method option on the Sheet Metal Hole
dialog must be set to Positioning.
The system will use the selected placement face as the reference plane for the
positioning dimensions. If this face is nonĆplanar, you must select another
planar face as the reference plane. When the placement face and the reference
plane are different, the hole center point will be projected along a vector
normal to the reference plane and onto the placement face.
You may also elect to locate the hole on a nonĆplanar surface using the Edge
Offsets option. With this placement option, the location of the hole is
determined by positive or negative offset distances from two intersecting face
edges which are attached to the selected placement face.
ÏÏÏ
ÏÏÏ
9
ÏÏÏ
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Selection Steps
The Sheet Metal Hole dialog is a Selection Steps type of dialog. The icons at the
top of the dialog are selectable, and will highlight as you step through the
process of placing and creating the Sheet Metal Hole.
Placement Face Direction Vector
Through Face Positioning Edge 2
Positioning Edge 1
Placement Face
Upon entering the Sheet Metal Hole feature creation function, the first
selection step to highlight is the Placement Face. This step prompts you to
select a single face on the body of the part on which you wish to place the hole.
The top of the hole follows the contours of this face. The pick point on the face
is used to calculate a default starting position for the hole center point.
ÏÏÏ Through Face

ÏÏÏ
9
ÏÏÏ Sheet Metal Hole can place a hole through more than one set of solid faces.
The Through Face step prompts you to select the last face on the opposite side
of the body from the placement face. The far edge of the last hole will follow
the contours of this face.
NOTE The Through Face selection step is only active when the
hole type is set to Through.
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Positioning Edge 1 & Positioning Edge 2
When the positioning method is set to Edge Offsets, these selection steps
become active. The positioning edges are used to position the hole center point.
These edges must be edges on the placement face and they must intersect with
each other. Upon selecting each edge, a conehead vector will display on the
edge, indicating the direction of a positive offset.
NOTE If a curved edge is chosen as a positioning edge, the offset

distance may be an arc extension. This can create
confusion in determining which arc and edge intersection
point is the desired location. ReĆorienting your view can
help alleviate mislocating the origin point.
Once positioning edges are selected, edge offset values can be entered into the
Edge 1 Offset and Edge 2 Offset fields. These values can be either positive or
negative and will be used to place the hole center point into, or outside of, the
placement face. There is no sequence order that must be followed, so any edge
may be chosen as the first or second positioning edge.
Direction Vector
The Direction Vector allows you to select a direction other than Face Normal to
define the axis of the Sheet Metal Hole. This option is only available when the
Face Normal Direction option is toggled OFF in the Sheet Metal Hole dialog. ÏÏÏ
ÏÏÏ
9
ÏÏÏ
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Vector Method
The Vector Method allows you to select a way to define the vector you will use
for the axis of the Sheet Metal Hole when Face Normal Direction is toggled
OFF. This will appear in the Sheet Metal Hole dialog after you select the
Direction Vector selection step.
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9
ÏÏÏ
EDS Unigraphics NX
Hole Types
There are three different hole types; Punch, Through, and Depth.
The Punch option creates a hole on the placement face which extends along the
direction vector to the nearest face. That is, it extends through the thickness of
the part. This hole type only requires the identification of an attachment face, a
position location, a diameter size, and a direction vector.
The Through hole type requires the same parametric information as the Punch
hole, but also requires the identification of the through face.
NOTE The diameter, position and orientation of through Holes

are associative to the first (or master) Hole. If you edit
any one of them, they will all change per your inputs.
Concentric, positionally and orientationally

associated sheet metal Through holes
ÏÏÏ
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9
ÏÏÏ
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9-7
The Depth hole type is fundamentally the same as the Punch hole type but you
can specify a depth and tip angle parameter for the hole geometry.
NOTE Unlike the Punch and Through holes, the Depth hole
currently does not distort when its placement face
changes its formed state.
Hole Diameter
Depth
Tip Angle
Size Parameters
The diameter and depth dimension are specified in the units of the existing part
(English or Metric). The Depth and Tip Angle parameters are only active when
the Depth hole type has been selected. Since a Depth hole may be placed on a
nonĆplanar surface with a nonĆnormal orientation, the actual depth of the sheet
metal hole with respect to the surrounding faces may vary. The depth value
defines the distance along the direction vector from the placement face center
point to the bottom of the hole.
ÏÏÏ
ÏÏÏ
9 The Tip Angle is added to the depth value of a hole. The tip angle value must
ÏÏÏ be greater than or equal to zero, but less than 180 degrees. A zero tip angle
value results in a flat end (blind) hole.
Face Normal Direction
When Face Normal Direction is toggled ON, the axis of the Sheet Metal Hole
will align normal to the placement face. If you prefer to define a specific vector
for this axis, turn this toggle OFF and use the Direction Vector selection step to
define a new vector.
EDS Unigraphics NX
Editing Sheet Metal Holes
When an Sheet Metal Hole is first created, the state of the part (formed or
unformed) is stored in the system and an undistorted hole is produced. Because
the sheet metal hole can be distorted by its underlying placement face, it is
important to place the model in this original creation state before editing its
geometric or positional parameters.
The system has a builtĆin warning mechanism that alerts the user whenever an
attempt is made to edit hole parameters while the model is in a different
formed state.
NOTE This mechanism is only available when you use the Edit
Feature operation. Editing a feature's parameters by
changing its expression value will bypass this warning
mechanism and may generate erroneous results. It is
imperative that all edits be accomplished through the
Edit Feature operation.
If you proceed with your edits despite the warnings, the system will reset the
holes creation state to the existing model state and an undistorted Sheet Metal
Hole will be created once the edits are accepted.
Editing Hole Positional Parameters
Depending on how the hole was originally positioned, different Edit Feature
operations must be used. ÏÏÏ
ÏÏÏ
9
If the Edge Offsets method was used to locate the hole, you must use the Edit
Parameters operation to modify the offset values for the hole. If Positioning
ÏÏÏ
dimensions were used to locate the hole, the Edit Positioning operation can be
used to add, modify, or delete positioning dimensions.
If you wish to convert from one location method to another, first use the Edit
Parameters operation to change the location Method, then proceed in the
normal manner required to define the new location.
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9-9
Hole Conversion
To help create multiple, associated sheet metal holes, you can now convert
simple Modeling holes and instances of simple Modeling holes into sheet metal
holes. Access this function through Edit→Feature→Parameters. Select the
SIMPLE_HOLE feature and choose OK. Then select Change Type in the
second Edit Parameters dialog.
Converted holes are named SMD_SIMPLE_HOLE and behave like Sheet

Metal Hole features with RPO dimensions. Sheet metal holes created in this
manner have all the properties of the original Hole feature, plus the
deformation capability of Sheet Metal Holes.
NOTE If you convert an instance of a Hole, the whole instance

set, including the master instance, is converted.
The state of every instance in an instance set matches the state of the master
instance. Therefore, all instances in an instance set form and unform together.
Their distorted forms may differ depending on their location on the part.
NOTE Because hole instances depend on the master instance to

dictate their formed state, instance sets must be limited to
like faces. That is, if the master instance is placed on a
bend surface, then all instances of the array should
remain on the bend surface, or their formed state will be
misrepresented (e.g. if an instanced hole falls entirely on
a planar face, it would be constructed using a BĆsurface).
ÏÏÏ Currently, we recommend creating separate arrays for
ÏÏÏ
9 bend areas and planar faces.
ÏÏÏ
Finally, any Modeling hole converted to a sheet metal hole can be reverted back
to a Modeling hole using the same Edit→Feature→Parameters ... Change Type
operation. However, Sheet Metal Holes cannot be converted to Modeling holes.
EDS Unigraphics NX
Activity 9-1: Creating Sheet Metal Holes
Step 1 Create a simple sheet metal hole.
Open the part smd_smhole.
Make sure you're in the Modeling application.
Open the Sheet Metal Preferences dialog.
Toggle ON Use Feature Standards and Enforce Creation

State Editing.
Choose OK to accept the preference settings.
Select the Form/Unform icon.
Choose the Unform All button to unform the part.
Select the Sheet Metal Hole icon.
First, make sure the hole locating Method is set to

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Positioning and the hole Type is set to Punch.
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NOTE You can create a simple Sheet Metal Hole using any of the
sheet metal hole types. However, it's important to use the
appropriate hole type for the design. In this case, if you
specify a Through hole type when Punch will suffice, you
may encounter unnecessary modeling errors later on.
Notice that the first selection step icon is highlighted and the
Cue line is prompting you to select a placement face.
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Select the right center bend segment.
Select this face
Change the Diameter value to 2.00 .
Choose MB2 (or Apply) to move to the next selection step.
Select the Perpendicular icon.
Select the front edge of the part as the first positioning edge.
Select this
edge first
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Enter 13.875 and choose MB2.
Select the Perpendicular icon again.
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Select the back outside edge of the face next to the

placement face as the tool edge.
Select this edge

second
Enter 1.50 and choose MB2.
The simple sheet metal hole is created.
Step 2 Check the hole deformation.

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Reform the part using the Form/Unform icon. ÏÏÏ
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Notice the deformation of the hole in the formed state.
Step 3 Edit the hole.

Try to edit the hole parameters without placing the part in the
original creation state of the hole.
Select the Edit Feature Parameters icon.
From the Edit Parameters dialog, select the

SIMPLE_SMHOLE feature.
Choose OK.
A warning message is displayed because the model is not

currently in the hole creation state.
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Choose OK to exit the warning message.
Step 4 Disable the hole creation preference.

Although it's good practice to leave the Enforce Creation State
Editing option on, let's turn this option off and edit the hole.
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Go to the Sheet Metal Preferences dialog and toggle the

Enforce Creation State Editing option OFF.
Choose OK.
In the Edit Parameters dialog, select the SIMPLE_SMHOLE

feature, again.
Choose OK.
The warning message presented now gives you the option of

modifying the hole in the current model state, unforming the
model to the original creation state, or canceling the operation.
Choose the Snap To Creation State button. Your model will

only unform the flanges affected by the Sheet Metal Hole
feature.
If you select the Yes option, the system will reĆcreate an

undeformed hole and apply it to the flange in its current formed
condition. This would become the new creation state of the hole
and deformation would only show in the unformed model state.
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This was not the original design intent of the hole.
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In the Diameter field, change the value to 1.00 .
Choose MB2 twice to accept the change and close the dialog.
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Now form the part again to review the change.
NOTE In some cases, if you encounter an error while editing a

sheet metal hole, it may be necessary to delete the
existing hole and then recreate it with the revised
parameters.
Step 5 Create a Through hole.

Rotate your work coordinate system 105 in the +ZC Axis
direction.
Activate the Sheet Metal Hole dialog.
Change the hole Method to Edge Offsets and the hole Type
to Through.
Select the nearest face of the part as the placement face.
ÏÏÏ Choose MB2 to move to the next selection step.

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ÏÏÏ Select this
face as the
placement
Select the back
face
face as the
Through face
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Select the far side of the middle face as the Through face.
Choose MB2 to advance to the next step.
Select the top edge of the first face as the first positioning
edge.
TIP Use the Shift key and MB1 to deselect any edge
chosen by mistake.
Set the Edge 1 Offset to 3.00 .
Choose MB2 to advance to the next step.
Select the near side edge as the second positioning edge.
First
positioning
edge
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Second
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positioning edge
Set the Edge 2 Offset to 1.00 .
DoubleĆclick MB1 in the Diameter field and change it to .50 .
Turn OFF the Face Normal Direction option.
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Select the Direction Vector icon in the Sheet Metal Hole

dialog. (See diagram below.)
Choose the Inferred Vector button and select the YC Axis

option.
1 Select the Direction

Vector icon
2 Select the Inferred
Vector button
3 Select the
YC Axis option
Choose OK to create the feature.
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Unform the part and review the geometry.
If you check the feature list of the part (Information→Feature),

you would notice that two separate SIMPLE_SMHOLE features
were created, one for each part intersection point. If you edit
either of the holes, both holes will change accordingly (size,
location and vector direction).
Step 6 Create and position a Modeling Hole.
Reform your part.
Reorient your WCS to the Absolute CSYS.
Select the Hole icon in the Form Feature palette.
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Select the Simple hole icon.
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Select the front face of the nearest flange as the placement

face.
Select the opposite face of the flange as the Thru Face.
Select the
Select this back face as
face as the the Thru Face
placement
face
Make sure the Diameter is set to 1.00 and choose MB2.
Position the hole center 1.50 inches from the side of the part.
TIP To avoid selecting a horizontal reference orientation,

use the Perpendicular positioning method to specify
both the horizontal and vertical dimensions.
Using the bottom edge of the part, position the hole 3 inches
vertically.
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Select this line
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Check the distance between the top edge of the flange and
the hole center point. (Use Analysis→Distance from the
menu bar.)
Now unform the part.
Check the distance again between the hole center point and
the top edge of the face.
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Because the hole is located from an edge other than a

placement face edge, the hole position on the flange will
relocate in order to maintain its vertical (or perpendicular)
positional parameter.
To avoid this flat pattern error, make sure you use static
placement face edges to position your modeling hole.
Reform your part.
Select the Edit Positioning icon.
Select the SIMPLE_HOLE feature from the Edit Positioning

dialog.
Choose MB2.
Delete the existing vertical dimension.
Select the SIMPLE_HOLE feature again and choose MB2.
Choose Add Dimension.
Select the Perpendicular icon.
Select the bend tangent line of the flange placement face as

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Select this
edge
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Choose Identify Solid Face.
Select the cylindrical face of the hole as the tool face and
accept the choice.
In the Create Expression dialog, insert the following

expression:
3-br-thk
Choose MB2 four times to relocate the hole.
Check the distance of the hole center point to the top edge
of the placement face.
Unform the part and check the distance again. The hole is
now positioned properly.
Step 7 Try using the Modeling Hole feature to create a hole

through all three flanges. What happens when you try to
unform the part?
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The Sheet Metal Slot Dialog
The Sheet Metal Slot feature, like the Sheet Metal Hole feature, will allow you
to place a slot feature on and through any type of planar and nonĆplanar
formable face. Sheet Metal Slots may completely or partially cross one or more
bend areas, and will distort when the underlying placement face changes shape.
Currently, the Sheet Metal Slot feature only allows for the creation of an
obround perimeter.
You can access the Sheet Metal Slot dialog from Insert→Sheet Metal
Feature→Slot or from the Sheet Metal Slot icon in the Sheet Metal
Feature toolbar. To edit a Sheet Metal Slot, use Edit→Feature or the Edit
Feature toolbar.
Creation
Selection
Steps Positioning
Method
Slot Types
Size
Parameters
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The Sheet Metal Slot dialog functions in the same manner as the Sheet Metal
Hole dialog. The icons across the top of the dialog represent the discrete steps
you must take to create and locate the sheet metal slot.
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Creation Selection Steps
The Sheet Metal Slot dialog is a Selection Steps type of dialog. The icons at the
top of the dialog are selectable, and will highlight as you step through the
process of placing and creating the Sheet Metal Slot.
Orientation
Vector
Placement Face
Through Face Direction Vector
Positioning
Positioning
Edge 2
Edge 1
Orientation Vector
The Orientation Vector allows you to select a vector to define the direction of
the length of the Sheet Metal Slot. The slot feature is associative to the
orientation vector. Therefore, if the vector used to define the orientation vector
changes, the slot will change its orientation to match the new vector.
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Size Parameters
The Sheet Metal Slot feature has three size parameters; Length, Width, and
Depth. The Depth parameter is only available when the Depth slot type is
selected. All input values for the size parameters are specified in the units of
the existing part (English or Metric), and all must be positive values.
Note that the Length is measured

from arc tangent to arc tangent
Slot Conversion
You can convert a Modeling Slot to a Sheet Metal Slot using the same
procedure as to convert a Modeling Hole to a Sheet Metal Hole. This is useful
to show slot deformation in a bend segment of your part when you have an
array of slots.
Slot Positioning Methods

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9 Sheet Metal Slots, like Sheet Metal Holes, can be positioned either from the
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The origin of the slot when using Edge Offsets to position the feature is defined
at the exact center.
Slot Origin
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To position a slot using the Positioning method, the Method option on the Sheet
Metal Slot dialog must be set to Positioning.
When using the Positioning method, you should specify the feature parameters
then select the OK or Apply button. You are then given the chance to add
Positioning Dimensions to the feature. If the Placement Face is nonĆplanar, you
must select a face (or datum plane) to serve as a reference plane for the RPO
dimensions. For the Slot, the Positioning dimensions can be referenced to any
of the Slot's tool edges including the additionally generated centerlines on the
reference plane. If the Placement Face and the reference plane are different,
the Slot position will be projected along a vector normal to the reference plane
and onto the Placement Face.
In the Edge Offset mode, the location of the slot center is determined by
positive or negative offset distances from two intersecting face edges which are
attached to the selected placement face.
Like the Sheet Metal Hole feature, when editing the position of a slot, make
sure to use the appropriate editing operation for the given positioning method.
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Construction Tips
Because data is maintained about their creation state, it is important
to place the model in the original creation state (formed or unformed)
before editing the hole. Make sure you use the Edit Feature operations
to insure that hole edits are implemented correctly.
Before converting Modeling holes or slots into Sheet Metal Holes or
Slots, make sure no object references such as dimensions or mating
conditions are tagged to the original hole. Once converted, the Sheet
Metal Hole or Slot can vary its shape and reference objects may loose
their constraints.
If Modeling Holes or Slots are used on flange web surfaces they must
be properly constrained from static placement face edges.
Currently, you cannot create sheet metal holes or slots on sheet
bodies.
Both the Sheet Metal Hole and Sheet Metal Slot features have a
builtĆin warning mechanism that alerts the user whenever an attempt
is made to edit their parameters while the model is in a different
formed state. Remember that this mechanism can be affected by the
Enforce Creation State Editing option in the Sheet Metal Preference
dialog.
To avoid corrupting the original design intent of your hole or slot
features, you may wish to prevent ANY hole or slot edits from
occurring until the model is placed in its original creation state. This
may be accomplished by toggling the Enforce Creation State Editing
option ON in the Sheet Metal Preferences dialog.
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Activity 9-2: Creating Sheet Metal Slots
Step 1 Create a slot on a bend surface.
Open the part smd_smslot.
Unform the part using the Form/Unform icon .
Select the Sheet Metal Slot icon.
Make sure the Method is set to Edge Offsets and the Type is
set to Punch .
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Select the first bend face of the back flange as the placement
face.
Use MB2 to move to the next selection step.
Select the near edge of the face as the first positioning edge.
Enter 2.50 in the Edge 1 Offset field.
Select the bend tangent line as the second positioning edge.
Enter .15 in the Edge 2 Offset field.
Select this face as

the placement
Second face
positioning edge
First positioning
edge
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Insert the following values:
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Width = .50
TIP Use the Tab key to cycle through the input fields.
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Select the Orientation Vector Selection Step.
Select an edge parallel to the YC Axis of the WCS.
Choose MB2 to create the slot.
Reform the part and inspect the slot distortion.
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Step 2 Create a partial slot.
Unform your part.
Return to the Sheet Metal Slot creation dialog.
Select the second bend face of the back flange as the

placement face.
Select the near edge of the face as the first positioning edge.
Select this face as

the placement face
First positioning
edge
Enter 2.50 in the Edge 1 Offset field.
Select the top bend tangent line as the second positioning

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ÏÏÏ Second positioning
edge
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Enter .625 in the Edge 2 Offset field.
Select an edge parallel to the XC Axis of the WCS.
Length = 1.50
Width = .25
Be sure the Face Normal Direction option is ON.
Choose MB2 to create the slot.
Reform and examine your part.
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SUMMARY The Sheet Metal Hole application creates holes

that will move respectively with formed and
unformed flanges and distort if located on bend
areas. The Sheet Metal Slot application creates
slots that will move respectively with formed
and unformed flanges and distort if located on
bend areas.
In this lesson you:

Created and Edited Sheet Metal Holes
Used the Through option to create multiple
holes quickly.
Learned the proper way to locate regular
Modeling Features (i.e.: Hole, Slot, Pad,
Pocket and Boss).
Created and oriented sheet metal slots
through bend areas of formable features.
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Sheet Metal Cutout
Sheet Metal Cutout

Lesson 10
PURPOSE To create cutout profiles on sheet metal parts which

will distort with the underlying surface.
Create a Sheet Metal Cutout feature.
Activity Page
10-1 Creating Sheet Metal Cutouts . . . . . . . . . . . . . . . . 10-9
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Sheet Metal Cutout
Sheet Metal Cutout
In many sheet metal parts there is a need for userĆdefined cutout patterns
which form, unform, and distort with the underlying surface. The Sheet Metal
Cutout feature was created for this application.
With this feature, a series of contiguous curves depicting the cutout profile are
used to punch completely through the part body in a Face Normal or
userĆspecified direction. These curves, which are associative to the resultant
cutout profile of the part, can be a closed or open loop shape. The ends of an
open loop profile must intersect or extend beyond the existing periphery of the
part. The curves can either be a standĆalone set of curves or they can be
contained within a sketch.
Open cutout profile

Open cutout
profile
Closed cutout
profile
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Sheet Metal Cutout
The Sheet Metal Cutout Dialog
When you choose the Sheet Metal Cutout icon from the Sheet Metal
Feature toolbar, the Sheet Metal Cutout dialog is displayed. You can also access
this dialog upon selecting Insert→Sheet Metal Feature→Cutout. To edit a Sheet
Metal Cutout, use Edit→Feature or the Edit Feature toolbar.
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Sheet Metal Cutout
Selection Steps
The Sheet Metal Cutout dialog is a Selection Steps type of dialog. The icons at
the top of the dialog are selectable, and will highlight as you step through the
process of placing and creating the Sheet Metal Cutout.
Placement Face Direction Vector

Through Face Outline
Placement Face
The placement face is the main face onto which the outline curves will be
projected. Additional faces through which the cutout outline will pass are
automatically identified by the system during the cutout creation process.
Once this placement face is selected, a conehead vector displays which shows
the direction by which the outline curves will be projected onto and through the
body of the part. You can reverse this projection vector, or you may specify a
new one. If you choose to apply the curves along a userĆdefined vector, you will
automatically be prompted to specify that vector.
Through Face
Sheet Metal Cutout can place a cutout through multiple sections on one solid
body. The Through Face step prompts you to select the last face on the opposite
side of the body from the placement face.
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cutout type is set to Through.
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Sheet Metal Cutout
Outline
This step allows you to select a contiguous (i.e. connected endĆtoĆend) set of
curves to use as the cutout outline. The outline curves are associated to the
cutout so when they are edited the cutout will update along with it.
NOTE When the curve profile is edited it will be reĆprojected

onto the placement face(s). Therefore, it is important to
change the curves only after the part has been placed in
the original creation state (formed or unformed). Failure
to do this may cause the curves to project onto different
faces or miss the solid body altogether during the update
sequence.
Direction Vector
The Direction Vector step becomes available if the Project option is set to Along
Vector. This lets you choose a direction other than Normal to Curves or Face
Normal for projecting the outline onto the placement face. This is also the
direction the curves will cut through the target body. When the Direction vector
selection step is active, the Vector Method option appears in the selection
window.
NOTE The cutout feature is associative to the Direction Vector.

If the vector used to define the Direction Vector changes,
the cutout will change its orientation to match the new
vector.
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Sheet Metal Cutout
Flip Discard Region
Once the curves are selected, the system displays another vector indicating the
region to be discarded from the part. You may reverse this region by selecting
the Flip Discard Region button.
Type
There are two types of Sheet Metal Cutouts: Punch and Through.
Punch is the default and requires you to specify a placement face and an
outline. A Punch cutout pierces one thickness of a solid body.
A Through cutout requires you to specify a placement face, an outline and a

second face. The second face or Through face is the end of the cutout opposite
to the placement face. A Through cutout pierces all faces in its path between
the placement face and the through face. Each cutout section created during
the creation process is associative to the curves selection in the Outline
selection step.
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Sheet Metal Cutout
Project
Use this option menu to decide how you want to project the curves onto the
target body.
The default method, Normal to Curves, uses a vector normal to the plane of the
Outline curves as the projection vector.
Along Face Normals projects the curves normal to all of the faces of the target
body that have smooth connection to the Placement Face.
The Along Vector method works along with the Direction Vector selection step.
This method allows you to explicitly define the vector you want to use.
Vector Method
The Vector Method allows you to choose a way to define the vector you will use
for the axis of the Sheet Metal Cutout when you are not using Normal to
Curves or Face Normals. This option will appear in the Sheet Metal Cutout
dialog after you choose the Direction Vector selection step.
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Sheet Metal Cutout
Construction Tips
When using open cutout profiles which terminate at the edge of the
part, we recommend you extend the ends of the profile beyond the
edge of the part. When the cutout profiles end tangent to the part,
extend the profile with short lines oriented ninety degrees to the
tangency point.
If a sketch is used to constrain the cutout profile, use a plane other
than the face of a formable flange to contain the sketch. When the
placement face forms and unforms, an attached sketch will
automatically update. This will cause the Sheet Metal Cutout feature
to update and projection problems may result.
Sheet Metal Cutouts that contain linear or circular (arc) segments will
produce Trimmed Planar and Cylindrical surfaces upon creation. The
Trimmed Planar surfaces are generated only by lines in the cutout
profile, therefore those planar surfaces do support the addition of
other modeling features (e.g. flanges). The edges created by the linear
segments can also be used as position edges for other modeling
features. Edges created by arcs can also be referenced by positioning
dimensions and can be dimensioned in the drafting application. This is
an enhancement over previous versions of the software.
Any nonĆlinear or non-circular curves (e.g. splines) create BĆsurfaces
upon creation of the cutout. Minor difficulties can occur when trying
to dimension the BĆsurfaces in the Drafting application.
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Sheet Metal Cutout
Activity 10-1: Creating Sheet Metal Cutouts
In this activity you'll add cutouts to the box you created in the Flange lesson.
Step 1 Create the cutout profile.
Open the part smd_cutout.
Unform the front flange of the part.
Unform
this flange
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Sheet Metal Cutout
Step 2 Create a sketch on the right side flange to be used for a

through cutout.
On layer 22, create a sketch on the right side flange.
Select here for your

horizontal reference
Select this face as

the placement face
Create and locate the profile to the dimensions shown below.
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Sheet Metal Cutout
Step 3 Create the through cutout.
Choose the Sheet Metal Cutout icon.
Change the Type option to Through.
Select the right side as the Placement Face.
Select this face as

the through face
Select this face as

the placement face
Click MB2 to advance to the Through Face selection step.

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Select the far left face as the Through Face. ÏÏÏ
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Sheet Metal Cutout
Click MB2 to advance to the Outline selection step.
Select the rectangle as the Outline.
TIP You can drag a window around the desired curves to

make the selection process easier.
Ensure the Discard Region is pointing towards the center of

the outline. If necessary, choose the Flip Discard Region
button.
Choose OK to create the cutout. Form the flanges and

review your part. What type of surfaces were created for the
cutout?
Step 4 Add a cutout to the joggled end on the left side of your
part.
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Sheet Metal Cutout
Make layer 21 selectable to reveal a sketch created to split

the left joggled flange.
Choose the Sheet Metal Cutout icon.
Change the Type back to Punch.
Select any face of the part that lies within the cutout outline.
Click MB2 to advance to the Outline selection step.
Select the curves and the Outline.
NOTE Only lines that cross the surfaces you cut through are
needed for the cutout profile.
This line may be selected, but is

not needed for the cutout profile.
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Sheet Metal Cutout
Ensure the Discard Region is pointing towards the center of

the outline. If necessary, choose the Flip Discard Region
button.
Choose OK.
Reform your part.
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Sheet Metal Cutout
SUMMARY The Sheet Metal Cutout function allows the

removal of material through formable features
and shows distortion when formed. The cutout
also maintains associativity to the defining
geometry.
In this lesson you:

Created a Sheet Metal Cutout.
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Sheet Metal Cutout
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Unbend/Rebend
Unbend/Rebend ÏÏÏ
Lesson 11
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11
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PURPOSE Create and edit sheet metal parts using the

Unbend/Rebend feature.
Create a Unbend and Rebend features.
Activity Page
11-1 Creating Unbend and Rebend Features . . . . . . . . 11-8
11-2 Creating Unbends from an Extrusion . . . . . . . . . . 11-19
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Unbend/Rebend
ÏÏÏ Unbend/Rebend
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The Unbend/Rebend function allows for non-self forming, sheet metal type
features, to be unbent and rebent to allow creation of features which may need
to pass through bend areas and depict distortion. The use of this function
produces a feature that has a specific timestamp in the feature tree and
therefor updates in order when the model is edited or updated.
Region Preparation
Self-forming features (also called formable features) are capable of changing

their state to represent formed and unformed conditions. The Unbend/Rebend
operators form and unform the geometry of upstream features. To accomplish
this, the upstream features must be non-self-forming.
Before the Unbend/Rebend operation is applied, the system will check for any
parent features that are self-forming. If any are found, the following dialog will
appear to confirm that these self-forming parents will be converted into
non-self-forming parents.
Boundary Faces
The system may also create one or more of the following features to
pre-process the faces which cross the boundaries of the bend region:
BOUNDED_PLANE
INTERSECTION_CURVES
SUBDIVIDE_FACE
FACE_SUBDIVISION feature set
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Unbend/Rebend
Forming Method
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If the desire is to use Unbend and Rebend to unform sheet metal features (e.g.
Flange, Inset Flange or Bend), the Forming Method in the Sheet Metal
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Preferences dialog needs to be set to Use Forming Operations. Use
Self-Forming Features is the default.
NOTE When using the Use Forming Operations method of

creation, all flange type features will be created is such a
manner that the Form/Unform function will not recognize
sheet metal flange type features.
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Unbend/Rebend
ÏÏÏ Advantages
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11
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The ability to use regular Modeling features in the creation of your
sheet metal part (e.g. extrusions, through holes, pockets, etc.). The
ability to use these features shortens the learning curve (i.e. more
knowledge is required for sheet metal features).
Only unbend and rebend a flange type feature if it is necessary to
create a feature that depends on a given formed" state.
The bend regions can be constructed from straight brake Sheet Metal
features such as Flanges and Bends as well as non-Sheet Metal
features such as Sketches and Extrusions.
Disadvantages
The unbend a rebend functions will create additional features to
prepare the boundary faces so they can be unbent or rebent. There
are two things that you should be aware of:
These features are blanked from the graphics window after the
creation of the feature is complete. Management of these
additional features/objects should be done through the use of
layers.
The feature list for the part will be increased based upon the
how much preparation needs to be done to the boundary faces.
(e.g. a sheet metal flange will not require preparation of the
boundary faces to Unbend it).
EDS Unigraphics NX
Unbend/Rebend
The Unbend/Rebend Dialog ÏÏÏ

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You can access the Sheet Metal Solid Punch dialog from Insert→Sheet Metal
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11
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Feature→Unbend/Rebend or from the Unbend/Rebend icon in the Sheet
Metal Feature toolbar. To edit a Sheet Metal Solid Punch, use Edit→Feature or
the Edit Feature toolbar.
Bend Operations
Unbend
The Unbend option will create a feature that unforms a cylindrical face that
depicts a bend segment on a sheet metal type part. The cylindrical face can be
created by several different modeling techniques (e.g. blends or extruded
shapes with fillets) and does not have to be a Sheet Metal Flange or Inset
Flange feature.
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Student Guide
11-5
Unbend/Rebend
ÏÏÏ If an Unbend operation is selected, the filter will allow both edges and
ÏÏÏ upstream Rebend features to be selected. The bend angle of the new Unbend
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11
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feature will be 0 degrees.
A bend edge is defined as a linear edge which defines the stationary side of a
bend region. Likewise the bend face is a cylindrical face which is adjacent to the
bend edge. The bending parameters are derived from the bend face.
Rebend
Use Rebend to reform an unbent feature, thus returning the bend region to its
original bend angle.
Unbend to Angle
If the Unbend to Angle operation is selected, the filter will allow both edges and
upstream Unbend/Rebend features to be selected. The angle of the new
Unbend to Angle feature will be specified by the user in the Angle expression
field.
Bend Angle
For Unbend to Angle operations, the bend angle field will be available. Use this
field to specify the new bend angle.
Adjacent Bend Face
The Bend region is defined by a bend edge and a bend face. If a bend edge is
selected, the dialog populates the bend face with the first cylindrical face it
finds which is adjacent to the bend edge. If multiple cylindrical faces are found,
the Adjacent Bend Face button will become available so that you can select a
different bend face. If an existing Unbend/Rebend operation is selected, its
bend edge and bend face will be used.
EDS Unigraphics NX
Unbend/Rebend
Once the bend edge and bend face have been determined, the system will
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highlight the faces which make up the bend region. These faces will be modified
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by the Unbend/Rebend operation.
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11
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If Bend Allowance Formula is chosen, you can select the Bend Allowance
Formula (BAF) from the list or you can enter the BAF in the text field. The
Bend Allowance Formula only applies to the current operation. This button
will not be available if you have enabled a global Bend Allowance Formula or
the bend face belongs to a SMD feature that already has a BAF associated with
it.
Global Bend Allowance Formula
This option will be available if you have enabled a global Bend Allowance
Formula. If a non SMD feature bend edge is selected, this option will be
selectable and can be turned ON to take advantage of the global setting.
Construction Tips
Converting parent features into non-self-forming features may lock
other SMD features (such as SMHOLEs and SMSLOTs) in a
non-creation state. To edit these features, you can temporarily
convert their parents back into self-forming features via the Make
Self-Forming Feature and Make Non-Self-Forming Feature MB3
pop-up menus in the Model Navigator. A Better solution is to replace
these features with regular Modeling features (e.g. Holes & Slots).
Unbend/Rebend operations can be used to unformed individual bend
regions of Profile Flange and Multibend Bracket features.
Unbend/Rebend operations cannot unform multiple regions at once
without ripping the material.
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Student Guide
11-7
Unbend/Rebend
ÏÏÏ Activity 11-1: Creating Unbend and Rebend Features

ÏÏÏ
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11
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In this activity you will use the Unbend/Rebend features in a different approach
to building a sheet metal part.
Step 1 Open the part smd_unbend and save it as xxx_unbend,

where xxx are your initials. Ensure you are in the
Modeling application.
Step 2 Create a through cutout.
Choose the Cutout icon.
Change the Type option to Through.
Select the right outside face as the Placement Face.
Choose MB2 to advance to Through Face.
Select the left outside face as the Through Face.
Choose MB2 to advance to Outline.
EDS Unigraphics NX
Unbend/Rebend
Select the profile on the right flange face. Do not select the
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centerline.
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11
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Placement
Through Face
Face
Outline
Ensure the Discard Region is pointing towards the inside

and choose OK to create the cutout.
Step 3 Edit the cutout in the unformed state to see what

happens.
Choose Unform All.
Notice the Sketch unforms with the right flange, this is

because the flange's web face is the placement face for the
sketch.
Cancel the Form/Unform dialog.
Double-click on the sketch centerline to enter the Edit

mode.
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11-9
Unbend/Rebend
ÏÏÏ Change the value of p17 to 1.500 .

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11
ÏÏÏ
Edit
Choose the Finish Sketch icon.
Notice the sketch profile is up to date but the two cutouts

are not. In order for the cutouts to update they must be put
into their creation state which is the formed state.
Choose Form All to see the updates to the cutout features.
Step 4 Convert self forming flanges to non-self forming flanges.

Choose File→Close→Reopen Selected Parts...
Select xxx_unbend from the list and choose OK.
Choose OK to the Confirm window.
Close the Information window.
EDS Unigraphics NX
Unbend/Rebend
Highlight the first Flange feature, place your cursor over the
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feature and press MB3.
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Choose Make Non-Self-Forming Feature from the list. ÏÏÏ
11
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In the Model Navigator, note the subtle difference between
the icons of the first and second flange.
Indicates
self-forming
feature
Repeat the steps to the second flange to Make

Non-Self-Forming.
Since the two flanges are no longer self forming the following
message appears.
Choose OK to dismiss the Info window.
Step 5 Create cutouts using a typical modeling feature.
Choose the Extruded Body icon.
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11-11
Unbend/Rebend
ÏÏÏ Select the sketch as the section string and choose OK.
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11
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Choose Trim To Face/Plane.
Choose Cycle Vector Direction to point the vector towards

the left flange and choose OK.
Select the left outside flange face as the trimming face and
choose OK.
Trimming
Face
Ensure the Offset and Taper values are set to 0 and choose
OK.
Choose Subtract.
Since the Flanges can no longer unform by themselves it is

acceptable to use an extrusion to create the cutout" type
features.
Step 6 Create an unbend feature to add a feature through the

bends.
Choose the Unbend/Rebend icon.
Select the left inside bend edge and choose Apply.
EDS Unigraphics NX
Unbend/Rebend
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11
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Inside
Edge
NOTE The bend edge you select determines the portion of the
part that remains stationary and which portion unforms.
Repeat the steps to create an Unbend feature for the right

flange.
Notice the sketch did not move with the flange this time.
This happens because there is now a feature that controls
the unformed state of the flange.
Open the Model Navigator and review the feature list.
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Unbend/Rebend
ÏÏÏ Step 7 Create another Modeling feature through one of the

ÏÏÏ bends.
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11
ÏÏÏ Choose the Pocket icon.
Select the top face as the planar placement face.
Select the front edge as the horizontal reference.
Placement
Face
Horizontal
Reference
X Length 2.00
Y Length .375
Z Length T
Corner Radius 0
Floor Radius 0
Taper Angle 0
Choose OK.
EDS Unigraphics NX
Unbend/Rebend
ÏÏÏ
Choose Parallel at a Distance. ÏÏÏ
Select the front edge of the part as the Target Edge.
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11
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Select the front edge of the rectangular pocket as the Tool
Edge.
Tool Edge
Target Edge
Enter a value of .375 and choose OK.
Choose Perpendicular.
Select the far left edge of the part as the Target Edge.
Select the far left edge of the rectangular pocket as the Tool
Edge.
Target Edge
Tool Edge
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Unbend/Rebend
ÏÏÏ Enter a value of .500 and choose OK.

ÏÏÏ
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11
ÏÏÏ Step 8 Edit the sketch in the unformed state to see what
happens.
Double-click on the sketch centerline to enter the Edit

mode.
Change the value of p17 to 1.500 .
Edit
Notice this time the sketch and both cutouts" updated. This
happened because as the update process rebuilt the model
the extrude feature was updated before the unbend features.
Step 9 Rebend the flanges.
Choose the Rebend icon.
EDS Unigraphics NX
Unbend/Rebend
Select the left flange choose Apply.

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Select the right flange and choose OK.
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11
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Notice the additional features created after the Rectangular

Pocket and between the Rebend features. These features are
created to prepare the boundary faces of the rectangular
pocket so it could be reformed. Some of these features (e.g.
bounded plane) are blanked so you do not see them.
Make layer 21 invisible.
Choose Edit"Blank"Unblank All of Part

(TIP: Ctrl+Shift+U).
Fit the view.
Choose Format"Move to Layer...
Select the solid body.
In the Class Selection dialog, choose All But Selected and

choose OK.
Enter 81 as the destination layer and press Enter.
Fit the view.
Step 10 Edit the rectangular pocket in the formed state.
Double-click on the RECTANGULAR_POCKET feature to

enter the Edit Parameters dialog.
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Unbend/Rebend
ÏÏÏ Choose the Feature Dialog option.

ÏÏÏ
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11
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Edit the X Length to 3.00 and choose OK twice.
EDS Unigraphics NX
Unbend/Rebend
Activity 11-2: Creating Unbends from an Extrusion ÏÏÏ

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11
ÏÏÏ
Step 1 Open the part smd_unbend_2 and save it as
xxx_unbend_2, where xxx are your initials. Ensure you
are in the Modeling application.
Notice the part was created from a sketch and an extrusion.
Step 2 Create Unbend features to unform the part.
Select the left inside bend edge and choose Apply.
Inside
Edge
Repeat the steps to create an Unbend feature for the right

flange.
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11-19
Unbend/Rebend
ÏÏÏ Again, notice there are two BOUNDED_PLANEs and

ÏÏÏ FACE_SUBDIVISIONs before each Unbend feature. These
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11
ÏÏÏ
were necessary to prepare the Bend Region for unforming.
Choose Edit"Blank"Reverse Blank All
(TIP: Ctrl+Shift+B).
Fit the view.

Choose Select All and choose OK.
Choose Edit"Blank"Reverse Blank All to return to the
original display.
Fit the view.
Step 3 Create a sketch to be extruded.

Make layer 22 the work layer.
Choose the Sketch icon.

Enter s22_cutout as the sketch name and press Enter.
Select the top face of the middle section as the sketch plane.
Select the front edge, on the right-hand side, for the
horizontal direction.
Placement
Face
Horizontal
Reference
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Unbend/Rebend
Choose MB2 to create the sketch.

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Free-hand sketch the shape below.
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11
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Create two lines across the corners of the diamond".
If necessary, apply vertical or horizontal constraints as

applicable to the two lines.
Convert the two lines to Reference.
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Unbend/Rebend
ÏÏÏ
ÏÏÏ Dimension the profile as indicated below.
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11
ÏÏÏ
Extrude the sketch downward using the Trim to Face/Plane
option and use the bottom face as the trimming face.
Choose Subtract.
Make layer 1 the work layer and all other layers invisible.
Step 4 Rebend the flanges.
Choose the Rebend icon.
Select the left flange choose Apply.
EDS Unigraphics NX
Unbend/Rebend
Select the right flange and choose OK.

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ÏÏÏ
Cancel the Unbend/Rebend dialog.
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11
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Step 5 Edit the parameters of the extrusion.
Double-click on the EXTRUDED(4) feature to enter the

Edit Parameters dialog.
Choose the Feature Parameters option.
Edit the End Distance to 4.00 and choose OK twice.
Shade and rotate your part to examine the cutout.
Step 6 Move the additional features to another layer.
Choose Edit"Blank"Reverse Blank All.
Fit the view.
Choose Select All and choose OK.
Choose Edit"Blank"Reverse Blank All to return to the

original display and Fit the view.
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11-23
Unbend/Rebend
ÏÏÏ
ÏÏÏ
ÏÏÏ
11
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SUMMARY The Unbend/Rebend feature allows better

control the unforming process of a sheet metal
part for aid in constructing features.
In this lesson you:

Unbent a non-self-forming flange and
created Modeling features through bends.
Unbent an extruded sketch to create a
feature that passed through the bends.
Applied rebend features to form the part
back to its original bend angles.
EDS Unigraphics NX
Bead
Bead
Lesson 12
PURPOSE To create and edit bead geometry using the Bead

feature.
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12
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Create UĆshaped, VĆshaped, and Circular Beads.

Create a bead from a sketch curve.
Activity Page
12-1 Creating Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
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12-1
Bead
Bead
Beads are useful in the design of sheet metal products to add strength to the
product or to control the formability of the material during metal stamping
operations (i.e. lock beads can stop a sheet metal blank from sliding into the die
cavity).
You can access the Bead dialog from Insert→Sheet Metal Feature→Bead or by
selecting the Bead icon from the Sheet Metal Feature toolbar. To edit a
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12
Bead, use Edit→Feature→Parameters or the Edit Feature toolbar.
ÏÏÏ
ÏÏÏ The Bead feature allows you to create formable geometry from existing solid
bodies. Like the general pad and general pocket features, beads form
protrusions or depressions in a variety of shapes. However, while pads and
pockets are defined by their outline shapes, beads are created by following a
prescribed centerline path.
NOTE The centerline guide curves cannot be selfĆintersecting or

a closed loop.
Beads come in three profiles or types: Circular, UĆshaped and VĆshaped.
Bead Types
UĆshaped VĆshaped Circular
For Circular beads, the length of the bead body is equal to the length of the
centerline curves. If the bead has optional end caps, a blend can be created
between the bead and the placement face, where the bead body will extend
beyond the centerline length.
For UĆshaped and VĆshaped beads, the tapered ends extend beyond the curve
endpoints. This cross section can also vary between the different shapes as you
move along the centerline.
EDS Unigraphics NX
Bead
The following figures show examples of the different types of beads:
UĆshaped bead with a Circular bead with reversed

projected centerline face normals
Guide curves ÏÏÏ

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12
ÏÏÏ
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Variable
shaped
bead
UĆshaped bead with

end caps fading
into placement face
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12-3
Bead
The Bead Dialog
Positioning
Selection
Steps and
Filters Bead Types
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12
UĆshaped
ÏÏÏ
ÏÏÏ This window
will change VĆshaped
per selection
step.
Circular
This window
will change
per bead
type.
EDS Unigraphics NX
Bead
Selection Steps
The Bead feature uses a selection steps type of dialog to create and edit the
bead geometry and positioning parameters. The first three selection step icons
require that input be provided before you can cycle to the next step. The
remaining icons provide optional operations which further define the
orientation and direction with which the bead is applied.
Placement Centerline Section

Face Projection Orientation Axis
ÏÏÏ
Centerline Vector Section
Plane
Points
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12
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Secondary Target
Face Definition Body
Placement Face
You may select one or more faces of the part on which to place the bead
feature. If multiple faces are chosen, they must be adjacent to each other.
While this step is active, different selection options are available within the
Filter control. These options allow you to construct a bead on other part faces,
datum planes, or userĆgenerated planes, then boolean the bead geometry to
different part faces using the Target Body selection step.
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Bead
NOTE If other part faces or planes are used as the construction

plane, it's important to note that the temporary bead tool
generated on that plane must be able to intersect with the
desired target body upon its creation, or a failure
condition will result.
Centerline
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12
Multiple curves may be selected as guide curves, but they must be contiguous
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and must form an open profile. These curves may be located on, or at a distance
to, the placement face. The bead body starts at the beginning of the centerline
and stops at the end of the centerline, unless a taper extends the bead. Bead
end caps are an example of an extension beyond this length.
Centerline Projection Vector
If the centerline guide curves do not lie on the placement face, you may specify
the vector along which the curves will be projected onto the placement face. If
you elect to use the Normal to String condition, the curves composing the
centerline must be coplanar. Other projection vectors may be specified by
selecting the Selected Direction button displayed in the Listing Box on the Bead
dialog.
EDS Unigraphics NX
Bead
Orientation Plane
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12
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The Orientation Plane is an optional step used to specify the orientation of the
cross section of the bead. The default setting (Normal to String ) creates the
bead cross section normal to all points along the guide curve. You can specify a
different orientation plane by selecting the option button displayed in the
Listing Box when this step is active.
Guide curve
Cross section planes along Cross section planes along

the bead are normal to all the bead have a constant,
points on the guide curve. userĆdefined orientation.
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Bead
Section Axis
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12
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The Section Axis step provides an optional means of adding a tilt characteristic
to the bead feature. This vector determines the rotational orientation of the
bead cross section with respect to the orientation plane. It's through the use of
this step that the bead geometry is added to, or subtracted from, the base solid.
Cross section of different bead structures

showing section axis orientation
Section Axis
Placement Face
Placement Width
Placement Width
Section Axis
NOTE The Placement Width is measured from the Placement

Face side regardless of the Section Axis orientation.
The default creation state is parallel to the placement face normal vector. You
can define a customized section axis by selecting the button shown in the
Listing Box when this step is active.
EDS Unigraphics NX
Bead
Section Points
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12
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The Section Points step allows you to define a variable shaped bead created by
specifying the section shape as variable. Specifically, a mixture of different
crossĆsections can be used at various points along the centerline by alternatively
displaying each section type and then selecting points for that section using this
step.
Note that the points should be on or near the centerline, as they will be
"dropped" to the nearest location on the centerline. These points will be
remembered for future updates if the centerline is modified. When sections are
not defined at the centerline endpoints, the closest section will be repeated at
the end. The point options in the changeable display are available to help you
select the points. Points may be deselected by reselecting the specified points
for each section type.
NOTE When creating a bead with varying shape using section

points it may be necessary to create the bead unattached
(Options menu). After creation the bead can be united to
the target body and a hollow operation can be performed.
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Bead
Secondary Face Definition
If the selected bead type has a UĆshaped cross section, this step is activated and
can be used to control the shape of the bead's top face, which is also called the
secondary face.
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12
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You may:
Specify a fixed Height for the bead.

Use the Offset Placement Face option. Enter a positive or negative
offset in the Distance input field corresponding to the direction of the
Section Axis.
Use the Offset Selected Face option. Select the desired face, then
provide a positive or negative value in the Distance input field.
Use the Translate Placement Face option. Select a vector to define the
direction (which must be consistent with the direction of the Section
Axis), and provide a Distance value.
Use the Translate Selected Face option. Select a face, select a
translation direction vector, and provide a Distance value.
EDS Unigraphics NX
Bead
Target Body
This optional step allows you to specify the target body for the bead geometry if
the original placement face is off the body of the part. You must use this option
if you have selected a datum plane or single plane as the original placement
face.
NOTE Once selected, you cannot change the target body while
editing the bead parameters. ÏÏÏ
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12
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Bead
Bead Type
The Type option in the Bead dialog allows you to preĆdefine bead parameters by
storing their information in the sheet metal standards file (see Lesson 1). When
no standards are defined, this option is grayed out and the system displays
default parameters for each bead structure.
The cross section of the bead is available in three different geometric shapes;
UĆshaped, VĆshaped, and circular. The pictorial icons presented on the Bead
dialog allow you to choose the desired shape.
ÏÏÏ
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12 Each pictorial icon depicts the geometric constraints required to parameterize
ÏÏÏ
ÏÏÏ
the specified bead structure. The changeable list below the pictorial icon
displays the parameter input fields for the selected bead cross section.
UĆshaped VĆshaped Circular
A complete shape can be derived for each bead type without specifying a value
for every given geometric constraint. Indeed, in some instances, too many
constraints are given and the system will warn you that the bead is
overĆparameterized and will ignore selective constraints while creating the
bead. You can see several combinations of constraints that are valid for creating
your bead by moving your cursor over the pictorial icon on the Bead dialog. The
displayed list gives the combinations of minimum parametric inputs necessary
to define the bead.
EDS Unigraphics NX
Bead
Bead Terminology
The changeable display in the Bead dialog contains a list of the parametric
constraints of the given bead type. The terminology for these constraints is
described below.
UĆAWH,AwH,WwH
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12
VĆAW,AH
ÏÏÏ
ÏÏÏ
CircularĆR,RH
Angle (A) - The taper angle for the sides of UĆshaped and VĆshaped beads.
Blend Radius - The radius value for the blend created between the placement
face and the walls of the bead. This parameter is only available for U and
VĆshaped beads.
End Cap Angle - The taper angle of the faces placed at the end of the
VĆshaped bead.
End Cap Radius - The radius value for the end caps of a Circular bead. The
value must be greater than or equal to the height of the bead.
Height (H) - The height (or depth) of the bead as measured from the
placement face.
Placement Width (W) - The width of the bead base without a Blend Radius.
This parameter is only available for U and VĆshaped beads.
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Bead
Radius (R) - For beads with UĆshaped cross sections, this is the radius on
either side of the top face. For beads with VĆshaped cross sections, this is the
radius at the top of the bead. For beads with Circular cross sections, this is the
radius of the cross section.
Secondary width (w) - The width of the UĆshaped bead top, or secondary, face.
This width can be measured either from the top face's theoretical intersections
with the bead's sides (Intersection Point), or from the tangents between the top
face and the bead's blended side edge (Tangent Point). The intersection points
are represented by the wider w" on the top face of the UĆshaped bead pictorial
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12
icon. The tangent points are represented by the top face's narrower w". This
preference can be set in the Bead Options dialog which appears when you
ÏÏÏ
ÏÏÏ
choose the Options button.
Distance Tolerance This value is used to approximate curves created internally

to build the bead. If the bead fails to build, some type of error message may be
given to indicate the system was unable to create the curves In this case, a
looser tolerance might resolve the problem.
EDS Unigraphics NX
Bead
Options
The Options button on the Bead dialog activates the Bead Options dialog. This
dialog lets you specify additional preferences for controlling the bead structure.
The availability of the listed options is based on the selected bead type specified
in the Bead dialog.
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12
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The Height for all three bead types can be specified as Constant or Law
Controlled. The height can be measured along the face normals or along the
section axis.
The Angle option appears for UĆshaped beads only. The Angle can be
measured from the section axis or from face normals.
The Secondary Width From options appear for UĆshaped beads only.
Secondary width can be measured either from the top face's theoretical
intersections with the bead's sides ( Intersection Point) or from the tangents
between the top face and the bead's sides (Tangent Point). Intersection Point is
represented by the wider w" dimension on the top face of the UĆshaped bead,
Tangent Point by the top face's narrower w" dimension.
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12-15
Bead
The End Cap options appear for all three types of constant shaped beads . End
caps can be defined for the Start, End or Both ends, or as None for no end caps.
End caps may be specified to fade into the placement face. A length for the end
caps may also be given which will define the distance used for fading the end
caps into the placement face.
Attach Bead appears for all three types of beads. If you decide to attach the
bead to a sheet body, the bead will be sewn to the sheet. If you attach the bead
to a solid body, it will be either united to or subtracted from the solid body,
depending on the direction of the section axis.
ÏÏÏ
ÏÏÏ
12 Hollow Bead appears for all three types of beads. If you attach the bead to a
ÏÏÏ
ÏÏÏ
solid body, the bead will remove volume from the face opposite the placement
face to maintain a constant thickness. This toggle is turned off and disabled if
Attach Bead is turned off. This has no effect on sheet bodies.
EDS Unigraphics NX
Bead
Construction Tips
You cannot create a bead of zero length, or with a closed or
selfĆintersecting centerline. Beads that end at the periphery of the face
can be created with some limitations.
Must be perpendicular to
the periphery with no end
cap on this end.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Acceptable Beads Unacceptable Beads
Flat patterns generated from parts with bead features will show the
outline of the bead intersection with the surface of the part. It should
be noted that if a blend radius has been added to the bead, the outline
will be derived from the blend intersection with the placement face.
Flat patterns generated for parts with unattached beads will not
produce a bead outline.
EDS
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Sheet Metal Design
Student Guide
12-17
Bead
Activity 12-1: Creating Beads
In this activity you will use different bead construction techniques to add
strength and functionality to a sheet metal part.
Step 1 Create a VĆshaped stiffening bead.
ÏÏÏ
ÏÏÏ
12
Open the part smd_bead.
ÏÏÏ
ÏÏÏ Make sure you're in the Modeling application.
Make Layer 41 selectable. A series of three straight lines will

become visible. You may want to rotate the model for
another view of the three lines.
Choose the Bead icon.
Select the top surface as the Placement Face.
Click MB2 to advance to the Centerline step.
Select the left outer line as the centerline curve.
Select the upper

surface as the
placement face.
Select this outside line

as the centerline.
EDS Unigraphics NX
Bead
Because the guide curve does not rest on the surface of the part
you will need to specify a Centerline Projection Vector such that
the guide curve will be projected onto the placement face.
Click MB2 to advance to the Centerline Projection Vector
step.
Choose the button below the Centerline Projection

Definition text and choose Specify New Vector...
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Choose the ZC Axis option. Notice that the centerline

projection vector points up and away from the part.
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12-19
Bead
Choose the Cycle Vector Direction button to point the vector

down toward the part. (See diagram below.)
ÏÏÏ
ÏÏÏ
12 Choose OK.
ÏÏÏ
ÏÏÏ In the Bead dialog, change the bead type to VĆshaped by
selecting the pictorial icon.
Radius = .50
Blend Radius = Ignore this field for now.
Height = 1.00
Angle = 30
Placement Width = 2.00
End Cap Angle = 60
Choose the Options button in the Bead dialog.
EDS Unigraphics NX
Bead
Set the End Cap option to Start.
Ensure the Attach Bead and Hollow Bead options are ON.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Choose OK to accept the options.
Choose Apply to create the bead.

Because more information was given for the bead geometry than
was necessary, the system flashes a Note message indicating that
the specified height will be ignored when the width is given.
Step 2 Create a VĆshaped bead with a userĆdefined orientation.

Choose WCS→Display to turn ON the WCS.
Double-click on the WCS to enter into WCS Dynamics.
Select the XC-YC rotation handle to rotate around the ZC

axis.
Enter -60 degrees into the Angle input field and choose
MB2.
With the Bead dialog still active, select the upper surface
again as the placement face.
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Student Guide
12-21
Bead
Select the right outer line as the centerline curve.
Select the upper

surface as the
Select this outside line
placement face.
as the centerline
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Click MB2 to advance to the Centerline Projection Vector
step.
Choose the button below the Centerline Projection

Definition text and choose Specify New Vector...
Choose OK to accept the previously defined vector direction

(should be -ZC, if NOT adjust it to point in that direction).
Now you'll reĆorient the section cut plane so that it's parallel to
the YCĆZC plane.
Choose the Orientation Plane icon.
EDS Unigraphics NX
Bead
Choose the Orientation Plane Normal button in the Listing

Box.
Choose Specify New Plane...
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Choose the Principle Plane option.
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Sheet Metal Design
Student Guide
12-23
Bead
Choose the YCĆZC Plane option. Now you've defined the

plane at which the cross sections of the bead will be
generated along the centerline curve.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
In the Bead dialog, remove the Radius value by inserting a 0
in the input field.
In the Bead Options dialog change the End Cap option to

None.
Choose OK.
You can leave the remaining parameters in place.
EDS Unigraphics NX
Bead
Choose Apply again to create the bead.

Shade your model and examine the ends of the two beads.
Notice the cross section of the second bead?
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Step 3 Create a depression in the center of the part.

In the Bead dialog, select the upper surface again as the
Placement Face.
Select the middle line as the centerline guide curve.
Click MB2 to advance to theCenterline Projection Vector
step.
EDS
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Student Guide
12-25
Bead
If necessary, adjust the Centerline Project Vector so that the

line is projected onto the placement face.
Choose the Orientation Plane icon.
Choose the Orientation Plane Normal button in the Listing

Box.
Change this option back to Normal to String...

ÏÏÏ

ÏÏÏ
12 Before you choose the bead type, you need to orient the bead
ÏÏÏ
ÏÏÏ
Section Axis such that a depression will be formed when the
bead is united with the part.
Choose the Section Axis icon.
Under the Section Axis text in the Bead dialog, choose

Reversed Face Normals.
Change the bead type to Circular.
Set the Radius equal to 6.00 and the Height equal to .20 .
Turn OFF the Hollow Bead option.
Choose OK to return to the Bead dialog.
EDS Unigraphics NX
Bead
Choose OK to create the depression. Examine your model.
Step 4 Create a bead on a flange surface.

Beads can move with a forming and unforming flange surface as
long as their centerline guide curves are associated to the flange
surface. The easiest way to accomplish this is to create a sketch
on the face of the flange surface and constrain it to static edges
of the flange surface. Such a sketch has been created for you on
Layer 21.
Make layer 21 selectable and layer 41 invisible. ÏÏÏ
ÏÏÏ
12
Create a hollow, circular bead using the middle line as a
guide curve. Set the Radius to 2.00 and the Height to .50 .
ÏÏÏ
ÏÏÏ
NOTE In theory, a single line cannot define a plane so you will
have to specify a Centerline Projection Vector to tell the
system how to project the curve onto the placement face.
You can specify a new vector" using the Two Points
method and select the control points of the flange edges
as shown below.
Use the flange edge

control points to specify
the Centerline Projection
Vector
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12-27
Bead
TIP Use Confirm Upon Apply to ensure it looks correct

before accepting your results.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Step 5 Check the bead integrity.
If the sketch and bead were created correctly, the part will
unform and the bead will remain associated to the flange
surface.
Choose the Unform All button. The part will completely

unform.
Reform the part using the Form All button.
EDS Unigraphics NX
Bead
Step 6 Create a UĆshaped bead on a flange surface.

We'll be placing a semiĆcircular bead around the hole, but we
must first create an associative guide curve.
Choose Sketch icon.
TIP You may want to change your work layer before you
create the sketch.
ÏÏÏ
ÏÏÏ
12
Select the upper surface of the flange with the hole cutout as
the sketch plane.
ÏÏÏ
ÏÏÏ
Select the left end of the flange edge as the new horizontal
direction. (See figure below)
Select this face as

the Attachment
face
Select on this side for the

Horizontal Reference.
Choose MB2 to create the sketch.
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12-29
Bead
Create an arc with a 20 inch radius. Make the arc concentric

with the hole and constrain its endpoints so that they are
8.00 inches from each edge of the part.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Choose Finish and verify that it will unform with the

associated flange.
TIP You only need to unform the second flange to check

associativity.
If the sketch was constrained correctly it should move with the

flange. The sketch must be properly constrained before you
proceed to the next step or your model will fail to unform.
Reform your part.
Return to the Bead dialog.
Select the upper surface as the placement face.
Select the arc as the centerline curve.

Because an arc is a planar curve, it is not necessary to specify a
Centerline Projection Vector. The default should be adequate.
EDS Unigraphics NX
Bead
Change the bead type to UĆshaped.

Radius = .30
Blend Radius = .50
Height = 1.00
Angle = 30
Placement Width = 5.00
In the Options dialog, make sure that Attach Bead, Hollow
Bead, and Both End Cap options are selected.
ÏÏÏ
ÏÏÏ
12
ÏÏÏ
ÏÏÏ
Choose OK to create the bead. Examine your model. Verify

that the bead unforms with the underlying flange.
EDS
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12-31
Bead
ÏÏÏ
ÏÏÏ
12 SUMMARY With the Bead feature you can create a variety
ÏÏÏ
ÏÏÏ
of bead shapes and sizes. Beads are fully
associative to their Placement Faces. When you
delete their parent feature, they will delete as
well. If sketches are used on the Placement
Face of the bead, the bead will also form and
unform to remain on their associated flange.
In this lesson you:

Created UĆshaped, VĆshaped, and Circular
Beads.
Created a bead with a parametrically
controlled guide curve (sketch).
EDS Unigraphics NX
Sheet Metal Bridge
Sheet Metal Bridge

Lesson 13
PURPOSE Create contoured sheet metal surfaces (bridges)

between existing solid bodies using the Sheet Metal
Bridge feature.
Create Sheet Metal Bridge surfaces

Edit Sheet Metal Bridge surfaces
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
Activity Page
13-1 Sheet Metal Bridge Creation . . . . . . . . . . . . . . . . . 13-13
EDS
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Sheet Metal Design
Student Guide
13-1
Sheet Metal Bridge
The Sheet Metal Bridge Dialog

The Sheet Metal Bridge feature will allow you to create a contoured surface
between base and target solids. Sheet Metal Bridge is unique from the Flange
and General Flange feature since the bridge can be created between two
bodies, as opposed to an extension from a single body.
You can access the Sheet Metal Bridge dialog from Insert→Sheet Metal
Feature→Bridge or from the Sheet Metal Bridge icon in the Sheet Metal
Feature toolbar. To edit a Sheet Metal Bridge, use Edit→Feature or the Edit
Feature toolbar.
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
EDS Unigraphics NX
Sheet Metal Bridge
You can use Sheet Metal Bridge to create single and double bend surfaces
between base and target solid bodies. During creation, the Sheet Metal Bridge
is constrained at the base and target profiles. During unforming, the Sheet
Metal Bridge behaves like the General Flange with distortion determined as an
extension from the base profile. The Sheet Metal Bridge supports the following
construction types:
Tangent at Target - This construction type may be used to create a

Sheet Metal Bridge with a single bend when base faces/edges have
been selected along with either target faces or target
faces/edges/curves.
Intersect Angle at Target - This construction type may be used to
create a Sheet Metal Bridge with a single bend when base faces/edges
have been selected along with either target edges/curves or target
faces/edges/curves.
Z-Bend - This construction type may be used to create a Sheet
Metal Bridge with a double bend when base faces/edges have been
selected along with any combination of target faces/edges/curves.
ÏÏÏ
ÏÏÏ
Intersect Angle
ÏÏÏ
13
ÏÏÏ
ZĆBend Intersect Angle Tangent at Target
at Target
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Sheet Metal Design
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13-3
Sheet Metal Bridge
Selection Steps
The Sheet Metal Bridge dialog, is a selection steps type of dialog. The icons at
the top of the dialog highlight as you progress through the bridge creation
process. You may also choose any icon at any time to specify, or reĆspecify,
information for that step of the process.
NOTE You can use expressions or arithmetic statements in the

Sheet Metal Bridge dialog, however, they will be
converted to their numeric equivalent upon execution of
the dialog.
Base Faces Target Profile

Base Profile Target Faces
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ Base Faces
The Base Faces selection step lets you select either single or multiple faces to
define the tangency constraints at the base of the Sheet Metal Bridge feature.
The base faces define a G1Ćcontinuous region which is used to tangentially

constrain the construction of the Sheet Metal Bridge feature at the base. The
Sheet Metal Bridge feature requires you to selection at least one base face.
Base Profile
The Base Profile selection step lets you select either single or multiple edges to
define the boundary at the base of the Sheet Metal Bridge feature.
The base profile is defined by G1Ćcontinuous edges which are used to define
the bend/extension edge at the base end of the Sheet Metal Bridge feature. The
Sheet Metal Bridge feature requires you to select at least one base edge. In
addition, the base profile selection is restricted to the edges that define the
peripheral boundaries of the base faces selected.
EDS Unigraphics NX
Sheet Metal Bridge
Target Faces
The Target Faces selection step lets you select either single or multiple faces to
define the tangency constraints at the target of the Sheet Metal Bridge feature.
The target faces define a G1Ćcontinuous region which is used to tangentially

constrain the construction of the Sheet Metal Bridge feature at the target. The
Sheet Metal Bridge feature does not require the selection of target faces.
Target Profile
The Target Profile selection step lets you select either single or multiple edges
or curves to define the boundary at the target of the Sheet Metal Bridge
feature.
ÏÏÏ
The target profile is defined by either a G1Ćcontinuous edges or curves. The
ÏÏÏ
Sheet Metal Bridge feature does not require the selection of a target profile. In
addition, the target profile selection is restricted to either the edges that define ÏÏÏ
13
ÏÏÏ
the peripheral boundaries of the target faces selected or curves that may be
projected to the surfaces of the target faces. If target faces are not selected, the
target profile may be any G1Ćcontinuous edges or curves.
EDS
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Sheet Metal Design
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13-5
Sheet Metal Bridge
Construction Parameters
Flip Extension Direction
The Flip Extension Direction option lets you toggle the extension direction of
the Sheet Metal Bridge feature. There are two extension directions shown on
the display: one for the base profile and one for the target profile. The direction
of each extension can be flipped while in their respective selection steps.
ÏÏÏ Construction Type

ÏÏÏ
ÏÏÏ
13
ÏÏÏ
The Construction Type option lets you choose the type of Bridge you will
construct. Choose from Tangent at Target, Intersect Angle at Target, and
ZĆBend.
EDS Unigraphics NX
Sheet Metal Bridge
A Bridge is built by creating section curves from the Base Profile to the Target
Profile. These section curves represent the top surface of the Bridge. The start
of these section curves are tangent to the Base Faces. Tangent at Target and
Intersect Angle at Target Bridges use section curves that contain a single bend,
whose angle is determined by the geometry. A ZĆBend Bridge contains two
bends of equal angles. See the figures below.
Base Faces Target Face
Intersect Angle
Target Faces
ZĆBend Intersect Angle Tangent at Target

at Target
Intersect Angle
ÏÏÏ
ÏÏÏ
The Intersect Angle is the angle between the Bridge surface and the Normal to
the Target Face, at the point where the Bridge surface intersects the Target ÏÏÏ
13
ÏÏÏ
Profile (see middle figure above). This value may be defined as follows:
Constant - The Intersect Angle may be defined by a constant number

or expression. The value entered in the text field can be any valid
Unigraphics expression or arithmetic statement, however, they will be
converted to their numeric equivalent upon execution of the dialog.
Law Controlled - The Intersect Angle may be defined using the Law
Subfunction.
NOTE The Intersect Angle parameter is only available when the

Intersect Angle at Target construction type has been
specified.
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13-7
Sheet Metal Bridge
Inside Radius
This parameter defines the Inside Radius of the Bridge feature. This value may
be defined similar to the Intersect Angle.
NOTE The Inside Radius must be specified regardless of any

other parametric or geometric input data.
Thickness
ÏÏÏ This parameter defines the Thickness of the Bridge feature. This value may be
ÏÏÏ defined similar to Intersect Angle and Inside Radius.
ÏÏÏ
13
ÏÏÏ
NOTE The direction of the Thickness may be specified either

Along Bend Direction or Opposite Bend Direction. The
default direction is Along Bend Direction.
EDS Unigraphics NX
Sheet Metal Bridge
This button displays the Bend Allowance Formula (BAF) dialog. You can
choose a bend allowance formula from the list or key in your own formula.
Toggle ON the Use Feature Standards option in the Sheet Metal Preferences
dialog to list the BAF's in the BAF dialog.
ÏÏÏ
Options ÏÏÏ
ÏÏÏ
13
ÏÏÏ
This button allows access to the settings for Global Parameters.
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Sheet Metal Design
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13-9
Sheet Metal Bridge
Distortion Method
Area Preserve and R Value
You can specify an r value (average strain ratio or normal anisotropy) or choose
area preserve, which is equivalent to specifying an infinite r value. The r value is
a property of the material being formed and will affect how the Bridge is
mapped to other states. Higher r values represent higher resistance to thinning
when the material is being stretched or resistance to thickening when the
material is being compressed. The default value of 1.0 corresponds to a
homogeneous material.
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
EDS Unigraphics NX
Sheet Metal Bridge
Construction Method
Unite
The Unite option controls how the Bridge feature unites with its construction
geometry. You may choose from None, Base, and Target. Because the creation
of a Bridge involves approximations, sometimes the Unite operation will fail.
You can improve the chances of success if you specify a tolerance that is no
more than 10 times the Modeling Distance Tolerance (found under
Preferences→Modeling in the Modeling application).
Tolerance ÏÏÏ
ÏÏÏ
This parameter defines the Tolerance that is used to construct the BĆSurface
Geometry of the Bridge feature. This value may be defined as follows:
ÏÏÏ
13
ÏÏÏ
Constant - The Tolerance may be defined by a constant number or
expression. The value entered in the text field can be any valid
Unigraphics expression or arithmetic statement, however, they will be
converted to their numeric equivalent upon execution of the dialog.
Inferred - The Bridge Tolerance is initially inferred from the
Modeling Distance Tolerance. However, the user may replace this
value with any valid Unigraphics expression or arithmetic statement, if
necessary.
EDS
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13-11
Sheet Metal Bridge
Construction Tips
should be followed when creating sheet bridge features:
Edit a Bridge as you would any feature. Note that during editing you
cannot change the Unite method.
The resultant bridge faces will be comprised of trimmed BĆsurfaces.
This may present minor difficulties while attempting to dimension the
feature, or a section cut of the feature.
The Construction Type does not allow for joining of the bridge, the
base and the target bodies. After creation if one solid body is desired,
an additional boolean operation must be performed to untie the
bodies together.
A bridge feature can be unformed in some cases. If an unform
operation is done to a body where a boolean is done between the
bridge, base and target bodies, the bridge will unform from the Base
ÏÏÏ
feature only. If the Construction type was set to Target, the system will
error and return a warning message.
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
EDS Unigraphics NX
Sheet Metal Bridge
Activity 13-1: Sheet Metal Bridge Creation
In this activity you will create a bridge feature.
Step 1 Open the part smd_seedpart. Save this part as xxx_bridge

Step 2 Edit the Expressions as follows:
Change T to .060.
Change R to .125.
ÏÏÏ
Step 3 Create the base feature.
ÏÏÏ
Create a block using the following parameters and locate it ÏÏÏ
13
ÏÏÏ
at (0,0,0).
X Length = 6.00
Y Length = 3.25
Z Length = T
Step 4 Remove rectangular sections from the base feature.
Create two Rectangular Pockets using the parameters

underlined below and locate the features according to the
figure on the next page. Use the top face as the Placement
Face and any edge parallel to the XCĆaxis of the WCS for the
Horizontal Reference.
X Length = l (lower case L) = 2.50

Y Length = w (lower case W) = 1.25
Z Length = T
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Sheet Metal Bridge
Hint: Use Line onto Line and Point onto Line to position the
Rectangular Pocket.
For the second Rectangular Pocket, just use the expressions l, w
and T for the parameters.
Step 5 Add Flange features to the two inset faces.
Choose the Flange icon and select the front bottom

edge of the inset face as the Bend Edge.
ÏÏÏ
ÏÏÏ Enter the following parameters:
ÏÏÏ
13
ÏÏÏ Width = .750 (change to Width Expression)
Tangent Length = 1.25
Inside Radius = R
Positioning Method = Manual
Locate the Flange by aligning the top edges and the far right
edges to the placement face.
EDS Unigraphics NX
Sheet Metal Bridge
Repeat the process for the opposite side. Use

Information→Feature to link the first Flange Width and
Length p" numbers to the new Flange (i.e. Width = p18).
Unform the part and orient your view to the Top view.
Notice the Flanges stick out farther than the original edges of
the block.
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
The next series of steps will lead you through the process of
associating the Tangent Length of the Flange with the original
edges of the base block.
Step 6 Edit the parameters of the Front Flange.

Choose Information→Expression→List All and locate the
first p" value for a Bend Allowance Formula (e.g.
p22=(p21+(p17*0.44))*rad(p19)) and then close the
Information window.
Choose the Edit Feature Parameters icon , select the

first flange, and choose OK.
Change Tangent Length value to w-the p" number found in

the previous step (e.g. w-p22).
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Sheet Metal Bridge
This sets the Tangent Length so it is 1.25 (w) minus the Bend
Allowance Formula (p22).
Choose OK to the Flange and Edit Parameters dialog

windows.
If you correctly set the second Flange's Tangent Length equal to

the first Flange's Tangent Length, you should see both flanges
change.
Step 7 Form your part and orient your view to the Trimetric view.
Step 8 Create the Bridge features.
Choose the Sheet Metal Bridge icon.
ÏÏÏ
Select the top face of the original block as the Base Face
ÏÏÏ
then choose MB2 to advance to the next selection step.
ÏÏÏ
13
ÏÏÏ Base Face
Base Profile
EDS Unigraphics NX
Sheet Metal Bridge
Select the top left edge of the front Rectangular Pocket

feature as the Base Profile edge as shown above and choose
MB2 to advance to the next selection step.
Select the top faces of the front Flange feature, which

include the bend face and the web face, as the Target Faces
and choose MB2 to advance to the next selection step.
Target Profile
ÏÏÏ
ÏÏÏ
Target Faces ÏÏÏ
13
ÏÏÏ
Select the left edges of the front Flange feature on the same
face selected in the previous step as the Target Profile.
Set the Construction Type option to ZĆBend (ArcĆLineĆArc).
Enter a value of .500 for the Inside Radius.
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Sheet Metal Bridge
Choose Apply to create the feature.
Repeat this process for the opposite side trying to follow the
steps in the Cue Line.
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
Step 9 Unform the Flange features.
Choose the Form/Unform icon and select the two

Flange features.
Choose the Unform Selected Features button. Notice the

resultant shape resembles a straight edge cut on both sides.
EDS Unigraphics NX
Sheet Metal Bridge
NOTE Since the Flange feature drives the shape of the

SMBridge feature, you can unform the SMBridge feature
by unforming the Flange. We do not recommend using
the Unform All function for Sheet Metal Bridge Features.
Step 10 Optional: Edit the Width of the front Flange feature and
the Inside Radius of the SMBridge feature to test the
limitations of the feature.
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
EDS
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Sheet Metal Design
Student Guide
13-19
Sheet Metal Bridge
SUMMARY The Sheet Metal Bridge application provides

you with a way to join two solid bodies.
In this lesson you:

Created and edited Sheet Metal Bridges
ÏÏÏ
ÏÏÏ
ÏÏÏ
13
ÏÏÏ
EDS Unigraphics NX
Multibend Bracket
Multibend Bracket
Lesson 14
PURPOSE To see the advantages of using the Multibend Bracket

feature.
Create and edit a multibend bracket
Activity Page
14-1 Creating a Multibend Bracket . . . . . . . . . . . . . . . . 14-10
ÏÏÏ
ÏÏÏ
14
ÏÏÏ
EDS
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14-1
Multibend Bracket
The Multibend Bracket Dialog
The Multibend Bracket enables you to create a fully associative sheet metal
bracket defined from user selected reference geometry. Select 3D reference
geometry to define a set of planes. Using bend parameters that you define, the
Multibend Bracket unfolds this reference geometry into a base plane. Use the
Sketcher to develop a sketch of the unformed bracket outline based on this
unfolded reference geometry. The system extrudes the sketch into a solid and
applies the appropriate bends.
You can access the Multibend Bracket dialog from Insert→Sheet Metal
Feature→ Multibend Bracket or by selecting the Multibend Bracket icon

from the Sheet Metal Feature toolbar. To edit a Multibend Bracket, use
Edit→Feature or the Edit Feature toolbar.
Tree
List
ÏÏÏ
Bend
Tools
ÏÏÏ
14
ÏÏÏ
Outline
Tools
for
Sketching
EDS Unigraphics NX
Multibend Bracket
Selection Steps
The Multibend Bracket dialog is a Selection Steps dialog. This dialog is unique
in that there is only one step on the dialog, (which has no bitmap).
Tree List
The tree list controls the target for each action within the Multibend Bracket
dialog. Selecting geometry defines the plane for the highlighted node. In
addition, functions such as Add Bend, Delete Bend, and set Inner Radius
applies to the highlighted node. You can reach the Add Bend and Delete Bend
functions by clicking the right mouse button on the node.
Right mouse button

on the node for
additional functions
Base Plane
Select geometry to define a plane for the highlighted node on the tree list. The
position and orientation of the planes will determine the angle and location of
ÏÏÏ
each bend. You must select sufficient geometry to define a plane.
ÏÏÏ
14
Each piece of selected reference geometry is unfolded onto the base plane for ÏÏÏ
inclusion in the sketch. When a face is selected, the edges of the face are
unfolded to the base plane. No geometry is unfolded when a datum plane,
datum axis, or CSYS is selected. All selected geometry is, however, used to
define the location and angle of the bend. If you select a CSYS, the XY plane
defines the reference geometry plane. Errors will occur if you select insufficient
geometry to define a plane, or geometry that does not define a single plane.
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14-3
Multibend Bracket
Add Bend
This function adds a new bend to the tree list. The new bend node will be a
child of the highlighted node. You can only add a bend node if a base plane has
been defined for the parent node. Select reference geometry to define the
plane for the bend. Specify a bend radius and bend allowance formula. If
desired, specify an offset from the plane. Add additional bends as necessary.
Bends can be added to any node in the tree list by selecting the node in the tree
list that is to be the parent of the new bend node.
Add Intersection
This function adds a new intersection node to the tree list. The new node will
be the child of the highlighted node. You can only add an intersection node if a
plane has been defined for the parent node. The intersection line between the
current plane and its parent plane will be included as a reference in the sketch.
Reverse Material Direction
This function is used to change the material direction for the highlighted node.
The material direction also defines the direction of a positive offset. You can
only reverse the material direction if a plane has been defined for the node.
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14
ÏÏÏ Delete Bend
This function deletes the highlighted bend node, and all of its children, from
the tree list. All data associated with these nodes is lost. You cannot delete the
base plane.
EDS Unigraphics NX
Multibend Bracket
Allowance Formula dialog is displayed below. You can select the Bend
Allowance Formula (BAF) from the list or you can enter the BAF in the text
field.
If Use Global is turned ON in global parameters for Bend Allowance Formula,

this option will be removed from the General Flange dialog.
Offset
You can offset the plane defined for the highlighted node from the selected
geometry using the Offset value. A positive offset value is always in the
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direction of the material direction vector. You cannot set an offset value until a
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14
plane has been defined. The value may also be an expression.
ÏÏÏ
If you have Preferences"Sheet Metal"Use Feature Standards turned ON, the
button on each field will give you a list of standard acceptable values.
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Multibend Bracket
Inner Radius
This field sets the inner radius for the highlighted bend node. The inner radius
must be a positive value or expression. You cannot set an inner radius value
until a plane has been defined. The base plane does not have an inner radius.
If you have Preferences"Sheet Metal"Use Feature Standards turned ON, the

button on each field will give you a list of standard acceptable values. This field
is not available if you have enabled a global inner radius value.
Intersection Thickness
This field defines the thickness of the intersection node. The intersection node
is treated a having two sides, separated by the given thickness value. The
Multibend Bracket feature determines which sides of the adjacent planes will
contact each other. In cases where you want to find intersections between
planes within one Multibend Bracket, (for example to avoid intersecting
bends), you should make the intersection thickness the same as the material
thickness.
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EDS Unigraphics NX
Multibend Bracket
Adjacent Face
The Adjacent Face button is only available for bend nodes that are defined
using the Attachment Edge selection filter. By default, the plane defined for an
attachment edge is that of the adjacent planar face that yields the smaller
thickness. The system will highlight the attachment face. Press the Adjacent
Face button to select the plane of the other adjacent face.
Sketch Tools
After all bends have been specified, the Sketch Tools must be accessed to
define the sketch. This function unfolds the selected reference geometry into a
sketch, and then invokes a subset of the normal Sketcher dialog. This dialog
lets you edit the hidden sketch that belongs to the Multibend Bracket. You ÏÏÏ
cannot create a new sketch or substitute an existing sketch. ÏÏÏ
14
ÏÏÏ
Upon completing the sketch, exit the Sketch Tools dialog to return to the
Multibend Bracket dialog.
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Multibend Bracket
Options
The Select only coplanar objects toggle allows you to only select objects that lie
in a single plane. Set the toggle OFF if you need to select any reference
geometry regardless of the plane. Objects that do not lie in the plane will be
projected into the reference plane.
Set the Global Parameters toggle ON to use the global preference settings for
Material Thickness, Inner Radius and Bend Allowance Formula. These settings
are only available if the global preferences are set appropriately. If you turn
OFF the toggle, the global value will not be used for that field.
Editing Multibend Brackets
Editing a Multibend Bracket is very similar to creating a Multibend Bracket. To

edit a Multibend Bracket, use Edit→Feature or the Edit Feature toolbar. Upon
entering the dialog, you can change bend parameters, add or delete bends, and
ÏÏÏ edit the sketch.
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14
ÏÏÏ If you add a new bend, the model will update when you enter the sketcher. Be
aware that if you delete faces and edges (due to deleting a bend or editing the
sketch) downstream features could be affected.
EDS Unigraphics NX
Multibend Bracket
Construction Tips
A Multibend Bracket will update if any of its parents (features,
expressions, geometry) change. In some cases, editing the geometry
that the bracket is associative to, by a significant amount, can cause
the Multibend Bracket to fail upon update. Many times what you will
find is that the sketch that controls the outline of the bracket has had
one of the dimensions reapplied in an alternate solution". If the
bracket fails to update, simply edit the Multibend Bracket feature,
enter the Sketch Tools dialog and apply an Alternate Solution to
resolve any incorrect dimension(s).
The Multibend Bracket creates bend centerlines for each bend node.
Since these lines are used as application curves for hidden Sheet Metal
Bend features, all rules associated with that feature apply. At least
part of the bend centerline must lie within the outline of the sketch
geometry. The bend centerline must not extend past the outline such
that when it is projected onto the extruded sketch, it will yield two
curves. The system will center each bend centerline based on the
position on the first reference object selected.
The Sketch Tools dialog allows you to create or edit the sketch that
defines the outer perimeter of a Multibend Bracket feature. Since the
sketch will be extruded, it is important to make sure there are no gaps
in this perimeter. When you leave the Sketch Tools dialog, the system
will extrude the sketch. If the extrusion failed, you will be shown the
location of possible gaps in the outline. Reenter the Sketch tools to
correct these gaps.
Use the Sketch Tools dialog to edit the sketch of a Multibend Bracket
feature. While editing, note that you cannot delete active sketch curves
that are part of the extrusion. To delete these curves, first change them
to reference geometry using the "Convert To/From Reference" ÏÏÏ
function. Then exit the Sketch Tools dialog to cause the Multibend ÏÏÏ
14
Bracket to update. You may then reenter the Sketch Tools dialog to
delete the unused sketch curves.
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Multibend Bracket
Activity 14-1: Creating a Multibend Bracket
In this activity you will create a multibend bracket around an existing solid
body.
Step 1 Open and examine the assembly.
Open the part smd_multibnd_brkt_2 and Save As

***_multibnd_brkt_2.
ÏÏÏ Ensure you're in the Modeling application.

ÏÏÏ

14
ÏÏÏ Step 2 Establish the parameters for the bracket.
Choose Tools"Expressions...
Choose the T variable and change the value to .080 .
Choose the R variable and change the value to .080 .
Choose OK.
EDS Unigraphics NX
Multibend Bracket
Step 3 Set the sheet metal preferences for the part.
Choose Preferences→Sheet Metal...
Choose the Global Parameters button.
Enter T for the Thickness expression.
Enter R for the Bend Radius expression.
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Multibend Bracket
Toggle ON Use Global for Bend Allowance Formula. No

changes to the default are required.
ÏÏÏ
ÏÏÏ
14 Confirm your settings and choose OK twice.
ÏÏÏ Step 4 Create the Multibend Bracket.
NOTE Consider turning OFF the Assembly and Model

Navigators to take full advantage of the graphics screen.
Change the work layer to 22 and choose the Multibend
Bracket icon.
EDS Unigraphics NX
Multibend Bracket
Select the top face as the BASE_PLANE.
Select this face
If needed, choose Reverse Material Direction

to flip the vector so it points upward.
Choose the Add Bend icon.
TIP Another way to add a bend is by placing the cursor

over the BASE_PLANE node in the tree listing,
ÏÏÏ
selecting MB3 and choosing Add Bend.
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Multibend Bracket
Select the bottom edge of the boss, as shown, for the

reference geometry.
NOTE Consider turning OFF shading.
Material direction
Select this edge

to flip the vector so it points in the direction shown above.
Highlight the BASE_PLANE at the top of the Multibend

Bracket dialog. This is necessary because the next flange
ÏÏÏ needs to be created off of the same base plane.
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EDS Unigraphics NX
Multibend Bracket
Select the front face of the solid for the reference geometry.
Select this face

Enter .030 for an Offset value.

Bracket dialog again.

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Multibend Bracket
Select the back face of the solid for the reference geometry.
Select the
back face


Bracket dialog. Once again this is necessary because the next
flange needs to be created off of the same base plane.
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EDS Unigraphics NX
Multibend Bracket
Select the three edges, as shown below, for the reference

geometry.
Select the three

bold edges

NOTE You can review your geometry selection for each bend by
highlighting the applicable bend node (e.g. BEND_01) in
the tree listing.
Step 5 Create an intersection curve.
Highlight BEND_01 at the top of the Multibend Bracket ÏÏÏ

dialog. ÏÏÏ
14
ÏÏÏ
Choose the Add Intersection icon.
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Multibend Bracket
Select the face shown below for the reference geometry.
Select this
face

Since we only selected the bottom edge of the boss for the
reference geometry we can use the Add Intersection option to
imprint" a curve onto the BEND_01 face for reference.
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14
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Step 6 Create the outline for the bracket.
Choose the Sketch Tools icon.
Make all layers but the work layer invisible.
EDS Unigraphics NX
Multibend Bracket
For clarity purposes, Blank the objects shown below.

(Edit"Blank"Blank...)
Blank these
objects
NOTE The reference geometry is added to the sketch as
ÏÏÏ
Extracted Curves and are made reference (grey and
ÏÏÏ
phantom font). They can be converted to active for use in
the outline if desired. 14
ÏÏÏ
Fit the view.
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Multibend Bracket
Using the Profile icon freehand sketch the " shape

shown below.
NOTE Make sure all lines created are horizontal and vertical. If
necessary, apply geometric constraints of horizontal or
ÏÏÏ
vertical to capture the constraints.
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14
ÏÏÏ Step 7 Constrain the bracket outline.
Choose the Constraints icon.
EDS Unigraphics NX
Multibend Bracket
Apply Collinear constraints to the pairs of curves shown

below.
1 2
Some of the geometry has been removed for clarity.
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14
ÏÏÏ
Choose the Dimensions icon.
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Multibend Bracket
Create the dimensional constraints shown below.
Intersection curve
2.000
1.500 1.000
0.500 0.500
1.000
0.500
0.125
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EDS Unigraphics NX
Multibend Bracket
Create the circle to the dimension shown below on both

sides. If necessary, apply concentric geometric constraints to
the extracted circles to align the arc centers.
∅ 0.625
Create the slot shape to the dimensions shown below.
0.625
0.3125
0.5625
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1.125
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14
ÏÏÏ
NOTE Make sure that the radius is tangent to both sides of the
vertical lines. If necessary, apply a tangent geometric
constraints to capture the intent.
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Multibend Bracket
Check to see if the Status Line states that the Sketch is fully
constrained. If it does not indicate how many constraints are
left choose the Dimensions icon again.

This will force the multibend bracket to update, the sketch and
datums will disappear, the sketch will be extruded into a solid
and bend features will be applied to the part. Once the update
is finished, the bracket should look like the one below.
Shade and rotate the part to examine the bracket.
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14
ÏÏÏ If necessary, orient the view to Trimetric.
Choose OK in the Multibend Bracket dialog.

This will force the multibend bracket to finish the creation
process establish the feature.
Step 8 Edit the base solid to test the associativity of the bracket.
Choose the Model Navigator icon.
EDS Unigraphics NX
Multibend Bracket
Place your cursor on the SIMPLE_HOLE(6) feature and

press MB3.
Choose Edit Positioning.
Choose Edit Dimension.
Select the vertical dimensions and edit the value to 1.25 .
Choose MB2 three times to accept the change and update

the model.
Place your cursor on the BOSS(5) feature and press MB3.
Choose Edit Positioning.
Choose Edit Dimension.
Select the vertical dimensions and edit the value to 3.00 .
Choose MB2 three times to accept the change and update

the model.
NOTE In some cases, editing the model a significant amount can

ÏÏÏ
cause the Multibend Bracket to not update properly.
ÏÏÏ
14
Many times what you will find is that the sketch that
controls the outline of the bracket has had one of the ÏÏÏ
dimensions reapplied in an alternate solution". If the
bracket fails to update, simply edit the Multibend Bracket
feature, enter the Sketch Tools dialog and apply an
Alternate Solution to resolve any incorrect dimension.
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14-25
Multibend Bracket
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14
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EDS Unigraphics NX
Multibend Bracket
SUMMARY The Multibend Bracket feature creates an

associative bracket that moves with the
respectively referenced geometry. It is
comprised of formable features so it can be
unformed.
In this lesson you:

Created and Edited a Multibend Bracket
Worked in an assembly environment.
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Student Guide
14-27
Multibend Bracket
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14
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EDS Unigraphics NX
Sheet Metal Bracket
Sheet Metal Bracket

Lesson 15
PURPOSE Create and edit sheet metal brackets using the Sheet
Metal Bracket utility.
Create and edit brackets
Activity Page
15-1 Bracket Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
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15-1
Sheet Metal Bracket
The Sheet Metal Bracket Utility
The sheet metal Bracket is a utility you can use to create a bracket from
reference geometry. It is a collection of features.
Each bracket consists of a Base Pad, created by an Extrude feature and a

Flange or General Flange feature built off the Base Pad. One or more Sheet
Metal Cutout features then trim the flange to size. The Sheet Metal Cutout is
built to match input reference points. The resulting bracket will align with the
reference geometry. It is possible to build subsequent flanges off of existing
bracket geometry.
The flanges and general flanges created by the Sheet Metal Bracket utility can
be formed and unformed as any other flange feature.
To edit a bracket, you must edit the individual features that make up the
bracket. A bracket is not associative to its reference geometry.
You can access the Sheet Metal Bracket dialog from Insert→Sheet Metal
Feature→Bracket or by selecting the Sheet Metal Bracket icon in the

Sheet Metal Feature toolbar. To edit a Sheet Metal Bracket, use Edit→Feature
or the Edit Feature toolbar.
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EDS Unigraphics NX
Sheet Metal Bracket
The Sheet Metal Bracket Dialog
Once you bring up the Sheet Metal Bracket dialog, you will see and have access
to the following menus:
Bracket
parameters
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15-3
Sheet Metal Bracket
Selection Steps
There are four choices for geometry selection. They are Base Face, Base
Clearance Points, Reference Face, and Reference Clearance Points.
Clearance Reference Face

Points
Flange
Base Pad
Clearance Base Face
Circles
Flat Pattern under Finished bracket

construction
Base Face
The first selection step leads you to pick the Base Face. The Base Face is a
single face used to construct the bracket Base Pad. The Base Face must be
planar. You may set the Filter to allow the selection of a Plane, Face, or Datum
Plane.
Base Clearance Points
The second step allows you to select Clearance Points on the Base Face. This
step is optional. If you don't select any geometry, the Pad Length parameter
will define the Base Pad dimension.
ÏÏÏ
ÏÏÏ
The system uses the Clearance Points to define the outline of the Base Pad.
There may be no more than two Base Clearance Points. Use the filter to allow
15
ÏÏÏ
ÏÏÏ
the selection of existing Points, an Edge, a Curve, or an Arc Center.
EDS Unigraphics NX
Sheet Metal Bracket
The selection of Points or Arc Centers causes the system to define a Clearance
Circle for each selection. If you select a curve, the system will construct a
Clearance Circle at each end point. The system will construct the Base Pad
outline tangent to the Clearance Circles.
If you select an Edge for this step, the Base Pad edge will coincide with the
selected edge. No Clearance Circles will be applied.
Reference Face
The third selection step lets you pick the Reference Face. This face defines the
mating surface for the bracket flange. The Reference Face must intersect the
plane of the Base Face. This will generate the Intersection Curve. If the
intersection curve is linear, a Flange feature is constructed. If the intersection
curve is nonlinear, a General Flange feature is constructed. When a General
Flange is built, it will approximate the Reference Face using linear cross
sections. The initial bracket width is the length of the intersection curve.
NOTE One of the benefits of the Bracket feature over the

Multibend Bracket feature is the ability to select a
non-planar face for a reference face.
You may set the Filter to allow the selection of a Plane, Face, or Datum Plane.
The bend direction of the Flange is determined from the pick point on the
Reference Face. The Flange will always bend toward the pick point.
Reference Clearance Points
The fourth selection step allows you to select Clearance Points on the
Reference Face. This step is optional. If you don't select any geometry, the
Flange Length parameter will define the Flange contour length.
The system uses the Clearance Points to define the outline of the Flange. There
may be no more than two Reference Clearance Points. Use the Filter to allow
ÏÏÏ
ÏÏÏ
15
the selection of existing Points, an Edge, a Curve, or Arc Centers. ÏÏÏ
ÏÏÏ
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Sheet Metal Bracket
The selection of Points or Arc Centers causes the system to define a Clearance
Circle for each selection. If you select a curve, the system will construct a
Clearance Circle at each end point. The system will construct the Flange
outline such that it is tangent to the Clearance Circles.
If you select an Edge for this step, the Flange edge will coincide with the
selected edge. No clearance circles will be applied.
Parameters
The following parameters define the overall dimensions of the bracket. After
building the Base Pad and Flange, you will be given the opportunity to edit the
outline.
If you have Preferences"Sheet

Metal"Use Feature Standards
turned ON, the arrow button on each
field will give you a list of standard
acceptable values.
Reverse Material Direction
Upon selecting a Base Face and Reference Face, the system will display two
vectors that indicate the material direction of the bracket. The bracket faces
will align with the Base and Reference Faces, however, you can choose to align
on the bracket inner or outer faces. Switch between the two using the Reverse
Material Direction button
Clearance Distance
The Clearance Distance defines the radius of the Clearance Circles. This
ÏÏÏ
parameter has two effects. Since the bracket outline is tangent to these curves,
it defines the minimum distance of the Clearance Point to the edge of the
ÏÏÏ
15 bracket. It also defines the corner radius (if the Add Rounded Corners option is
ÏÏÏ
ÏÏÏ
enabled).
EDS Unigraphics NX
Sheet Metal Bracket
Material Thickness
A bracket is constructed from an Extrude feature and a Flange or General

Flange. The Material Thickness is used as the extrusion distance and the
Flange thickness.
Bend Radius
The Bend Radius is the constant inside radius of the Flange or General Flange
feature.
Pad Length
The Pad Length defines the distance from the Intersection Curve to the
opposite edge along the Base Face. This parameter is only used if no Base
Clearance Point geometry is selected.
Flange Length
The Flange Length defines the contour length of the Flange or General Flange
feature. This parameter is only used if no Reference Clearance Point geometry
is selected.
Offset Distance
When you specify an Offset Distance, the resulting Flange or General Flange
will be offset from the Reference Face, by the given distance. With offset
distance, you can allow room for the bend to go around an outside corner or
provide for a shim under the reference flange.
Chordal Tolerance
ÏÏÏ
The Chordal Tolerance defines how closely the resulting General Flange will
match a non-planar Reference Face along the Bend Edge. The General Flange
is built from section curves. This parameter controls the number of sections ÏÏÏ
15
generated. ÏÏÏ
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Sheet Metal Bracket
Linear Tolerance
The Linear Tolerance defines how closely the resulting General Flange will
match a non-planar Reference Face. The General Flange is built from section
curves, each consisting of an arc and a line. This parameter controls the
maximum distance between the Reference Face and the General Flange face.
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EDS Unigraphics NX
Sheet Metal Bracket
Allowance Formula dialog is displayed. You can select the Bend Allowance
Formula (BAF) from the list or you can enter the BAF in the text field.
Add Rounded Corners
The Add Rounded Corners toggle lets you create a bracket in which the corners
are constructed from the Clearance Circles. The default is "ON".
NOTE When this option is "OFF" the bracket outline is created

using lines that are tangent to the Clearance Circles. It is
possible that these tangent lines could intersect a
considerable distance from the bracket, or even be
parallel. This can cause undesirable effects when the
outline is applied. For this reason, we recommend the use
of this option whenever possible. You can reduce such
problems by increasing the Bracket Margin under
Preferences→Sheet Metal.
Options
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Sheet Metal Bracket
Create or Unite
After you press OK or Apply on the main dialog, you will be asked if a new
body should be created for the Base Pad or it if should be United to some
existing body. You may use the Unite option to build a single bracket that
consists of several Flanges. After choosing one of these options, the system will
build the Base Pad and the Flange or General Flange features. It will then
unform the Flange and allow you to edit the bracket outline.
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EDS Unigraphics NX
Sheet Metal Bracket
Edit Outline
After the system builds the bracket and unforms the Flange, you are given the
opportunity to edit the bracket outline. The default outline extends from the
Clearance Circles to the ends of the Base Face ć Reference Face intersection
curve. You may edit each intersection curve end point independently. The end
points are labeled "Point 1" and "Point 2". The buttons on the Edit Outline
dialog refer to Edit Point1 and Edit Point2 respectively.
While editing one of the intersection curve end points, a temporary point
marker will indicate the new position of the point. When you press OK, the
outline will update. If you press Back, the geometry you created will be
removed, and control will return to the main dialog.
You are given several editing methods:
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Sheet Metal Bracket
Normal to Curve
The Normal to Curve option moves the intersection curve end point to a position on a line
tangent to the Base Face Clearance Circle and normal to the intersection curve. The tangent
line on the Flange side will meet that point, but it might not be normal to the curve. This
option is not available if there are no Clearance Points on the Base Face. In the figure
below, the original outline is shown as a solid line and the modified outline is shown as a
dashed line.
Flange Side
Intersection
Curve
Original
Outline
Base
Face
Base Face
Clearance
Circles
Normal to Curve
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Sheet Metal Bracket
Between Circles
The Between Circles option moves the intersection curve end point to lie on a
line tangent to the Clearance Circles from the Base Face to the Reference Face.
This option is not available if there are no Clearance Points. In the figure
below, the original outline is shown as a solid line and the modified outline is
shown as a dashed line.
Original
Outline
Flange Side
Intersection
Curve
Base Face
Clearance
Circles
Base Face
Between Circles
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Sheet Metal Bracket
Along Vector
The Along Vector option lets you choose the direction of the outline on the Base
Face. The system presents the Vector Constructor dialog. You may select any
vector. The system will project the vector onto the base face plane and move the
intersection curve end point to lie on a line that is parallel to the specified
vector and tangent to the Base Face Clearance Circle. The tangent line on the
Flange side will meet that point. If the specified vector and tangent line does
not intersect the Base Face ć Reference Face intersection curve, an error is
given. In the figure below, the original outline is shown as a solid line and the
modified outline is shown as a dashed line.
Original
Outline
Vector
Base Face
Clearance
Circles
Base Face
Along Vector
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Sheet Metal Bracket
Drag Point
The Drag Point option lets you interactively drag the intersection curve end
point along the curve. The point starts at one end of the intersection curve (0%
or 100%) and can be moved by adjusting the slider to a point anywhere along
the curve. You can also enter a percentage of the arc length or an actual arc
length. It is not possible to extend beyond the original intersection curve
endpoints.
Drag Point
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Sheet Metal Bracket
Point Constructor
The Point Constructor option lets you pick any point in space to serve as the
intersection curve end point. The system will project the point onto the
intersection curve in a direction normal to the curve, then create a line from
that point tangent to the Clearance Circles. In the figure below, the original
outline is shown as a solid line and the modified outline is shown as a dashed
line.
Point in Space
Original
Outline
Point in Space
Point Constructor
Reset
The Reset option is a convenience function that simply moves the intersection
curve end point to its original position.
Creation of a Sheet Metal Cutout
Press OK or Apply on the Edit Outline dialog to complete the construction of

the Bracket. The system creates a Sheet Metal Cutout feature to define the
ÏÏÏ
ÏÏÏ
outline and then forms the Flange or General Flange feature.
15
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EDS Unigraphics NX
Sheet Metal Bracket
Construction Tips
MultiĆflanged Brackets
It is possible to make a bracket that contains multiple flanges. The procedure is

identical to that of a singleĆflange bracket, however, you must unite the Base
Pad of the second bracket to the Base Pad of the first bracket. In order to build
the second Base Pad to the proper size, you could select an edge from the first
Base Pad in the Base Clearance Points selection step.
If you select the web of an existing flange as the Base Face, the system will
create the Base Pad using Sketch, Bounded Plane, and Thicken features. This is
necessary to make the Base Pad follow the Base Face as it forms and unforms.
Editing Sheet Metal Brackets
A Sheet Metal Bracket is not a feature, but a collection of features, thus, each
feature must be edited independently. The Flange and General Flange features
are not associative to the Reference Face. Further, the Sheet Metal Cutout is
not associative to the Clearance Points. However, the curves that define the
initial Base Pad shape may be edited if desired. Also, the curves that define the
Sheet Metal Cutout may be modified. Either set of curves may be added to a
sketch for better parametric control of the outline, however, keep in mind the
feature creation hierarchy when trying to add the curves to a sketch.
Bracket Margin
During construction of a bracket, the system creates a base pad trimmed to the
proper size. The original base pad's size is determined by the intersection curve
and the clearance distance dimension. The Bracket Margin value is a
percentage that increases these dimensions. It only affects the size of the
original base pad and not the final bracket. You should increase this margin if
the Bracket outline curves do not lie entirely on the base pad. There may be a
need to increase the margin if you have Add Rounded Corners turned OFF.
You can access the Bracket Margin in Preferences→Sheet Metal.
NOTE If desired, the bracket margin can also be changed in the

ÏÏÏ
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15
ug_smd.def default file.
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Sheet Metal Bracket
Activity 15-1: Bracket Creation
In this activity you will create and edit sheet metal brackets.
Step 1 Open the part smd_bracket. Save this part as

xxx_bracket where xxx are your initials.
Step 2 Change the default material for the part.

Make sure you are in the Modeling application.
If necessary, toggle ON Use Feature Standards.
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EDS Unigraphics NX
Sheet Metal Bracket
Choose OK to accept the preference settings.
Step 3 Identify the mating surfaces and clearance objects of the

bracket.
Choose the Sheet Metal Bracket icon.
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Sheet Metal Bracket
Select the top of the horizontal solid the Base Face.
Base Face
Click MB2 to advance to the Clearance Points step.
Change the filter pulldown to Arc Center.
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EDS Unigraphics NX
Sheet Metal Bracket
Select the left and right holes on the Base Face as your Base
Face Clearance Points.
Base Face
Clearance
Points
Click MB2 to advance to the Reference Face step.
Select the front face of the other solid as your Reference

Face.
Reference
Face
Click MB2 to advance to the Clearance Points step.
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Sheet Metal Bracket
Again, change the filter pulldown to Arc Center.
Select the left and right holes on the Reference Face as your
Reference Face Clearance Points.
Clearance
Points
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EDS Unigraphics NX
Sheet Metal Bracket
Step 4 Establish the size parameters of the bracket.
Change the parameters of the bracket to match the values

shown below.
NOTE Use the Standard arrows to help define valid size

parameters. If the values shown are not available type
them in.
Use
Standard
arrows
Choose OK.
Change your work layer to 42. This is to place the bracket

curves on a separate layer.
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15-23
Sheet Metal Bracket
Step 5 Create the flat pattern.
Choose Create in the dialog to create the flat pattern.
Now you will adjust the flat pattern by moving the end points.
Choose the Edit Point1 icon.
The Editing Options dialog offers you several options to move

point 1.
Choose the Between Circles option.
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Choose OK.
EDS Unigraphics NX
Sheet Metal Bracket
Choose the Edit Point2 icon.
Choose the Between Circles option.
Choose OK twice.
Step 6 Clean up your screen.
Move the bracket to layer 15.
Make layer 15 your work layer, layer 41 selectable and layer

42 invisible. This will display points at the hole centers and
open a new layer for your bracket.
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15
Shade your model by selecting the Shaded icon.
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Sheet Metal Bracket
Notice the new bracket is without fastener holes. You will need
to add them.
Return your model to wireframe by selecting the Wireframe
icon.
Step 7 Copy the mating holes from the reference solid onto the
reference flange of your new bracket.
Choose Edit→Copy Feature...
Select SIMPLE_HOLE(1) in the filter window.
This hole will highlight
Reference
Flange
Choose OK.
Choose Edit→Paste.
Change the Expression Transfer Mode to Link to Original.
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EDS Unigraphics NX
Sheet Metal Bracket
Select the top surface of the Reference Flange as the Trim

Face.
Select the back surface of the Reference Flange as the

Planar Placement Face.
Choose OK.
Choose the Point onto Point icon.
Select the point at the center of SIMPLE_HOLE(1).
Select this point
Reference
Flange
Repeat the Copy/Paste using SIMPLE_HOLE(2) and its

corresponding point.
Step 8 Copy the mating holes from the base solid onto the base
pad of your new bracket.
Choose Edit→Copy Feature...
Select SIMPLE_HOLE(6) in the filter window.
Base Pad
This hole will

highlight
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Sheet Metal Design
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15-27
Sheet Metal Bracket
Choose OK.
Choose Edit→Paste.
Select the top surface of the Base Pad as the Trim Face.
Select the bottom surface of the Base Pad as the Planar

Placement Face.
Choose OK.
Choose the Point onto Point icon.
Select the point at the center of SIMPLE_HOLE(6).
Select this point
To get:
Repeat the Copy/Paste using SIMPLE_HOLE(7) and

SIMPLE_HOLE(8) and their corresponding points.
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EDS Unigraphics NX
Sheet Metal Bracket
Make layer 41 invisible. Your finished part should look like

the one below:
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Sheet Metal Design
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15-29
Sheet Metal Bracket
SUMMARY The Sheet Metal Bracket utility combines the

functions of extrusion, flange, and sheet metal
cutout to create brackets with a variety of edge
styles.
In this lesson you:

Created a sheet metal bracket
Edited sheet metal brackets
Added holes to sheet metal brackets
The edges of your bracket can be normal to the intersection
curve, tangent to the clearance circles, parallel to a vector or
lined up with a point in space.
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EDS Unigraphics NX
Flat Pattern
Flat Pattern ÏÏÏ

Lesson 16
ÏÏÏ
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16
ÏÏÏ
PURPOSE To create, edit, and annotate different sheet metal flat

patterns.
Create flat patterns

Change preferences for flat patterns and flat
pattern annotations
Edit and update flat pattern displays.
Activity Page
16-1 Creating a Simple Flat Pattern Drawing . . . . . . . 16-12
16-2 Creating a Flat Pattern Drawing Assembly . . . . . 16-27
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16-1
Flat Pattern
ÏÏÏ The Sheet Metal Design Flat Pattern function allows for the creation of a 2D
ÏÏÏ wireframe profile of an unformed 3D part that accounts for material
ÏÏÏ
16
ÏÏÏ
deformation and elongation. Whereas the Part In Process function operates
only on sheet metal features, the Flat Pattern operation works on any solid or
sheet body, with or without sheet metal features, and independent of associated
forming tables.
NOTE If the part is a sheet body, the thickness of the part is set
to zero and the default Bend Allowance Formula (BAF)
used by the Flat Pattern function does not affect the
resultant flat pattern wireframe profile.
Three different mathematical solving methods are employed to map the model
geometry into the flat pattern definition. With these solvers, the user has the
control to specify which faces of a part are flattened and how they are flattened.
The generated flat pattern is associated to the model geometry and will update
when the model geometry changes.
NOTE The flat pattern profile has a oneĆway associativity to its

defining 3D part. Changes in the model geometry will be
reflected in the flat pattern definition. Changes in the flat
pattern profile will not be reflected in the 3D model
geometry.
EDS Unigraphics NX
Flat Pattern
The Flat Pattern Dialog ÏÏÏ

ÏÏÏ
To enter the Flat Pattern function you must be in the Sheet Metal Design
application. The Flat Pattern dialog is presented when you choose Tools→Flat
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16
ÏÏÏ
Pattern.
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16-3
Flat Pattern
ÏÏÏ Creating a Flat Pattern

ÏÏÏ
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16
ÏÏÏ
When you enter the Flat Pattern function for the first time, you are prompted
to select a starting face. Once you select a face on the active part, the system
automatically traverses the face and all adjoining faces on the same side of the
part, and then calculates the flat pattern definition for its given face.
Once part face identification is established, the Apply or OK buttons becomes

active. Simply choosing either of these buttons will create the flat pattern, with
the group name, on the layer specified within the Flat Pattern dialog. This
automated capability allows you to quickly create a flat pattern with a minimal
amount of effort.
You may traverse a solid body at any time while in the Flat Pattern module,
even if a flat pattern already exists, by simply selecting another start face.
Depending on your flat pattern preferences, the system will either allow you to
create a new flat pattern, or will attempt to replace the existing one.
Updating a Flat Pattern
If the Auto Update option in the SMD Flat Pattern Preferences dialog is toggled
ON, the flat pattern geometry will update whenever you enter or exit the Sheet
Metal Design application. If you disable the Auto Update option, you must
manually update the flat pattern using the Apply button in the Flat Pattern
dialog. When the flat pattern is updated, either automatically or manually, only
the master flat pattern for the active body is changed.
NOTE When the flat pattern is updated, any associated objects

(such as Drafting objects) will maintain their associativity
to any curve geometry that didn't change.
The Apply button is always active whenever a flat pattern already exists for the
active body. This allows you to reĆassign a mathematical solver to any selected
face Then you can update the flat pattern at any time while in the Sheet Metal
Design application, even if Auto Update is ON.
EDS Unigraphics NX
Flat Pattern
Name and Layer

ÏÏÏ
ÏÏÏ
You may enter a name and layer designation for the flat pattern in the
respective input fields at any time prior to creating the flat pattern. Or you may
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16
ÏÏÏ
accept the default values shown which are set within the Preferences→SMD
Flat Pattern dialog. If you are creating multiple flat patterns, each flat pattern
must have a unique name.
NOTE If you create multiple flat patterns, only the most recent
flat pattern maintains associativity with the part. This is
called the master flat pattern.
Traverse Body
If a flat pattern already exists for the active body, then the Traverse Body option
becomes available. If Auto Update is turned OFF, you can use the Traverse
Body to reĆtraverse the solid body to find any new part faces and reĆcreate the
flat pattern definition.
You must be careful, however, since this function wipes out any manual
modifications you have made to the flat pattern. It will identify mathematical
solvers for all the faces just as it did during the original traversal. If you had
reĆassigned a mathematical solver to an existing face, you must repeat this
procedure again after reĆtraversing the solid body.
Once the body has been reĆtraversed, you must use the Apply button to update
the flat pattern geometry.
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16-5
Flat Pattern
ÏÏÏ Unform and Form Sheet Metal Features

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16
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These two options allow you to unform and form the sheet metal features on
the active body.
In cases where you have deformed features that pass into or thorough bends, it
is recommended that you completely unform all sheet metal features before
creating a flat pattern. Ambiguity in the flat pattern definition and loss of
deformation characteristics embedded in the sheet metal feature will then be
avoided.
The state of the part body will be saved when you create the flat pattern. Then,
whenever the flat pattern is updated, and if Auto Update is ON, the part will
automatically revert to the original flat pattern creation state upon entering the
Sheet Metal Design application.
NOTE Currently, accurate flat pattern geometry can only be

created for parts in a fully formed or fully unformed state.
Change Body
You may only work with one solid or sheet body at a time. If you wish to create
or update a flat pattern for a different body in your partfile, you must choose
the Change Body button and select the different body.
You can choose a desired Bend Allowance Formula to be applied to a body that
does not contain sheet metal features from the Flat Pattern dialog. If no BAF is
selected, the default BAF will be used as specified in the Sheet Metal
Preferences dialog (under the Global Parameters button).
NOTE Parts that contain sheet metal features will always use the
BAF assigned to each feature at the time of creation. In
order to change this BAF you must edit each features
BAF. In cases where it is desired to change all the BAF
assigned to a part it is recommended that you use the Use
Global option for Bend Allowance Formula in the Global
Parameters dialog.
EDS Unigraphics NX
Flat Pattern
Traverse Control Algorithm

ÏÏÏ
ÏÏÏ
Traverse Control refers to the method by which the system identifies the faces
of a part to be flattened. Four methods are available; Sheet Metal, Generic,
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16
ÏÏÏ
Woven, and None. If the Sheet Metal or Generic methods are used, the system
automatically finds all of the faces on the same side of the part as the initial flat
pattern base, or start, face. If Woven or None is used, only the start face of the
part is identified; no traversal of the part occurs. Different flat pattern creation
requirements may warrant the use of the different Traverse Control Algorithms:
Sheet Metal Ć Choose the Sheet Metal traversal algorithm for parts
that reflect a formable manufacturing process, and typically exhibit a
uniform thickness.
Generic Ć When flat representations are required for parts where the
concept of thickness does not apply, better results are obtained with
the Generic algorithm.
Woven Materials Ć This method is used when you want to flatten a part
made of woven materials such as composites. With this method only
the selected start face is flattened.
NOTE See Appendix B for more information and an activity on

this Algorithm.
None Ć Choose None when you want to flatten only the start face or a
subset of faces of the body. You may then select additional faces to
flatten using the appropriate Layout Option. You must insure that the
additional faces you select are connected somehow to the start face.
Specifying None will also prevent traversal of the part during
automatic update.
Location
Previously only available on Preferences"SMD Flat Pattern, the Location

window is now also available on the Flat Pattern dialog. This option allows you
to locate the flat pattern from the WCS or the Start Position on the Start Face.
NOTE When the Location option is set to WCS the Orientation

Vector Layout Option becomes available.
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Flat Pattern
ÏÏÏ Layout Options

ÏÏÏ
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16
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Distortion Faces Projection Faces
Additional Curves
Area Preserving
Faces
Features
Starting Position Cutting Edges
Orientation Vector
The Layout Options provide a means to interrogate the traversed part faces to
identify and add, change, or remove the mathematical solver which was
automatically assigned to the face. These options also provide the capability of
defining cut edges, projecting extraneous curve geometry onto the flat pattern,
respecifying the starting position and orientation for flat pattern generation,
and identifying faces defined by sheet metal features in the part.
Area Preserving Faces
This icon, when selected, highlights all the faces in the traversed part which are
assigned the Area Preserving mathematical solver. This solver preserves the
area of the face upon creation of the flat pattern definition. Most faces in a part
are assigned this solver.
While the class selection dialog is displayed, you may select additional part
faces to which this Area Preserving solver will be assigned, or you may deselect
highlighted faces by using the Shift key and selecting the face.
NOTE Only one solver method may be assigned to a face at a

time. If a face is already assigned a mathematical solver,
you can change the assigned solver by reselecting the face
with any of the other mathematical solver icons selected.
Doing this will automatically remove the old solver and
assign the new one.
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Flat Pattern
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Distortion Faces ÏÏÏ
For some extreme bend geometry, faces of the part actually distort upon
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forming (A toroidal face is an example of a face that will distort upon forming).
For these faces, an area preserving solver is not desired. A more realistic
solution may be obtained using the Distortion solver. Faces which must stretch,
compress, or buckle are good candidates for the Distortion solver.
The Distortion Faces icon behaves in the same manner as the Area Preserving
icon. Once selected, all affected faces will highlight. You may add or delete
highlighted faces using the class selection dialog.
NOTE When a distorted face is flattened, it may stretch or

compress. This stretching or compressing continues
through the part until the part edge is reached.
Therefore, when a distortion solver is assigned to a face,
you must make sure that the face is at the edge of the
part, or next to a set of distortion faces at the edge of the
part.
Projection Faces
This solver is used to project its assigned face onto the flat pattern plane
without distorting adjacent faces. Bead faces are examples of projectionĆtype
faces.
NOTE Currently, the Projection solver only functions if an Area

Preserving face is beneath the projected faces. This
allows the Projection solver to map the flat pattern curves
of the projection faces onto the underlying faces. Hollow
beads, punched, and semiĆpierced features are currently
unsupported projectable features.
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Flat Pattern
ÏÏÏ
ÏÏÏ Cutting Edges
ÏÏÏ
16
ÏÏÏ In some cases, adjacent faces in the body are not intended to be adjacent in the
flat pattern. Unforming your part before allowing a traversal to occur will
prevent most of this type of flat pattern ambiguity. For parts with nonĆsheet
metal features, the Cutting Edges option allows you to identify the separation
edge between these faces. Thus the system will not attempt to create a
continuous flat pattern profile of the adjacent faces.
NOTE If you reĆtraverse a part with established cutting edges,

you will have to reĆidentify these edges.
Cutting Edges
Additional Curves
In addition to the normal curves that are created for the flat pattern, you may
use this option to select additional curves, edges, or points and add them to
your flat pattern definition. The selected geometry is first projected to the body
of the part, and then created with the flat pattern profile.
NOTE If you unform a part before creating a flat pattern, make

sure your additional curves will project onto the correct
face of the part. Or add the curves after the flat pattern is
created and the part is reĆformed.
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Flat Pattern
ÏÏÏ
Features ÏÏÏ
This option, when selected, will highlight all the faces of sheet metal features
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identified during traversal of the part.
Start Position
The start face is defined as the first face you select to begin the traversal
operation. With the appropriate preference setting, the flat pattern geometry
will be created coĆplanar with the start face. The Start Position is the point on
the start face, as given by the cursor selection point, from which all material
distortion will radiate. Selecting this icon will allow you to change the start
position on a face. By changing a start position location you can modify the
distortion profile reflected in a Woven Materials generated flat pattern.
NOTE To reselect a new start face simply select another face.

The system will reĆtraverse the part and allow you to
either replace the existing flat pattern or create a new
one.
Orientation Vector
The Orientation Vector button allows you to specify the orientation of the flat
pattern when using the WCS location method. Choose the orientation using the
standard Vector Constructor dialog. The selected vector, projected to the start
face, will align with the XĆaxis of the start face.
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16-11
Flat Pattern
ÏÏÏ Activity 16-1: Creating a Simple Flat Pattern Drawing

ÏÏÏ
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16
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In this activity you will create a flat pattern drawing within the part file. You
will also see how the flat pattern geometry can be updated while in the Drafting
application.
Step 1 Create a flat pattern.
Open the part smd_flange_complete.
Choose Tools→Flat Pattern...
Since the part has a couple deformed features that pass

through bends we must first unform the part.
Choose the Unform Sheet Metal Features button in the Flat

Pattern dialog to completely unform your part.
Notice the Cue line directs you to select a starting face for
the flat pattern.
Select the top face of the body of the part as the start face.
Select the top face

as the start face.
Change the Layer field in the Flat Pattern dialog to 161 and
choose Apply.
Choose the Form Sheet Metal Features button in the Flat

Pattern dialog to completely form your part.
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Flat Pattern
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Step 2 Create a flat pattern drawing.
Enter the Drafting application.
Change your work layer to 101.
Choose Drawing→Edit and change your drawing size to

B Ć 11 X 17 .
Choose OK to save the change and close the window.
Make all layers invisible, then make layer 161 selectable.
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Flat Pattern
ÏÏÏ Choose Drawing→Add View and place the Top view in the
ÏÏÏ center of the drawing.
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16
ÏÏÏ Choose Cancel in the Add View dialog.
Use Insert→Dimension→Horizontal,
Insert→Dimension→Vertical and Insert→Dimension→Hole
to add the following dimensions to your drawing:
NOTE You may have to change the Text Placement option to

Manual Placement - Arrows In to get the dimension
locations shown below.
Step 3 Edit your part.

Return to the Modeling application and make layer 1
selectable.
Unform all of the flanges.
EDS Unigraphics NX
Flat Pattern
From the Edit Parameters dialog, select

ÏÏÏ
S22_HOLE:SKETCH(22) and choose OK.
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Change the diameter to 1.00 . ÏÏÏ
16
ÏÏÏ
Choose OK twice to update the part.
Form all of the flanges.
Again, choose the Edit Feature Parameters icon.
From the graphics window, select the squaredĆoff flange on

the left side of the part (Watch the Status Line).
Select this flange

to edit.
Choose OK.
Change the Inside Radius value to .25 .
Choose OK twice to update the part.
Step 4 Update the flat pattern and the drawing.

When a change is made to a simple part, you can update the flat
pattern geometry directly from the Drafting application.
NOTE The Auto Update option in the SMD Flat Pattern

Preferences dialog must be toggled ON for this type of
flat pattern update to occur. By default, this option is
always toggled ON.
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Flat Pattern
ÏÏÏ Enter the Drafting application.

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16
ÏÏÏ
Choose Drawing→Update Views...
Choose the Top view from the listing box.
Choose OK. Notice that the flat pattern geometry and the
bottom dimensions updated to reflect the part changes.
Dimensions
have changed.
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Flat Pattern
Flat Pattern Preferences ÏÏÏ

ÏÏÏ
Flat pattern preferences can be established while in the Sheet Metal Design
application. Selecting Preferences→SMD Flat Pattern activates the SMD Flat
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Pattern Preferences dialog.
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Flat Pattern
ÏÏÏ Name and Layer

ÏÏÏ
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These preference settings provide the default name given to the flat pattern
group entity, and the default layer on which the flat pattern objects will reside.
Chord and Angle Tolerance
These preference settings can be used to override the modeling default chord
and angle tolerances for deriving curves from solid edges. Typically the default
modeling tolerances are sufficient.
NOTE If you reduce the tolerance value below the model

default, it may result in slower system performance.
Orientation
You can orient the flat pattern relative to the work coordinate system (WCS)
and place it on the XCĆYC plane, or you can use the start face (Start Position)
to designate the flat pattern orientation and placement plane.
NOTE Although the flat pattern can be placed on the XCĆYC

plane, its orientation is governed by the UĆV vector
orientation of the start face surface. It is recommended to
use the WCS→Orient option to orient the WCS to
absolute before creating a flat pattern.
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Flat Pattern
Output Objects ÏÏÏ

ÏÏÏ
This section of the SMD Flat Pattern Preferences dialog is used to specify what
type of objects are created in the flat pattern. ÏÏÏ
16
ÏÏÏ
Curve Set
This option is used to determine what type of curves can appear in the flat
pattern profile. Lines, Lines/Arcs, or Lines/Arcs/Splines are the available curve
types.
NOTE If only Lines/Arcs are specified then all BĆsurface edges

will be approximated by lines and nonĆconcentric arc
segments. If Lines/Arcs/Splines are specified, then
BĆsurface edges will be approximated by splines.
Bend Tangent Curves

This option is used to turn ON or OFF the output of bend tangent lines in the
flat pattern. Bend tangent lines are defined by the intersection between the
bend segment and the web segment of a flange.
Bend Center Curves

This option is used to turn ON or OFF the display of a line centered between
the two bend tangent lines.
Bend Tangent Line
(Body) (Web)
Bend Center Line
NOTE Once Tangent Curves or Centerline Curves are turned

ON or OFF the flat pattern must be updated to see the
affect of the preference changes.
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Flat Pattern
ÏÏÏ Auto Update

ÏÏÏ
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16
ÏÏÏ
The Auto Update option enables or disables automatic flat pattern update when
entering or exiting the Sheet Metal Design application. Turning this option
OFF is similar to turning ON Suppress View Update in the Drafting
Application. Careful consideration should be taken because there are no out
of date" labels that identify an out of date flat pattern. Turning Auto Update
OFF can make the process of changing the model faster when switching back
and forth between Sheet Metal Design and other applications.
Distortion Constraint
When a distortion type of face (e.g. a toroidal face) has two unbounded edges,
this option is used by the system to determine which open edge of the distorted
face will be the controlling edge.
NOTE This option is currently unavailable.
Allow Multiple Flat Patterns
This option, when toggled ON, allows for multiple flat patterns to be created
for the active body. Only the newest flat pattern maintains associativity to the
body.
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Flat Pattern
Use Bend Allowance Formula

ÏÏÏ
ÏÏÏ
This toggle turns ON or OFF the use of the BAF during flat pattern creation
Turning OFF the BAF is useful when the part has nonĆuniform thickness, or
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16
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when you just don't want the BAF included in calculating the developed length
of the faces.
Geodesics Algorithm
This option lets you control the Geodesics Algorithm used to split each face
into small segments. Each algorithm yields an approximation. If one algorithm
doesn't produce a desirable flat pattern, try another one. Parametric is the
default and should give the best results in most cases. The Knights algorithm
can be used as an alternative. The Projection algorithm was the default for all
flat patterns prior to V16. Generally, this method is the least accurate of the
three.
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Flat Pattern
ÏÏÏ Flat Pattern Annotation

ÏÏÏ
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16
ÏÏÏ
The Flat Pattern Annotation dialog, located within the Sheet Metal Design
application under Tools→Flat Pattern Annotation, allows you to edit display
properties of the flat pattern wireframe geometry, and annotate the flat pattern
with text callouts.
Edit Display Dialog
The Edit Display dialog allows you to selectively edit the layer, color, line font
and width of each type of existing flat pattern object. If multiple flat patterns
exist within the partfile, the class selection dialog will be presented, thus
allowing you to select the objects you wish to modify. Once an object has been
edited, all subsequent flat pattern objects of this type will be created with the
specified edits.
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Flat Pattern
Text Callout Dialog

ÏÏÏ
ÏÏÏ
Text Callout allows annotation of the flat pattern within the Sheet Metal Design ÏÏÏ
16
application. The text created interrogates the geometry selected, but is not
associative, therefore, if changes are made to the flat pattern the text callouts
ÏÏÏ
will need to be updated manually. Text or labels can also be added using the
Annotation Editor in the Drafting application. These can be made associative
by using the Expression option in the Annotation Editor (e.g. Bend Radius
parameter).
EDS
All Rights Reserved
Sheet Metal Design
Student Guide
16-23
Flat Pattern
ÏÏÏ Flat Pattern Annotation Preferences

ÏÏÏ
ÏÏÏ
16
ÏÏÏ
You can modify the display of a flat pattern object before it is created using the
Annotation Preferences dialog found under Preferences→Flat Pattern
Annotation.
With this dialog you can specify the default color, line font, and width for each
type of flat pattern entity.
EDS Unigraphics NX
Flat Pattern
Flat Pattern Information ÏÏÏ

ÏÏÏ
While in the Sheet Metal Design module, you have the option of listing the flat
pattern information associated with the solid or sheet body. When you choose
ÏÏÏ
16
ÏÏÏ
Information→Flat Pattern, the class selection dialog displays allowing you to
select a solid or sheet body. The information for the flat pattern associated with
the selected body is displayed in the information window. An example is shown
below.
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Sheet Metal Design
Student Guide
16-25
Flat Pattern
ÏÏÏ Construction Tips

ÏÏÏ
ÏÏÏ
16
ÏÏÏ
To create a complete flat pattern of a solid or sheet body, all defining
part geometry must be properly connected by either relative
positioning or boolean operations.
Flat pattern curves are automatically grouped upon creation. Thus the
flat pattern group can be manipulated in the same way as any group
entity. However, if the flat pattern group is deleted then the curves in
the group are also deleted. Ungrouping operations will also cause flat
pattern curves to be deleted.
The Flat Pattern traversal function requires that the starting face be
an areaĆpreserving type of face. This means that in order to create a
flat pattern using the standard Sheet Metal traversal algorithm, there
must be at least one areaĆpreserving face in the solid or sheet body.
A flat pattern can be generated for a solid or sheet body which does
not contain sheet metal features. However, if the part contains an
unmodeled bend (i.e. a sharp edge depicting the transition from one
face to another), the resultant flat pattern will have varied dimensions
depending on which side of the model is selected as the start face. To
create a flat pattern with the expected developed length, you must
blend the transition edge.
EDS Unigraphics NX
Flat Pattern
Activity 16-2: Creating a Flat Pattern Drawing Assembly ÏÏÏ

ÏÏÏ
ÏÏÏ
16
ÏÏÏ
In this activity you'll create an assembly file which will contain flat pattern
geometry and drawing data for a sheet metal part.
Step 1 Add the sheet metal component to your partfile.

Open the part smd_fp_dwg.
Toggle ON the Assemblies application.

Choose Assemblies→Components"Add Existing or choose
the Add Existing Component icon.

In the Select Part dialog, choose the Choose Part File button.
Select the smd_fp file.
Choose OK.
From the Add Existing Part dialog, verify the Reference Set
is set to BODY.
Ensure the Layer options are set to Original.
Choose OK in the Add Existing Part dialog and in the Point
Constructor dialog locate the component at an origin of 0, 0,
0.
EDS
All Rights Reserved
Sheet Metal Design
Student Guide
16-27
Flat Pattern
ÏÏÏ Step 2 Set up your flat pattern default preferences.

ÏÏÏ
ÏÏÏ
16
ÏÏÏ
Enter the Sheet Metal Design application.
Choose Preferences→SMD Flat Pattern...
Verify the Output Objects Curve Set is on the Lines/Arcs

option.
Choose OK to save the preference settings and close the

dialog.
EDS Unigraphics NX
Flat Pattern
Step 3 Set up your flat pattern annotation default preferences.

ÏÏÏ
ÏÏÏ
Choose Preferences→Flat Pattern Annotation...
ÏÏÏ
16
ÏÏÏ
Change the Bend Center Lines Color option to Cyan and the
Line Font option to CenterĆline.
Cyan
Choose Apply.
Change the Type field to Bend Tangent Lines. Set the Color
to Blue and the Line Font option to Phantom.
Choose Apply.
Change the Type to Exterior Edges and set the Color to

Yellow.
Choose Apply.
Change the Type to Interior Cutouts and set the Color to

Yellow.
Choose OK to accept the preference settings and close the

dialog.
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Sheet Metal Design
Student Guide
16-29
Flat Pattern
ÏÏÏ Step 4 Create the flat pattern.

ÏÏÏ
ÏÏÏ
16
ÏÏÏ
Choose Tools→Flat Pattern...
Change the Layer option to 161.
Select the top face of the body of the part as the start face.
Accept the selection if necessary.
Select this face as the

start face
Note the status line indicates Unigraphics is identifying faces to

flatten.
Check which faces have been identified as area preserving
faces by selecting the Area Preserving Faces icon.
NOTE Area preserving faces will highlight on the unformed

model.
Choose Cancel to close the class selection dialog.
Check for distortion faces by selecting the Distortion Faces
icon.
Since no faces highlighted, the system did not allocate the

distortion solver to any surface of the part. Choose Cancel to
close the dialog.
EDS Unigraphics NX
Flat Pattern
ÏÏÏ
Choose the Projection Faces icon. ÏÏÏ
Since no faces highlighted, the system did not allocate the
ÏÏÏ
16
ÏÏÏ
projection solver to any surface of the part. Choose Cancel to
close the dialog.
Choose Apply on the Flat Pattern dialog to generate the flat

pattern geometry.
Blank the solid body and review the flat pattern geometry
from the top view. Note the color and font of the flat pattern
objects.
Step 5 Add curve geometry to the flat pattern.
Unblank your solid model if necessary.
Return to the trimetric view, if necessary.
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Student Guide
16-31
Flat Pattern
ÏÏÏ Make layer 41 selectable. Notice that points are now visible
ÏÏÏ on the return flanges of the part.
ÏÏÏ
16
ÏÏÏ Choose the Additional Curves icon.
Select all four points and choose OK.
Choose Apply. The curves should now be reflected on your

flat pattern.
NOTE Your part must be in the formed state if you wish the
curves to be reflected accurately on the flat pattern. If the
part was in the unformed state, the curves would have
been projected onto the wrong surface of the part.
Step 6 Create a flat pattern drawing.

By design, whenever you add or update flat pattern geometry to
a drawing, the system will automatically reĆtraverse the
associated solid or sheet body and will regenerate the flat
pattern geometry. If you wish to avoid this process, make sure
the Auto Update option in the SMD Flat Pattern Preferences
dialog is toggled OFF before adding or updating drafting views.
Choose Preferences→SMD Flat Pattern...
Toggle OFF the Auto Update option.
Choose OK.
Enter the Drafting application.
Change your drawing size to B - 11 X 17 (Drawing→Edit).
Make layers 1 and 41 invisible and leave layer 161 selectable.
EDS Unigraphics NX
Flat Pattern
Add a Top view to your drawing and center it.

ÏÏÏ
ÏÏÏ
Add the following annotations and dimensions to your flat
pattern: ÏÏÏ
16
ÏÏÏ
Step 7 Edit the sheet metal part.
Return to the Modeling application.
Using the Assembly Navigator make the component your

work part (double-click on it).
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Sheet Metal Design
Student Guide
16-33
Flat Pattern
ÏÏÏ Change the Contour Length of the middle flanges to 1.20 .

ÏÏÏ
ÏÏÏ
16
ÏÏÏ
Change the contour

length of the middle
flanges
Make the smd_fp_dwg file the work part.

At this point, if Auto Update was activated, you could enter the
Drafting application and the flat pattern geometry would
automatically update. But remember, you don't want to
reĆtraverse the part, so you have to manually update the flat
pattern.
NOTE You do not have to unform your part to update the flat
pattern.
Activate the Flat Pattern dialog from the Tools pulldown

menu.
Choose Apply to update the flat pattern.
Unform your part and verify that the flat pattern profile
updated correctly.
Step 8 Return to your drawing and update your view boundary.
Return to the Drafting application.
EDS Unigraphics NX
Flat Pattern
Choose Drawing→Update Views...

ÏÏÏ
ÏÏÏ
Choose the Top view from the listing box and choose OK.
ÏÏÏ
16
ÏÏÏ
If any dimensions or annotations loose associativity, you can
reĆassociate your drafting objects using the Edit→Drafting
Object Associativity and Edit→Leader functions.
EDS
All Rights Reserved
Sheet Metal Design
Student Guide
16-35
Flat Pattern
ÏÏÏ
ÏÏÏ
ÏÏÏ
16
ÏÏÏ
SUMMARY The activities in this lesson demonstrated the
application of the Flat Pattern features
available in Unigraphics.
In this lesson you:

Applied the various Layout Options
Created a flat pattern using the Sheet Metal
algorithm
Created a flat pattern using the Woven
Material algorithm
EDS Unigraphics NX
Additional Projects
Additional Projects
ÏÏÏ
Appendix A
ÏÏÏ
A
ÏÏÏ
ÏÏÏ
The following pages contain part drawings for the assembly shown below which
you may use to practice the skills you've learned within this manual. Please
refer any questions you may have regarding this material to your instructor.
EDS Sheet Metal Design

All Rights Reserved Student Guide
A-1
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ
A-2 Sheet Metal Design

Student Guide
EDS
All Rights Reserved
Unigraphics NX
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

A-3
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

Student Guide
EDS
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Unigraphics NX
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

A-5
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

Student Guide
EDS
All Rights Reserved
Unigraphics NX
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

A-7
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

Student Guide
EDS
All Rights Reserved
Unigraphics NX
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

A-9
Additional Projects
ÏÏÏ
ÏÏÏ
A
ÏÏÏ
ÏÏÏ

Student Guide
EDS
All Rights Reserved
Unigraphics NX
Sheet Metal Part in Process

Appendix B
PURPOSE To form Sheet Metal parts in increments to simulate

the manufacturing process. ÏÏÏ
ÏÏÏ
ÏÏÏ
B
OBJECTIVES
ÏÏÏ
Upon completion of this lesson, you will be able to:
Create, edit, and manipulate Part in Process

features.
Manipulate and execute bend operation groups
using the Part In Process dialog.
Create a drawing using your Part in Process
information.
Activity Page
B-1 Creating a Process . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
B-2 Generate Family Members for Model States . . . . B-28
B-3 Adding Part in Process States to a Drawing . . . . . B-32

B-1
The next series of lessons will focus on the manufacturing processes supported
within the Sheet Metal Design application.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Within the Sheet Metal Design application, Flat Pattern, Wireframe Flattening,
Flat Pattern Annotation, and Part in Process functions are available to support
manufacturing requirements for part definition and fabrication. This lesson
content will focus on Part in Process processes only.
B-2 Sheet Metal Design

Student Guide
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Part In Process
When you enter the Sheet Metal Design application, the Part In Process dialog
appears.
NOTE If you happen to open a part that does not contain a solid
or sheet body, the Wireframe Flattening dialog will
appear instead of the Part In Process dialog.
ÏÏÏ
The Part In Process dialog allows you to manipulate and execute groups of
operations on sheet metal features. This tree list dialog makes it easy to
ÏÏÏ
ÏÏÏ
B
manipulate individual sheet metal features or groups of sheet metal features.
You can add entire Processes, Groups, or Features to customize this dialog to
ÏÏÏ
define the state of your part at any stage of your entire process.
This is a standard tree list dialog. You can use the plus and minus signs to
expand and collapse the tree. You can also right click on any node in the tree
and get a menu that is specific to the type of node on which you clicked. In
addition, you can do a slow double-click on any Process, Group, or Features to
rename it.
Listing
Box
While in the Sheet Metal Design application, the Part In Process dialog can
also be accessed through Tools→Part In Process.

B-3
Process
You can use a Process to define all of the stages that your part goes through
from blank to fully formed product. The two default states of Unform and
Form All in Part can be accessed at any time. You can execute either of these at
any time by simply double clicking on the name (node). Execute the Unform
All in Part node to see the fully unformed state of the model. Execute the Form
All in Part node to see the creation or "as designed" state of the model.
ÏÏÏ If you click MB3 on the SMD Process node, you will see the Process Menu
ÏÏÏ
ÏÏÏ
B
show below. You can use this menu to Unform, Form, Add a new Process or
Group, or to Delete a Process. A Process is a collection of Groups, similar to a
ÏÏÏ station in a forming shop. A Group is a collection of Feature operations

performed at that station. A Feature is a defined state of a sheet metal feature
in the model.
Unform Process
Adding a Process means adding a new root node on the tree list. This Process
can be used to contain new Groups, which in turn contain new Feature nodes.
NOTE You cannot Unform a Process if there are no Process

nodes in the tree list.

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Unigraphics NX
Form Process
NOTE You cannot Form a Process if there are no Process nodes

in the tree list.
ÏÏÏ
Add Process ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Add Group
Adding a Group will add a new Group named "New Group" to the tree list
under the current Process. This Group can then be used to contain a set of
Feature nodes.
Delete Process
Deleting a Process deletes all of the Feature and Group nodes under the
Process as well as the Process itself.
NOTE You cannot Delete a Process if there are no Process

nodes in the tree list.

B-5
Group
When you click MB3 on a Group, you will see the Group Menu shown below.
You can use this menu to Unform, Form, Execute, Add a new Group or
Feature, or Delete a Group.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Unform Group
Unforming a Group means setting all of the features in the model to the fully
unformed state for each Feature node within the Group.
Form Group
Forming a Group means setting all of the features in the model to the fully
formed state for each Feature node within the Group.
Execute Group
Executing a Group means setting all of the features in the model to the states
defined for each Feature node within the Group.
Add Group
Adding a Group means adding a new Group node on the tree list. This Group
can be used to contain new Feature nodes.

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Add Features
Adding a Feature means defining a state for a given sheet metal feature in the
model and then adding a Feature node into the tree list under the current
Group. You must select one or more sheet metal features in the graphics
window before you selected Add Feature.
Delete Group
ÏÏÏ
Deleting a Group deletes all of the Feature nodes under the Group as well as
the Group itself. ÏÏÏ
ÏÏÏ
B
ÏÏÏ

B-7
Feature
When you choose the Add Features node under a Group, you are defining the
state of that sheet metal feature in the model at this point in the Process. The
dialog boxes that you will see depend on the currently selected sheet metal
feature.
Bridge and Bend
ÏÏÏ These two features are the easiest features for which to define states. Both of
ÏÏÏ
ÏÏÏ
B
these features can only be either fully formed or fully unformed. The dialog
that is presented to you when you select a sheet metal Bridge or Bend feature is
ÏÏÏ shown in the figure below. You simply check whether the feature is formed at
this stage in the Process.
Flange and Inset Flange
It is also easy to define a state for Flanges and Inset Flanges. These two
features simply require that you enter an angle to define how far the feature is
bent at this stage in the Process.
Process Angle
The process angle is an angle, either positive or negative, simulating an

intermediate state of the flange. Negative angular values can be used to
indicate a back bend, and angular values larger than the design angle can be
used to simulate over forming.

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General Flange
The General Flange is the most complex feature for which to define a state.
The General Flange has five methods that can be used to define a completely
new shape for the feature. This new shape can be used to represent a complex
die forming operation or hydroform operation. The five methods are
Parameters, Build to Sections, Build to Faces, Punch Vector, and Surface
Extension. You can change from one method to another simply by selecting the
appropriate icon at the top of the dialog. The dialog boxes for these methods
are nearly identical to those used to create and edit the General Flange. The
dialog for Parameters method is shown below. ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

B-9
Surface Extension
The Surface Extension method is only available in the General Flange State
dialog. This method causes the underlying surface to be created as a tangential
extension to the target face. You do not need to specify any additional
parameters. If the target face(s) were planar, the resulting General Flange
State would be planar as well.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
Edge Constrains
ÏÏÏ The Edge Constraints option allows you to specify how the three edges of the
General Flange not attached to the target face will deform. The two side edges
are selectable only if the deformation algorithm for the General Flange is set to
BiĆdirectional. If this is the case, the far edge will only be selectable when the
side edges are constrained.
The different types of edge constraints are:
None Ć No additional constraints are placed on the edges other than

the original distortion constraint applied during the flange creation.
Along Section Ć This constraint will cause the edge to behave much as
if the Along Section distortion option was used during the creation of
the General Flange. The length of the edge will vary according to
adjustments made for distortion.
Along Profile Ć With this option, you will be prompted to select a string
of curves, edges or faces along which the flange edge will lie. Again,
the length of the edge will vary according to adjustments made for
distortion.
To Profile Ć This option functions in the same manner as Along Profile,
but the flange edges will match the length of the profile string.

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BiĆDirectional deformation
at each edge of the
flange.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
General Flange with BiĆDirectional
distortion and no edge constraints.
ÏÏÏ
Outer edge is still

distorted.
Inside edge follows

the profile of the
adjacent edge.
General Flange with BiĆDirectional distortion

and Along Profile edge constraints.

B-11
Activity B-1: Creating a Process
In this activity you will define the manufacturing bend process for the part
shown below.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Step 1 Open the partfile smd_pip and save it as xxx_pip where
xxx are your initials.
Step 2 Create the first process in the Part in Process dialog.

The Part in Process dialog will appear.
DoubleĆclick MB1 on the Unform All in Part node to fully

unform your part.

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NOTE You can also use MB3 on the node and choose Execute.
Slowly doubleĆclick MB1 on the SMD Process node and

change the name to Process 1 and press Enter.
Slowly doubleĆclick MB1 on the New Group node and

change the name to Stage 1 and press Enter.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
From the graphics window, select the inner back flange

features. The Status line should read INSET_FLANGE(6),
(7) or (8) as you select each feature.
Select these
flanges

B-13
From the Part in Process dialog, click MB3 on the

Stage 1 node and choose Add Features.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Notice that the Process Angle dialog appears.
Enter 30 in the Process Angle field and choose OK.
Another Process Angle dialog appears, enter 30 again for the

remaining two inset flanges.
Step 3 Create the next bend sequence.

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Click MB3 on Process 1 or Stage 1 node and choose Add

Group.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ

change the name to Stage 2.

B-15
From the graphics window, select the outer back flange

features. The Status line should read FLANGE(9), (10) or
(11) as you select each feature.
Part has been rotated 1805 for clarity
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ Select these
flanges
Click MB3 on the Stage 2 node and choose Add Features.
Enter 30 in the Process Angle field for all three features.

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Step 4 Create a new process.
Click MB3 on the Process 1 node and choose Add Process.
Slowly doubleĆclick MB1 on the SMD Process node and

change the name to Process 2 and press Enter.

change the name to Stage 3 and press Enter.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
From the graphics window, select the inner front flange

features. The Status line should read FLANGE(12) or (13) as
you select each feature.
Select these
flanges
Enter 45 in the Process Angle field for both flanges.
Step 5 Insert a group.

B-17
Slowly doubleĆclick MB1 on the Stage 3 node and change the

name to Stage 4.
Click MB3 on the Stage 2 node and choose Add Group from
the popĆup menu.
Change the name of the New Group to Stage 3.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Select the right and left flange features from the graphics
window. The Status line should read SMBEND(20) or (21)
as you select each feature.
Select these
flanges

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Click MB3 on the Stage 3 node in the Part in Process dialog

and choose Add Features.
Notice the Form/Unform dialog box appears. This appears

because the feature selected was a Sheet Metal Bend
feature, which can only be shown in the fully formed or
unformed condition. A Bridge feature would present the
same dialog.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Toggle ON the option to Form Feature SMBEND for both
features.
Step 6 Edit a sequence.
Select the curved flange feature from the graphics screen.
Select this
flange

B-19
Notice the General Flange State dialog appears. This

appears because the feature selected was a General Flange
feature, which can have various properties edited in a
forming operation. We will only adjust the bend angle.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Enter 45 in the Angle field and choose OK.

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ÏÏÏ
ÏÏÏ
ÏÏÏ
B
DoubleĆclick on the Form All in Part node to completely ÏÏÏ
form your part.
Step 7 Save your part. You will be working with this part in the
next activity.

B-21
Working in Assemblies
Because of the inherently dynamic nature of sheet metal parts, using them in
assembly applications presents some unique concerns. Unlike typical modeling
features, sheet metal features must alter their shape states upon command by
external sources (e.g. Form and Unform operations). Thus a dependency is
established between sheet metal component parts and the assembly models
which contain them.
ÏÏÏ At any assembly level model, it is possible to place the sheet metal component
ÏÏÏ
ÏÏÏ
B
in an intermediate or unformed state. When the assembly partfile is saved, the
system will attempt to also save the sheet metal component part in its altered
ÏÏÏ state. If a user does not have write access to the component part, then an error
message will be produced, the component partfile save operation will abort, and
the user can continue to save the assembly partfile only.
If the user does have write permission to the sheet metal component partfile,
then the system will successfully save the component part in its altered state.
This state is then reflected everywhere the component is used. Subsequent
problems, such as failed mating constraints, can then occur while accessing
other assemblies. To avoid such problems, it is strongly recommended that you
always place the sheet metal component part in its fully formed state before
saving any partfile.

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Creating Process Drawings
The Part in Process operation is the only method by which you may place a
sheet metal part in a semiĆformed state. To help prevent inadvertent component
geometry changes from occurring when Part in Process data is saved, it is
possible to create a separate assembly file to contain the Part in Process data.
If you wish to create a manufacturing process drawing which depicts

intermediate states of the part, then it is necessary to create the Part in Process
drawing utilizing an assembly partfile. The best results are achieved by creating
ÏÏÏ
associative copies of the sheet metal part, as placed in its intermediate states.
This process can be accomplished by utilizing the Part Family option under ÏÏÏ
ÏÏÏ
B
Tools"Part Families within the Modeling application.
ÏÏÏ
NOTE Again, it is essential that you remember to completely
form the parent sheet metal part before you save the
partfile.

B-23
Sequential Processing
This option is found within the Sheet Metal Preferences dialog and can be
accessed from either the Modeling or Sheet Metal Design applications.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Toggling this option ON or OFF to control the processing of groups or items in

Part in Process. If it is processed sequentially then the selected item and
everything above it in the tree list will be formed. Non-sequential will only
form the selected object.
Part Families
As with a typical Part Family, multiple part files can be created which are
derived from a single parent part. This allows associative control of all family
members from the template part (parent). While establishing the part family an
unique attribute, called PIPNAV_GROUP, is available. The unique attribute
field in the family table can then be used for identifying Group names within
the Part In Process dialog. Once the part family is established, separate part
files (components), can be created to depict each intermediate state (group) in
the Part In Process dialog.
The Unigraphics spreadsheet is used to define the members of the family and
their values for each of these properties. Changes to the template part can be
propagated to all parts which are members of that family.

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Terminology
There are some terms that are specific to the Family of Parts functions, as
explained below.
Template part - A Unigraphics part file constructed in such a way as to allow a

family of parts to be built based on it.
Family table - A table created from the template part, in the Unigraphics
spreadsheet function, that describes the various attributes of the template part ÏÏÏ
that you can change when you create a family member. ÏÏÏ
ÏÏÏ
B
Family member - A readĆonly part file created from, and associated with, a
template part and family table.
ÏÏÏ
Part Family - The template part, family table, and family member parts.
General Procedure
In the template part, create the Process and define the groups in the
Part In Process dialog.
In the template part, define the PIPNAV_GROUP in the attributes
class, which will be used in the family table.
Create and save a family table in the spreadsheet, defining the various
configurations of the family members.
Choose Part Family→Create Parts in the family table (spreadsheet).

B-25
Part Families Dialog
The Part Families dialog is accessed in the Modeling application by choosing

Tools→Part Families from the main menu bar.
You can use the areas in the upper portion of the Part Families dialog to specify
the columns in the Part Families spreadsheet.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
Option menu for
Attribute Classes
ÏÏÏ
Available
columns
Chosen
columns
Chosen
columns
Available Columns
The Available Columns list box shows you the items available in the current
part to be defined as columns in the family table spreadsheet. Only the items of
the class shown on the option button are displayed.

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Attribute Classes
You can choose from six different attribute classes when defining the columns
in the part family spreadsheet. You can later change the values of these
attributes in the spreadsheet to define parts with different configurations. We
will only use the Attributes class for the creation of the family table.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
The identical
Unique part group name as
names given to listed in the Part
each group (row) In Process
dialog.
NOTE In order for a part to be created which represents the

proper intermediate state, the exact name of the group,
as it appears in the Part In Process dialog, must be
entered in the PIPNAV_GROUP column. The Unform
group is automatically added to the family table.

B-27
Activity B-2: Generate Family Members for Model States
In this activity you'll create part files depicting the different states of the part
using the Part Family functionality and the Part in Process groups you created
in the previous activity.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
Step 1 Continue using xxx_pip. Choose Application"Modeling
and verify that the Assemblies application is enabled.
ÏÏÏ Step 2 Set up part for family creation.
Choose the Form/Unform icon from the Sheet Metal

toolbar.
Cancel the Form/Unform dialog.
The Why" It is necessary to unform the part prior to creating the family members
because the intermediate stages begin from the unformed state.
You will notice when the parts are added to the assembly later that the
progression of the groups are all derived from the unformed model. You
will not see a natural progression that is similar to what you went through
in the previous activity. If this is desired you need to turn ON the
Sequential Processing option within the Sheet Metal Preferences dialog.

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Step 3 Define the columns for the family table.

Choose Tools→Part Families... from the main menu bar.
Change the option menu at the top of the dialog from

Expressions to Attributes.
Highlight the PIPNAV_GROUP attribute from the list.
Choose the Add Column button.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Step 4 Create the family table.

Choose the Create button from the bottom portion of the
Part Families dialog.
NOTE In general you want to be aware of the path identified in

the Family Save Directory field. This identifies the
location to which all of the family members will be saved.

B-29
In the xxx_PIP spreadsheet, select cell A:2. Enter the part

names shown on the right in the figure below, where xxx
represents your initials, in the Part_Name column.
Enter the exact names of the groups from the Part In Process
dialog in the PIPNAV_GROUP column. See the figure on
the right below.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Step 5 Create the parts in the family table.
Highlight row numbers 2 through 6 (Hold down MB1 and

drag your cursor over the row numbers).
From the spreadsheet menu bar choose

PartFamily→Create Parts.
Your spreadsheet will disappear while the system creates the

part files. Once finished you should see an information
window with the following information listed:

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Exit the Information Window.
Choose the Resume button from the bottom portion of the

Part Families dialog.
Step 6 Save the Part Family and the template part.
From the spreadsheet menu bar choose
ÏÏÏ
PartFamily→Save Family.
ÏÏÏ
ÏÏÏ
B
NOTE The Save Family option internally stores the spreadsheet
data within the template part file. It does not save the ÏÏÏ
template part file itself.
From the Unigraphics menu bar choose File→Save to save

the template part file containing the spreadsheet data.

B-31
Activity B-3: Adding Part in Process States to a Drawing
In this activity you will add the different process states you created in the
previous activity to an assembly, which will become the process drawing.
ÏÏÏ
Step 1 Create a New part named xxx_pip_dwg, where xxx
ÏÏÏ
represents your initials.
ÏÏÏ
B
ÏÏÏ Step 2 Add the intermediate stages (components) to the Process
drawing.
Choose Format"Layer Settings or the
Layer Settings icon.
In the Range or Category field at the top of the Layer

Settings dialog, enter 10-15 and press Enter.
Verify that layers 10 through 15 have been made selectable

and choose OK.
Change the view orientation to Trimetric.
Choose Preferences"Assemblies...
If necessary, toggle ON Preview Component on Add and

choose OK.
Choose Assemblies→Components→Add Existing or the Add
Existing Component icon from the Assemblies

toolbar.
Choose the Choose Part File button from the top of the
Select Part dialog..

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Select the part xxx_blank from the file selection dialog.
Choose OK.
Verify the Reference Set is set to BODY.
Change the Layer options to As Specified.
Enter 10 for the Layer number.
ÏÏÏ
Choose OK.
ÏÏÏ
ÏÏÏ
B
Locate the component using the coordinates 0,0,0 .
ÏÏÏ
Fit the view to the graphics screen.
Again, choose the Choose Part File button from the top of
the Select Part dialog.
Select the part xxx_stage1 from the file selection dialog.
Choose OK.
The reference set should still be set to BODY and layer

options to As Specified.
Choose OK.
Locate the component using the coordinates 0,0,0 .
Repeat the above actions to add the parts xxx_stage2,

xxx_stage3 and xxx_stage 4 on layers 12, 13, and 14
respectively.
Again, choose the Choose Part File button from the top of
the Select Part dialog.
Select the part xxx_pip from the file selection dialog.

B-33
Choose OK.
Choose the Select Template button at the bottom of the

Select Family Members dialog.
This dialog came up because the system recognized the part

as a Part Family template part and therefore allows you to
select family members from search criteria. We could have
also used this method to select the different stages of the
part.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ Choose OK.
NOTE You did not see the any noticeable difference when
adding the last component (xxx_pip) because it was
unformed at the beginning of the previous activity. We
will form again later.
Cancel the Select Part dialog.
Step 3 Create the Process drawing.
Choose Application→Drafting.
Choose Drawing"Edit...
Change the drawing size to D-22x34.
Choose OK.
Step 4 Add sequence views to the drawing.
Make layer 10 selectable and all remaining layers invisible.
NOTE Layer 101 should still be your work layer.

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Choose Preferences→View Display... and check that your

Hidden Line Removal Font is set to Invisible.
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Choose OK to accept and close View Display the dialog.
Choose Drawing→Add View...
From the list choose TFRĆTRI and place the view in the
upper left corner of the drawing.

B-35
ÏÏÏ
ÏÏÏ
ÏÏÏ
B
ÏÏÏ
Change your layer settings so that layer 11 is selectable and

layer 10 is invisible.
Place the new TFRĆTRI view to the right of the first view.
Change your layer settings so that layer 12 is selectable and

layer 11 is invisible.
Place the new TFRĆTRI view below to the first view.
Repeat the above actions until all six views are added to the
drawing.
NOTE Again, the model on layer 15 will be in the unformed

state, we will fix that in a later step.
Step 5 Reform the parent part and update the drawing.
Choose Application→Modeling.

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Choose Window from the main menu pulldown and change

your displayed part to xxx_pip.
Choose the Form/Unform icon from the Sheet Metal

toolbar.
Choose the Form All button.
ÏÏÏ
Choose Window from the main menu pulldown and change
your displayed part back to xxx_pip_dwg.
ÏÏÏ
ÏÏÏ
B
Choose Application→Drafting. ÏÏÏ
Choose Drawing→Update Views and choose OK.
Your drawing should resemble the one below when you are
finished.
Step 6 Save and close your part.

B-37
ÏÏÏ
ÏÏÏ
ÏÏÏ
B SUMMARY The Sheet Metal Part in Process application
ÏÏÏ allows you to record manufacturing steps on a

drawing.
In this lesson you:

Created Processes, Groups, and Features.
Created a Part Family of the various forming
states.
Created a drawing using intermediate
manufacturing steps of a part.

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Flat Pattern Additional Information

Appendix C
Flat Pattern Woven Materials Options
ÏÏÏ
ÏÏÏ
C
ÏÏÏ
When a flat pattern for a nonĆsheet metal, highly complex, multiĆdirectional

curve defining surface needs to be constructed, simple flattening techniques are
no longer effective. The Woven Materials traversal option will map these
complex surfaces using a biĆaxial grid of curves having nearĆright angle
orientations to each other.
Upon selection of a starting point, the woven materials algorithm maps out the
strands of a flat grid onto the complex surface, allowing the angular orientation
of the strands to distort into an equally sided quadrilateral. The system
determines the overall length of the flat pattern by summing the distances along
each strand out to the edges of the surface. These lengths are then translated to
the flat pattern plane where the trajectory of the strand end points defines the
outline boundary of the flat pattern.

C-1
ÏÏÏ
ÏÏÏ
C
ÏÏÏ
C-2 Sheet Metal Design

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Warp Direction
The weave of a woven material can be depicted by interlaced threads which

have a vertical (warp) and horizontal (woof) orientation. The Warp Direction
option allows you to specify the positive warp direction of the material with
respect to the original formed surface. This direction will also be used to orient
the flat pattern.
Material Weave Pattern
woof
threads
ÏÏÏ
ÏÏÏ
C
ÏÏÏ
warp threads
Positive
VĆvector
Positive
UĆvector
U Parameter indicates that the positive warp orientation will parallel

the positive UĆvector of the mapped surface.
V Parameter indicates that the positive warp orientation will parallel
the positive VĆvector of the mapped surface.
Point Tool allows you to specify a vector direction from the start point
on the surface of the part as the positive warp direction.

C-3
Origin Point
The flat pattern that results from the woven materials algorithm is defined by
the input conditions and constraints you specify. The starting point for applying
the flat grid to the part surface can affect the shape of the resulting flat pattern.
Therefore, you should select the start point in a region of the surface that is
relatively flat. This supports the assumption made by the system that the woof
and warp strands of the material in the starting area are at right angles to each
other.
The Flat Pattern dialog box allows you to specify the start point two ways. The
Point Tool allows you to specify a generic point on the formed surface of the
part. The UV Midpoint indicates that the center of the UĆV mapped surface
area will be the start point.
Upon creation of the flat pattern, the chosen start point is located at the origin
of your work coordinate system, and the flat pattern geometry is created in the
XCĆYC plane.
ÏÏÏ
ÏÏÏ
C Grid Size
ÏÏÏ Each intersection point between the warp and woof threads of the material
weave define a grid Node. The Grid Size option allows you to define the
horizontal and vertical spacing of these nodes in the grid. The task of the woven
materials traversal algorithm is to locate the position of these nodes on the
formed surface of the part.
This parameter can have considerable effect on both the accuracy of the flat
pattern and the required computer run time needed for its determination.
Experience has shown that values ranging from .1 to 1 inch provide reasonably
smooth surfaces. You should experiment with values within this range to
determine acceptable accuracy and processing speed.

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Lock Angle
This option represents the minimum angle allowable, in degrees, between two
strands of a grid originating from the same node.
NonĆdeformed weave in vicinity Distorted weave as material is

of start point worked to contoured surface
ÏÏÏ
ÏÏÏ
C
ÏÏÏ

C-5
Activity C-1: Flat Patterns for NonĆSheet Metal Parts
In this activity you'll see how different flat patterns can be generated using
different traverse control algorithms.
Step 1 Add a sheet metal feature to a nonĆsheet metal part.
Open the file smd_freeform. Notice that a free form solid

object has been created for you.
ÏÏÏ
ÏÏÏ
C
ÏÏÏ
It is impossible to add a modeling hole to this free form object

without also creating reference data to support the hole
location.
Using Sheet Metal Hole, you can avoid creating reference data
and can quickly locate the hole using intersecting edges of the
part.
Select the Sheet Metal Hole icon.
Select the outer face of the free form part as the Placement
Face.
Select MB2 to advance to the next step.

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Select the left edge of the part as the first positioning edge.
Enter 2.0 for the Edge 1 Offset value.
Click MB2 to advance to the next step.
Select the bottom edge of the part as the second positioning

edge.
Type in 1.0 for the Edge 2 Offset value and use the Tab key
to advance to the Diameter window.
ÏÏÏ
Placement
Face
First Positioning Edge
ÏÏÏ
C
Second Positioning Edge ÏÏÏ
Type in 1.0 for the Diameter value.
Leave the Face Normal Direction toggled ON.
Select OK to create the hole.
NOTE This hole will take more time to create than previous
sheet metal holes.

C-7
Step 2 Create a flat pattern.
Select Preferences→SMD Flat Pattern.
Toggle ON Allow Multiple Flat Patterns.
Change the Geodesics Algorithm to Knights.
ÏÏÏ
ÏÏÏ
C
ÏÏÏ
Choose OK.

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Enter the Flat Pattern function under the Tools menu

option. Notice that the Traverse Control Algorithm is set to
Sheet Metal.
In most cases this traversal routine will adequately map the

ÏÏÏ
nonĆformable object to be flattened.
ÏÏÏ
C
Replace the TRFĆTRI view with the TOP view. (MB3 in the ÏÏÏ
screen, Replace View→Top)
Choose the top face of the part as the Start face. Select the
face as close to X,Y,Z=0,0,0 with your cursor and accept the
choice.
Select the Area Preserving Faces icon.
Notice that the system has assigned this solver to the face.
Select Cancel to close the class selection window.
Select the Apply button in the Flat Pattern dialog box to

generate the flat pattern geometry.

C-9
Review the flat pattern definition. Does it look correct?
Flat
pattern
geometry
NOTE Your flat pattern may vary from the one shown above.
The flat pattern generated depends on where you pick
ÏÏÏ the surface of the part.
ÏÏÏ
C
ÏÏÏ The Area Preserving Faces algorithm attempts to preserve the
area of the face and does not account for the multiĆdirectional
deformation inherent within the part. The Distortion Faces
solver also will not adequately handle faces of this type.
The Woven Materials traversal algorithm was created to map
and solve these types of complex surfaces.

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Step 3 Create a flat pattern using the Woven Materials Traverse

Control Algorithm.
Change the Traverse Control Algorithm option within the

Flat Pattern dialog box to Woven Materials. The Woven
Materials options (in the bottom of the dialog box) now
become available.
ÏÏÏ
ÏÏÏ
C
ÏÏÏ
Options
are now
available
These options are explained in detail in the description portion

of this lesson. For now, we'll just accept the default values.
Change the Name field to FLAT_PAT1.

C-11
TIP You will generate an error message if you do not

assign a new name to each additional flat pattern.
Choose the top face of the part again to reĆcalculate the flat
pattern using the Woven Materials algorithm. Accept your
choice.
Select OK in the Flat Pattern dialog box. A much more

realistic flat pattern is created.
ÏÏÏ
ÏÏÏ
C
ÏÏÏ
Flat pattern geometry Flat pattern geometry by the

by the Sheet Metal Woven Material algorithm
algorithm
In this exercise, the Woven Material algorithm generated a more
viable flat pattern definition of the free form part. However, it's
important to remember that this algorithm traverses and maps
only the selected start face. Therefore, to produce a complete
flat pattern definition of a free form part, the surface of the part
must be one continuous face.
Close your part.

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Multibend Bracket
Multibend Bracket
Appendix D
PURPOSE To see the advantages of using the Multibend Bracket

feature.
Create and edit a multibend bracket
Activity Page
D-1 Creating a Multibend Bracket . . . . . . . . . . . . . . . . D-2
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

D-1
Multibend Bracket
Activity D-1: Creating a Multibend Bracket
In this activity you will create a bracket in an assembly. The assembly is a simple
representation of a mounting ring with a section of hydraulic tubing
surrounding it. There is a component which contains the necessary information
for the needed multibend bracket. The bracket will help secure the tubing
around the mounting ring.
Step 1 Open and examine the assembly.

Open the part smd_engine_assm.
Toggle ON the Assemblies application.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ
D-2 Sheet Metal Design

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Multibend Bracket
Choose the Assembly Navigator icon.
Step 2 Examine the information within the bracket component.
In the Assembly Navigator, place the cursor over the

smd_multibnd_brkt node.
Press MB3 and choose Make Displayed Part from the

popĆup menu.
Notice the various features in the part file. There are two linked
features which give us some of the information needed to
construct the bracket. There are also some datums to aid in
creation.
Linked Features
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ
NOTE Only a small portion of the ring is needed to help in the
construction of the bracket, therefore it has been
trimmed to make it easier to work with.

D-3
Multibend Bracket
Step 3 Copy the bracket and assembly to the parts directory.

Choose File→Save As.
The system automatically displays a Session Where Used
Report to tell you which loaded assemblies are referencing
the bracket.
Enter ***_multibnd_brkt as the new part file name, where
*** represent your initials, and press Enter.
NOTE Read the Cue Line! At this point the system will also
prompt you to perform a File→Save As for each of the
loaded assemblies that reference the bracket, if desired.
Enter ***_engine_assm as the name for the new assembly

and press Enter.
The system displays a Do you want the SaveAs to Continue"
message allowing you to cancel if you had made a mistake. The
listing window will also reflect the specified action and show the
directory paths and filenames you entered.
Choose OK to continue with the Save As.
***_ENGINE_ASSM
***_MULTIBND_BRKT SMD_ENGINE_TUBING SMD_ENGINE_RING
ÏÏÏ
ÏÏÏ Exit the Information Window.
ÏÏÏ
D
ÏÏÏ Step 4 Import and edit some sheet metal expressions.
Choose Tools"Expressions...
Choose the Import icon.
Select the expressions.exp part file from the parts directory.

Notice that the expressions from the sheet metal seedpart have
been added. You can now edit the values to reflect the correct
sizes.

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Multibend Bracket
Choose the T variable and change the value to .070 .
Choose the R variable and change the value to .070 .
Choose OK.
Step 5 Set the sheet metal preferences for the part.
Choose the Global Parameters button.
Enter T for the Thickness expression.
Enter R for the Bend Radius expression.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

D-5
Multibend Bracket
Toggle ON Use Global for Bend Allowance Formula. No

changes to the default are required.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D Confirm your settings and choose OK twice.
ÏÏÏ Step 6 Create the Multibend Bracket.
NOTE Consider turning OFF the Assembly and Model

Navigators to take full advantage of the graphics screen.
Ensure the work layer is set to 21 and choose the Multibend
Bracket icon.

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Multibend Bracket
Select the bounded plane shown as the BASE_PLANE.
Select this plane

to flip the vector so it points downward.
TIP Another way to add a bend is by placing the cursor

over the BASE_PLANE node in the tree listing,
selecting Mouse Button 3 (MB3) and choosing Add
Bend.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

D-7
Multibend Bracket
Select the front edge of the two holes, as shown, for the
reference geometry.
Material direction
Select these
two edges


Bracket dialog. This is necessary because the next flange
needs to be created off of the same base plane.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

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Multibend Bracket
Select the front edge of the holes on the back side, as shown,
for the reference geometry.
Material direction
Select these
two edges


Bracket dialog again.
Choose the Add Bend icon. ÏÏÏ

ÏÏÏ
ÏÏÏ
D
ÏÏÏ

D-9
Multibend Bracket
Select the curve, as shown, for the reference geometry.
Select this curve
Material
direction


Bracket dialog. Once again this is necessary because the next
flange needs to be created off of the same base plane.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

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Multibend Bracket
Select the other curve, as shown, for the reference geometry.
Select this curve
Material direction

NOTE You can review your geometry selection for each bend by
highlighting the applicable bend node (e.g. BEND_01) in
the tree listing.
ÏÏÏ
Step 7 Create the outline for the bracket.
ÏÏÏ
ÏÏÏ
D
ÏÏÏ
Make all layers but the work layer invisible.

D-11
Multibend Bracket
For clarity purposes, Blank the objects shown below.

(Edit"Blank"Blank...)
Blank these
objects
NOTE The reference geometry is added to the sketch as

Extracted Curves and are made reference (grey and
phantom font). They can be converted to active for use in
the outline if desired.
Fit the view.
Since everyone's sketching skill level varies, a rough outline for

the bracket has already been created. The curves will be added
to the sketch and constrained as necessary.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

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Multibend Bracket
Outlining profile
Choose the Add Existing Curves icon.
Choose the Chain option at the bottom of the Class

Selection dialog.
Select one of the curves outlining the bracket profile, as

shown above, and choose MB2 to complete the chain.
Choose OK to add the curves. ÏÏÏ

ÏÏÏ
ÏÏÏ
D
Step 8 Constrain the bracket outline.
ÏÏÏ
Since the curves have been added to the sketch they have no
dimensional or geometric constraints.
Choose the Automatic Constraint Creation icon.
Choose the Clear button.
Toggle ON Horizontal and Vertical and choose OK.

D-13
Multibend Bracket
Choose the Show/Remove Constraints icon to check

the constraints that where just applied.
Change the List Constraints for option to All in Active

Sketch. There should be several horizontal and vertical
constraints listed.
Choose the Constraints icon.
Apply Collinear geometric constraints to the pairs of curves

shown below.
1 3 5 6 4 2
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

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Multibend Bracket
Apply Concentric and Equal Radius constraints to the pairs

of curves shown below.
Apply a Point on Curve constraint between the line and

center point shown below. Do this on both sides.
Point on Curve
Concentric &
Equal Radius
1 2
Some of the geometry has been removed for clarity. ÏÏÏ

ÏÏÏ
ÏÏÏ
D
Choose the Dimensions icon. ÏÏÏ

D-15
Multibend Bracket
Create the dimensional constraints shown below on both

sides.
Bend tangent line
The expression names may vary on your part.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

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Multibend Bracket
Create the dimensional constraints shown below.
ÏÏÏ
ÏÏÏ
The Status Line should now state that the Sketch is fully ÏÏÏ
D
ÏÏÏ

constrained. If it does not indicate how many constraints are
left choose the Dimensions icon again.

D-17
Multibend Bracket
This will force the multibend bracket to update, the sketch and
datums will disappear, the sketch will be extruded into a solid
and bend features will be applied to the part. The part should
look like the one below.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ Choose OK in the Multibend Bracket dialog.
This will force the multibend bracket to finish the creation

process establish the feature.
Make layer 15 selectable and Fit the view.

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Multibend Bracket
Step 9 Edit the Multibend Bracket.

Notice that there are no mounting holes in the part to attach it
to the assembly. Next we will edit the Multibend Bracket and
convert the extracted curves to active and update the bracket.
Make layer 15 invisible and turn OFF the shading.
Double-Click on the MULTIBEND_BRACKET feature to

edit its parameters.
Notice how the sketch and datum references planes reappear.
Choose the Convert To/From Reference icon.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

D-19
Multibend Bracket
Change the toggle to Active and select the four corner circles
shown below.
4 places
ÏÏÏ
ÏÏÏ
Choose OK in the Multibend Bracket dialog.
ÏÏÏ
D
The bracket should now have the mounting holes and resemble
ÏÏÏ the bracket shown below.

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Multibend Bracket
Make layer 15 selectable and Fit the view.
Step 10 Create a reference set and return to the assembly.
Choose Format"Reference Sets...
Choose the Model ("BODY") reference set from the list.
Choose the Remove Objects icon.
Select the engine ring and choose OK. ÏÏÏ

ÏÏÏ
ÏÏÏ
D
Close the Reference Set dialog.
ÏÏÏ
Choose the Assembly Navigator icon.

***_multibnd_brkt node.
Press MB3 and choose Display Parent from the popĆup

menu and select ***_engine_assm.

D-21
Multibend Bracket

***_multibnd_brkt node.
Press MB3 and choose Replace Reference Set from the

popĆup menu and choose BODY.
Examine the assembly.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

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Multibend Bracket
SUMMARY The Multibend Bracket feature creates an

associative bracket that moves with the
respectively referenced geometry. It is
comprised of formable features so it can be
unformed.
In this lesson you:

Created and Edited a Multibend Bracket
Worked in an assembly environment.
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

D-23
Multibend Bracket
ÏÏÏ
ÏÏÏ
ÏÏÏ
D
ÏÏÏ

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Glossary
Glossary
ABS - Absolute coordinate system.

Absolute Coordinate System - Coordinate system in which all geometry is located
from a fixed or absolute zero point.
active view - One of up to 49 views per layout in which you can directly work.
angle - In Unigraphics, an angle measured on the XĆY plane of a coordinate
system is positive if the direction that it is swept is counterclockwise as viewed from
the positive Z axis side of the XĆY plane. An angle swept in the opposite direction
is said to be negative.
arc - An incomplete circle; sometimes used interchangeably with the term circle."
ASCII - American Standard Code for Information Interchange. It is a set of 8Ćbit
binary numbers representing the alphabet, punctuation, numerals, and other
special symbols used in text representation and communications protocol.
aspect ratio - The ratio of length to height which represents the change in size of a
symbol from its original.
assembly - A collection of piece parts and subĆassemblies representing a product.
In Unigraphics, an assembly is a part file which contains components.
assembly part - A Unigraphics part file which is a userĆdefined, structured
combination of subĆassemblies, components and/or objects.
associativity - The ability to tie together (link) separate pieces of information to
aid in automating the design, drafting, and manufacture of parts in Unigraphics.
attributes - Pieces of information that can be associated with Unigraphics
geometry and parts such as assigning a name to an object.
block font - A Unigraphics character font which is the default font used for
creating text in drafting objects and dimensions.
body - Class of objects containing sheets and solids (see solid body and sheet body).
bottomĆup modeling - Modeling technique where component parts are designed
and edited in isolation of their usage within some higher level assembly. All ÉÉÉ
ÉÉÉ
GL
assemblies using the component are automatically updated when opened to reflect
the geometric edits made at the piece part level. ÉÉÉ
ÉÉÉ
All Rights Reserved Student Guide GL-1
Glossary
boundary - A set of geometric objects that describes the containment of a part

from a vantage point.
CAD/CAM - Computer Aided Design/Computer Aided Manufacturing.
category, layer - A name assigned to a layer, or group of layers. A category, if

descriptive of the type of data found on the layers to which it is assigned, will assist
the user in identifying and managing data in a part file.
chaining - A method of selecting a sequence of curves which are joined

endĆtoĆend.
circle - A complete and closed arc, sometimes used interchangeably with the term
arc."
component - A collection of objects, similar to a group, in an assembly part. A

component may be a subĆassembly consisting of other, lower level components.
component part - The part file or master" pointed to by a component within an

assembly. The actual geometry is stored in the component part and referenced, not
copied, by the assembly. A separate Unigraphics part file that the system associates
with a component object in the assembly part.
cone direction - Defines the cone direction using the Vector Subfunction.
cone origin - Defines the base origin using the Point Subfunction.
half angle - The half vertex angle defines the angle formed by the axis of the cone
and its side.
constraints - Refer to the methods you can use to refine and limit your sketch.
The methods of constraining a sketch are geometric and dimensional.
construction points - Points used to create a spline. Construction points may be

used as poles (control vertices), defining points, or data points. See POLES,
DEFINING POINTS, and DATA POINTS.
control point - Represents a specific location on an existing object. A line has

three control points: both end points and the midpoint of the line. The control
point for a closed circle is its center, while the control points for an open arc are its
end and midpoints. A spline has a control point at each knot point. A control point
is a position on existing geometry. Any of the following points: 1. Existing Points 2.
Endpoints of conics 3. Endpoints and midpoints of open arcs 4. Center points of
ÉÉÉ
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GL
circles 5. Midpoints and endpoints of lines 6. Endpoints of splines.
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convert curve - A method of creating a bĆcurve in which curves (lines, arcs, conics
or splines) may be selected for conversion into a bĆcurve.
Sheet Metal Design

GL-2 Student Guide EDS Unigraphics NX
All Rights Reserved
Glossary
Coordinate System - A system of axes used in specifying positions (CSYS).
counterclockwise - The rightĆhand rule determines the counterĆ clockwise

direction. If the thumb is aligned with the ZC axis and pointing in the positive
direction, counterclockwise is defined as the direction the fingers would move from
the positive XC axis to the positive YC axis.
current layout - The layout currently displayed on the screen. Layout data is kept
in an intermediate storage area until it is saved.
curve - A curve in Unigraphics is any line, arc, conic, spline or bĆcurve. A

geometric object; this may refer to a line, an arc, a conic, or a spline.
defaults - Assumed values when they are not specifically defined.
defining points - Spline construction points. Splines created using defining points
are forced to pass through the points. These points are guaranteed to be on the
spline.
degreeĆofĆfreedom arrows - ArrowĆlike indicators that show areas that require

more information to fully constrain a sketch.
design in context - The ability to directly edit component geometry as it is

displayed in the assembly. Geometry from other components can be selected to aid
in the modeling. Also referred to as edit in place.
dimensional constraint - This is a scalar value or expression which limits the

measure of some geometric object such as the length of a line, the radius of an arc,
or the distance between two points.
directory - A hierarchical file organization structure which contains a list of

filenames together with information for locating those files.
displayed part - The part currently displayed in the graphics window.
edit in place - See design in context.
emphasize work part - A color coding option which helps distinguish geometry in
the work part from geometry in other parts within the same assembly.
endpoint - An endpoint of a curve or an existing point.
expression - An arithmetic or conditional statement that has a value. Expressions

are used to control dimensions and the relationships between dimensions of a
model.
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GL
face - A region on the outside of a body enclosed by edges. ÉÉÉ
ÉÉÉ
Glossary
feature - An allĆencompassing term which refers to all solids, bodies, and

primitives.
file - A group or unit of logically related data which is labeled or named" and
associated with a specified space. In Unigraphics, parts, and patterns are a few
types of files.
filtering - See object filtering.
font box - A rectangle or box" composed of dashed line objects. The font box
defines the size, width and spacing of characters belonging to a particular font.
font, character - A set of characters designed at a certain size, width and spacing.
font, line - Various styles of lines and curves, such as solid, dashed, etc.
free form feature - A body of zero thickness. (see body and sheet body)
generator curve - A contiguous set of curves, either open or closed, that can be
swept or revolved to create a body.
geometric constraint - A relationship between one or more geometric objects that

forces a limitation. For example, two lines that are perpendicular or parallel
specifies a geometric constraint.
grid - A rectangular array of implied points used to accurately align locations

which are entered by using the screen position" option.
guide curve - A set of contiguous curves that define a path for a sweep operation.
virtual intersection - Intersection formed by extending two line segments that do

not touch to the position that they cross. The line segments must be nonĆparallel
and coplanar.
inflection - A point on a spline where the curve changes from concave to convex,
or vice versa.
interactive step - An individual menu in a sequence of menus used in performing a

Unigraphics function.
isometric view (TfrĆISO) - Isometric view orientation - one where equal distances
along the coordinate axes are also equal to the view plane. One of the axes is
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GL
vertical.
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ÉÉÉ
knot points - The defining points of a spline. Points along a BĆspline, representing
the endpoints of each spline segment.
Sheet Metal Design

All Rights Reserved
Glossary
layer - A layer is a partition of a part. Layers are analogous to the transparent

material used by conventional designers. For example, the user may create all
geometry on one layer, all text and dimensions on a second, and tool paths on a
third.
layout - A collection of viewports or window areas, in which views are displayed.
The standard layouts in Unigraphics include one, two, four or six viewports.
layouts - Standard layouts are available to the user. These include:
L1 - Single View,
L2 - Two Views,
L3 - Two Views,
L4 - Four Views,
L6 - Six Views.
Information window - The window used in listing operations, such as Info.
loaded part - Any part currently opened and in memory. Parts are loaded explicitly
using the File→Open option and implicitly when they are used in an assembly being
opened.
menu - A list of options from which the user makes a selection.
model space - The coordinate system of a newly created part. This is also referred
to as the absolute coordinate system." Any other coordinate system may be
thought of as a rotation and/or translation of the absolute coordinate system.
name, expression - - The name of an expression is the single variable on the left
hand side of the expression. All expression names must be unique in a part file.
Each expression can have only one name. See expression.
objects - All geometry within the Unigraphics environment.
offset face - A Unigraphics surface type created by projecting (offsetting) points
along all the normals of a selected surface at a specified distance to create a true"
offset.
options - A number of various alternatives (functions, modes, parameters, etc.)
from among which the user can choose.
origin - The point X = 0, Y = 0, Z = 0 for any particular coordinate system.
parametric design - Concept used to define and control the relationships between
the features of a model. Concept where the features of the model are defined by
parameters. ÉÉÉ
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GL
part - A Unigraphics file containing a .prt extension. It may be a piece part
containing model geometry, a subĆassembly, or a topĆlevel assembly. ÉÉÉ
ÉÉÉ
Glossary
part or model - A collection of Unigraphics objects which together may represent

some object or structure.
partially loaded part - A component part which, for performance reasons, has not
been fully loaded. Only those portions of the component part necessary to render
the higher level assembly are initially loaded (the reference set).
point set - A distribution of points on a curve between two bounding points on that
curve.
Point Subfunction Menu - A list of options (methods) by which positions can be

specified in Unigraphics.
readĆonly part - A part for which the user does not have write access privilege.
real time dynamics - Produces smooth pan, zoom, and rotation of a part, though
placing great demand on the CPU.
Refresh - A function which causes the system to refresh the display list on the
viewing screen. This removes temporary display items and fills in holes left by Blank
or Delete.
rightĆhand rule, conventional - The rightĆhand rule is used to determine the

orientation of a coordinate system. If the origin of the coordinate system is in the
palm of the right fist, with the back of the hand lying on a table, the outward
extension of the index finger corresponds to the positive Y axis, the upward
extension of the middle finger corresponds to the positive Z axis, and the outward
extension of the thumb corresponds to the positive X axis.
rightĆhand rule for rotation - The rightĆhand rule for rotation is used to associate
vectors with directions of rotation. When the thumb is extended and aligned with a
given vector, the curled fingers determine the associated direction of rotation.
Conversely, when the curled fingers are held so as to indicate a given direction of
rotation, the extended thumb determines the associated vector.
screen cursor (cursor) - A marker on the screen which the user moves around
using some position indicator device. Used for indicating positions, selecting
objects, etc. Takes the form of a fullĆscreen cross.
sheet - A object consisting of one or more faces not enclosing a volume. A body of
zeroĆthickness. Also called sheet body.)
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GL
sketch - A collection of geometric objects that closely approximates the outline of
a particular design. You refine your sketch with dimensional and geometric
ÉÉÉ
ÉÉÉ
constraints until you achieve a precise representation of your design. The sketch
can then be extruded or revolved to obtain a 3D object or feature.
Sheet Metal Design

All Rights Reserved
Glossary
Sketch Coordinate System (SCS) - The SCS is a coordinate system which

corresponds to the plane of the sketch. When a sketch is created the WCS is
changed to the SCS of the new sketch.
solid body - An enclosed volume. A type of body (see Body).
spline - A smooth freeĆform curve.
stored layout - The last saved version of a layout.
stored view - The last saved version of a view.
string - A contiguous series of lines and/or arcs connected at their end points.
subĆassembly - A part which both contains components and is itself used as a

component in higherĆlevel assemblies.
surface - The underlying geometry used to define a face on a sheet body. A

surface is always a sheet but a sheet is not necessarily a surface (see sheet body).
The underlying geometry used to define the shape of a face on a sheet.
system - The Unigraphics System.
temporary part - An empty part which is optionally created for any component
parts which cannot be found in the process of opening an assembly.
topĆdown modeling - Modeling technique where component parts can be created

and edited while working at the assembly level. Geometric changes made at the
assembly level are automatically reflected in the individual component part when
saved.
trim - To shorten or extend a curve.
trimetric view (TfrĆTri) - A viewing orientation which provides you with an

excellent view of the principal axes. In Unigraphics II, the trimetric view has the
ZĆaxis vertical. The measure along the XĆaxis is 7/8 of the measure along Z, and the
measure along the YĆaxis is 3/4 of the measure along Z.
Unigraphics - A computer based turnkey graphics system for computerĆaided

design, drafting, and manufacturing, produced by UGS.
units - The unit of measure in which you may work when constructing in
Unigraphics. Upon log on, you may define the unit of measure as inches or
millimeters.
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GL
upgraded component - A component which was originally created preĆV10 but has
been opened in V10 and upgraded to remove the duplicate geometry. ÉÉÉ
ÉÉÉ
Glossary
version - A term which identifies the state of a part with respect to a series of
modifications that have been made to the part since its creation.
view - A particular display of the model. View parameters include view orientation
matrix; center; scale; X,Y and Z clipping bounds; perspective vector; drawing
reference point and scale. Eight standard views are available to the user: Top,
Front, Right, Left, Bottom, Back, TfrĆISO (topĆfrontĆright isometric), and TfrĆTri
(topĆfrontĆright trimetric).
view dependent edit - A mode in which the user can edit a part in the current work
view only.
view dependent modifications - Modifications to the display of geometry in a

particular view. These include erase from view and modify color, font and width.
view dependent geometry - Geometry created within a particular view. It will only
be displayed in that view.
WCS - Work Coordinate System.
WCS, work plane - The WCS (Work Coordinate System) is the coordinate system
singled out by the user for use in construction, verification, etc. The coordinates of
the WCS are called work coordinates and are denoted by XC, YC, ZC. The XCĆYC
plane is called the work plane.
Work Coordinate System - See WCS.
work layer - The layer on which geometry is being constructed. You may create
objects on only one layer at a time.
work part - The part in which you create and edit geometry. The work part can be
your displayed part or any component part which is contained in your displayed
assembly part. When displaying a piece part, the work part is always the same as
the displayed part.
work view - The view in which work is being performed. When the creation mode
is view dependent, any construction and view dependent editing that is performed
will occur only in the current work view.
XC axis - XĆaxis of the work coordinate system.
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GL
YC axis - YĆaxis of the work coordinate system.
ÉÉÉ
ZC axis - ZĆaxis of the work coordinate system.
ÉÉÉ
Sheet Metal Design
All Rights Reserved
Index
Index
ÉÉÉ
ÉÉÉ
ÉÉÉ
IN
A
ABS, GL-1
target body, 12-11
Body, GL-1 ÉÉÉ
Bottom-Up Modeling, GL-1
Absolute Coordinate System, GL-1 Boundary, GL-2
Active View, GL-1 Bracket
Angle, GL-1 bracket margin, 15-17
constructions tips, 15-17
Arc, GL-1
create or unite, 15-10
ASCII, GL-1 dialog, 15-3
Aspect Ratio, GL-1 add rounded corners, 15-9
bend allowance formula, 15-9
Assemblies, GL-1 options, 15-9
Associativity, GL-1 parameters, 15-6
bend radius, 15-7
Attribute, GL-1
chordal tolerance, 15-7
clearance distance, 15-6
flange length, 15-7
B linear tolerance, 15-8
material thickness, 15-7
Bead, 12-2 offset distance, 15-7
bead terminology, 12-13 pad length, 15-7
angle, 12-13 reverse material direction, 15-6
bend radius, 12-13 edit outline, 15-11
distance tolerance, 12-14 along vector, 15-14
end cap angle, 12-13 between circles, 15-13
end cap radius, 12-13 drag point, 15-15
height, 12-13 normal to curve, 15-12
placement width, 12-13 point constructor, 15-16
radius, 12-14 reset, 15-16
secondary width, 12-14 editing brackets, 15-17
construction tips, 12-17 multi-flanged brackets, 15-17
dialog, 12-4 selection steps, 15-4
bead type, 12-12 base face, 15-4
circular, 12-12 clearance points, 15-4, 15-5
U-shaped, 12-12 reference face, 15-5
V-shaped, 12-12 utility, 15-2
options, 12-15
angle, 12-15
attach bead, 12-16
end caps, 12-16
C
height, 12-15 Category, Layer, GL-2
hollow bead, 12-16
Chaining, GL-2
secondary width from, 12-15
selection steps, 12-5 Circle, GL-2
centerline, 12-6 Component, GL-2
centerline projection vector, 12-6 Part, GL-2
orientation plane, 12-7
placement face, 12-5 Cone
secondary face definition, 12-10 Direction, GL-2
section axis, 12-8 Origin, GL-2
section points, 12-9 Constraints, GL-2
EDS Sheet Metal Design IN-1

Index
ÉÉÉ
Construction Points, GL-2 Expressions, GL-3
Names, GL-5
ÉÉÉ
Construction Tips
bead, 12-17
ÉÉÉ
IN bracket, 15-17
F
ÉÉÉ flange, 2-61
flat pattern, 16-26
general flange, 6-24
Face, GL-3
multibend bracket, 14-9 Features, GL-4
Sheet Metal Bend, 5-9 File, GL-4
sheet metal bridge, 13-12
Sheet Metal Corner, 3-10 Filtering, GL-4
sheet metal cutout, 10-8 Flange, 2-2
sheet metal hole, 9-28 bend angle formula (BAF), 2-8
sheet metal punch, 7-13 construction tips, 2-61
sheet metal slot, 9-28 dialog, 2-3
sheet metal solid punch, 8-8 adjacent face, 2-9
unbend/rebend, 11-7 angle, 2-7
Confirm Upon Apply, 2-18
Control Point, GL-2
length, 2-6
Convert, Curves to BĆCurves, GL-2 options, 2-10, 4-8
Coordinate Systems, GL-3 global preferences, 2-17
Sketch, GL-7 parameter options, 2-11
reference lines, 2-12
Counterclockwise, GL-3 thickness, 2-11
Creating Process Drawings, B-23 relief options, 4-9
part families left and right relief, 4-10
general procedure, B-25 side options, 2-14
terminology, B-25 full miter, 2-57
left and right settings, 2-14, 2-56
Current Layout, GL-3 miter parameters, 2-58
Cursor, GL-6 miter angle, 2-59
miter phase, 2-60
Curve, GL-3 miter relief, 2-60
miters, 2-56
simple miter, 2-57
D parameter options, width, 2-4
Positioning method, 2-5
Defaults, GL-3 radius, 2-8
Defining Points, GL-3 reverse direction, 2-9
instancing, 2-19
DegreeĆofĆfreedom Arrows, GL-3
Flat Pattern, 16-2
Design in Context, GL-3 annotation, 16-22
Dimension Constraints, GL-3 edit flat pattern display dialog, 16-22
text callout dialog, 16-23
Direction, Cone, GL-2 annotation preferences, 16-24
Directory, GL-3 construction tips, 16-26
dialog, 16-3
Displayed Part, GL-3 bend allowance formula, 16-6
change body, 16-6
create flat pattern, 16-4
E form sheet metal features, 16-6
layer, 16-5
Edit in Place, GL-3 layout options, 16-8
additional curves, 16-10
Emphasize Work Part, GL-3
area preserving faces, 16-8
Endpoint, GL-3 cutting edges, 16-10
IN-2 Sheet Metal Design

EDS
Student Guide All Rights Reserved Unigraphics NX
Index
distortion faces, 16-9 options, 6-18

features, 16-11 distortion, 6-20
ÉÉÉ
projection faces, 16-9 infer spine, 6-19
ÉÉÉ
ÉÉÉ
start position, 16-11 infer thickness, 6-18 IN
r value , 6-20
ÉÉÉ
location, 16-7
name, 16-5 tolerance, 6-21
traverse body, 16-5 parameter method, 6-9
traverse control algorithm, 16-7 parameters, 6-8
generic, 16-7 Angle, 6-11
none, 16-7 length, 6-11
sheet metal, 16-7 plus, 6-10
woven materials, 16-7 radius, 6-11
unform sheet metal features, 16-6 step data, 6-11
update flat pattern, 16-4 punch vector, 6-15
woven materials options, C-1 punch vector, 6-7
reverse bend direction, 6-10
grid size, C-4
spine string, 6-5
lock angle, C-5
infer spine, 6-19
origin point, C-4
thickness, 6-8
warp direction, C-3
infer thickness, 6-18
information, 16-25 part in process, B-9
preferences, 16-17
allow multiple flat patterns, 16-20 Generalized Flange, 13-2
angle tolerance, 16-18 dialog
auto update, 16-20 bend edges, add tangent edges, 6-8
construction method, tolerance, 13-11
chord tolerance, 16-18
distortion constraint, 16-20 Generator Curve, GL-4
geodesics algorithm, 16-21 Geometric Constraint, GL-4
layer, 16-18 Grid, GL-4
name, 16-18
Guide Curve, GL-4
orientation, 16-18
output objects, 16-19
bend center curves, 16-19 H
bend tangent curves, 16-19
curve set, 16-19 Half Angle, GL-2
use bend allowance formula, 16-21
Font I
Box, GL-4
Inflection, GL-4
Character, GL-4
Line, GL-4 Inset Flange, 4-2
dialog, 4-3
Free Form Feature, GL-4 inset
DIN mold line, 4-7
inner mold line, 4-7
G inner tangent line, 4-6
outer mold line, 4-6
General Flange, 6-2 outer tangent line, 4-5
construction tips, 6-24 use expression, 4-5
dialog, 6-2 options, flange width, 4-9
bend edges, 6-4
adjacent faces, 6-17
K
build to faces, 6-14 Knot Points, GL-4
shaping faces, 6-6
build to sections, 6-12
extend start and end, 6-13
L
section strings, 6-6 Layer, GL-5

Index
ÉÉÉ
Layout, GL-5 general flange, B-9
edge constraints, B-10
ÉÉÉ
Listing Window, GL-5
surface extension, B-10
ÉÉÉ
IN Loaded Part, GL-5 add group, B-5, B-6
ÉÉÉ
add process, B-5
delete group, B-7
M delete process, B-5
execute group, B-6
Menu, GL-5 execute sequence, B-4, B-6, B-8
form group, B-6
Model, GL-6 form process, B-5
Model Space, GL-5 unform group, B-6
unform process, B-4
Multibend Bracket, 14-2
construction tips, 14-9 Partially Loaded Part, GL-6
dialog, 14-2 Point Set, GL-6
adjacent face, 14-7
Point Subfunction, GL-6
creation selection steps, tree list, 14-3 Preferences
inner radius, 14-6 flat pattern annotation, 16-24
intersection thickness, 14-6 reference line color, 1-4
offset, 14-5 SMD flat pattern, 16-17
options, 14-8
selection steps, 14-3
add bend, 14-4 R
add intersection, 14-4
base plane, 14-3 ReadĆOnly Part, GL-6
delete bend, 14-4 Real Time Dynamics, GL-6
reverse material direction, 14-4
Refresh, GL-6
sketch tools, 14-7
editing multibend brackets, 14-8 Right Hand Rule, GL-6
global parameters, 14-8 Rotation, GL-6
O S
Object, GL-5 SCS, GL-7
Offset Surface, GL-5 Sheet, GL-6
Origin, Cone, GL-2 Sheet Metal Bead, dialog, 5-2
Overview, -1 Sheet Metal Bend
construction tips, 5-9
dialog
application curve, 5-3
P curve type, 5-7
base face, 5-3
Parametric Design, GL-5 bend allowance formula (BAF), 5-8
Part, GL-5, GL-6 bend direction vector, 5-7
construction methods, 5-3
Part Families, dialog, B-26
cylindrical face, 5-4
Part In Process, 16-2, B-3 existing edge, 5-5
dialog options, 5-8
add features, B-7 parameter options
bridge and bend, B-8 angle, 5-6
flange and inset flange, B-8 radius, 5-7
process angle, B-8 stationary direction vector, 5-7

EDS
Index
Sheet Metal Bridge, 13-2 hole types, 9-7

construction tips, 13-12 depth, 9-8
ÉÉÉ
dialog, 13-2 punch, 9-7
ÉÉÉ
ÉÉÉ
bend allowance formula, 13-9 through, 9-7 IN
ÉÉÉ
construction method, 13-11 selection steps, 9-4
unite, 13-11 direction vector, 9-5
construction parameters, 13-6 vector method, 9-6
construction type, 13-6 placement face, 9-4
flip extension direction, 13-6 positioning edges, 9-5
inside radius, 13-8 through face, 9-4
intersect angle, 13-7 size parameters, 9-8
thickness, 13-8 depth, 9-8
distortion method, 13-10 diameter, 9-8
area preserve, 13-10 tip angle, 9-8
r value, 13-10 editing positioning, 9-9
options, 13-9 editing sheet metal holes, 9-9
selection steps, 13-4 hole conversion, 9-10
base faces, 13-4 Sheet Metal Preferences, 1-2
base profile, 13-4 bracket margin, 1-7
target faces, 13-5 check standards on create, 1-6
target profile, 13-5 default material, 1-5
enforce creation state edit, 1-6
Sheet Metal Corner
forming method, 1-7, 11-3
construction tips, 3-10
global parameters, 1-3
dialog, 3-2
load standards, 1-5
butt joint, 3-4
part materials, 1-4
associate flange, 3-4 sequential processing, B-24
gap, 3-5 use feature standards, 1-5
overlap, 3-5
parent flange, 3-4 Sheet Metal Punch
switch parent, 3-4 construction tips, 7-13
construction methods, 3-3 dialog
full miter, 3-8 flip side vector, 7-11
multiple steps, 3-9 options, 7-12
machinery, 3-6 punch direction, 7-11
simple miter, 3-7 punch type, 7-7
gap/relief radius, 3-7 selection steps, 7-3
multiple steps, 3-9 placement face, 7-3
placement outline, 7-4
Sheet Metal Cutout, 10-2 tool center, 7-5
construction tips, 10-8 vector direction, 7-7
dialog, 10-3 size parameters, 7-9
flip discard region, 10-6 top type, 7-8
project, 10-7 Sheet Metal Slot, 9-24
selection steps, 10-4 construction tips, 9-28
direction vector, 10-5 dialog, 9-24
outline, 10-5 creation selection steps, 9-25
placement face, 10-4 positioning selection steps, orientation vector,
through face, 10-4 9-25
vector method, 10-7 size parameters, 9-26
type, 10-6 depth, 9-26
Sheet Metal Hole, 9-2 length, 9-26
construction tips, 9-28 width, 9-26
dialog, 9-2 slot positioning methods, 9-26
direction parameter, 9-8 slot conversion, 9-26
hole positioning methods, 9-2 Sheet Metal Solid Punch, construction tips, 8-8

Index
ÉÉÉ
Sketch, GL-6 bend allowance formula, 11-7
Coordinate System, GL-7 bend operations
ÉÉÉ Solid Body, GL-7 rebend, 11-6
ÉÉÉ
IN unbend, 11-5
Solid Punch, dialog, 8-2
ÉÉÉ
unbend to angle, 11-6
bend operations, 11-5 bend angle, 11-6
options, 8-7 global bend allowance formula, 11-7
create auto centroid, 8-7 forming method, 11-3
edge blend, 8-7 region preparation, 11-2
thickness, 8-7
selection steps, 8-3 Unigraphics, GL-7
pierce faces, 8-5 Units, GL-7
target face, 8-3
Upgrade, Component, GL-7
tool body, 8-4
transformation, 8-5
Spline, GL-7
V
Standards
checking standards, 1-9 Version, GL-8
defining standards, 1-8 View, GL-8
Stored Layout, GL-7 Isometric, GL-4
Trimetric, GL-7
Stored View, GL-7
Work, GL-8
String, GL-7
SubĆassembly, GL-7
Surface, GL-7 W
System, GL-7 WCS, GL-8
Work Layer, GL-8
T Work Part, GL-8

Working In Assemblies, B-22
Temporary Part, GL-7
TfrĆISO, GL-4
TfrĆTri, GL-7 X
Top-Down Modeling, GL-7 XCĆAxis, GL-8
Trim, GL-7
Y
U YCĆAxis, GL-8
Unbend/Rebend
boundary faces, 11-2
construction tips, 11-7 Z
dialog, 11-5
adjacent bend face, 11-6 ZCĆAxis, GL-8

EDS
Reference Chart Tear Outs
These tear out reference charts are provided for your convenience.

Sheet Metal Design EDS Unigraphics NX

V18 Sheet Metal Design
Course Agenda
This agenda is only an approximation. Class size and level of experience may have
a slight impact on the schedule.
Day 1
Morning
Introduction
Lesson 1 Preferences and Standards
Lesson 2 Flange
Afternoon
Lesson 3 Sheet Metal Corner
Lesson 4 Inset Flange
Lesson 5 Sheet Metal Bend
Day 2
Morning
Lesson 6 General Flange
Lesson 7 Sheet Metal Punch
Lesson 8 Sheet Metal Hole & Slot
Afternoon
Lesson 8 Sheet Metal Hole & Slot (cont.)
Lesson 9 Sheet Metal Cutout
Lesson 10 Sheet Metal Bead
Day 3
Morning
Lesson 11 Sheet Metal Bridge
Lesson 12 Multibend Bracket
Lesson 13 Sheet Metal Bracket
Afternoon
Lesson 14 Flat Pattern
Lesson 15 Part In Process
Lesson 16 User Defined Features


Student Profile
Sheet Metal Design
Name Date
Employer
U.S. citizen? Yes / No
When is your planned departure time?________________am/pm
Please answer the following questions as honestly as you can. We are concerned about providing training that
meets your needs. If you have any additional comments please write them on the back of this form.
1. Job title:
2. Current responsibilities:
3. How long have you held these responsibilities? Years ______ Months ______
4. How long have you been working with CAD/CAM/CAE systems? Years ______
5. What other CAD/CAM/CAE systems are you familiar with?
6. Are you currently using Unigraphics? _______ Version _______ Hours per week?
7. What is the function of your CAD/CAM/CAE system (documentation, modeling, analysis,
translation interface, etc.)?
8. What do you model in your Unigraphics part files (castings, assemblies, floor plans, etc.)?
9. Please list other completed CAD/CAM/CAE courses and the provider including Unigraphics CBT
and CAST:
Course Provider
10. Please check the box that best describes your current skill level in the various Unigraphics
disciplines listed below.
none novice intermediate advanced future use

Wireframe Modeling
Solid Modeling
Parametric Modeling
Drafting
Assemblies
Manufacturing

Additional Comments

Sheet Metal Design
Training Course Evaluation
Name (Optional) Date
Instructor Location UG Version ___
Please give your honest opinion about the training you have received during this class. Provide additional
comments on the reverse side of this evaluation form.
Please check the box if you would like your comments, regarding the training you just received, featured in
our training publications. We will contact you if more information is needed.
Hotel Accommodations (if applicable) Hotel name
What was your overall impression of this hotel? Poor 2 3 4 5 6 7
Facilities - How would you rate the training facilities? Poor 2 3 4 5 6 7
Instruction - How would you rate the instruction? Poor 2 3 4 5 6 7
Was the instructor knowledgeable of the subject? Poor 2 3 4 5 6 7

Comments
1. Were the course objectives clearly defined and were they met? Yes No
Please explain:
2. Were concepts effectively communicated so that you understand how to apply the software? Yes
No Please explain:
3. How well prepared do you now feel to use the functions covered in this course in your day to day
activities? Please explain:
4. Were the student activities effective in learning the Sheet Metal functions? Yes No
Please explain:
over

5. What additional topics related to modeling would you like to see covered in this course? Please
explain:
6. Do you have any other suggestions on how the course could be improved? Yes No
Please explain:
7. Do you find the tips and techniques in the manual useful? Yes No
Please explain:
8. In order to continually improve our courseware a post class survey is conducted; would you be
willing to participate in this survey. (If you checked this box, make sure that your name is on this sheet.)
Course - What was your overall impression? Poor 2 3 4 5 6 7

Additional Comments


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UNIGRAPHICS

SHEET METAL DESIGN

2003 Electronic Data Systems Corporation. All rights reserved.

Restricted Rights Legend

Warranties and Liabilities

EDS, the EDS logo, UNIGRAPHICS SOLUTIONS, UNIGRAPHICS, GRIP, PARASOLID,

Sheet Metal Design Student Guide Publication History:

Sheet Metal Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ii Sheet Metal Design

Butt Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Sheet Metal Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Flip Stationary Direction Vector . . . . . . . . . . . . . . . . . . . . . . 5-7

General Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

iv Sheet Metal Design

Sheet Metal Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Sheet Metal Solid Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Sheet Metal Hole and Sheet Metal Slot . . . . . . . . . . . . . . . . . . . . . . 9-1

Hole Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

vi Sheet Metal Design

Unbend to Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

Distortion Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

viii Sheet Metal Design

Flange Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Flat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Orientation Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11

x Sheet Metal Design

Flange and Inset Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Flat Pattern Additional Information . . . . . . . . . . . . . . . . . . . . . . . . C-1

Multibend Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

(This Page Intentionally Left Blank)

xii Sheet Metal Design

The sheet metal design product supported within Unigraphics uses a

This section contains the following activities:

Key Features of Sheet Metal Design

Some highlights of the sheet metal design product include:

FeatureĆspecific attributes and standards checking to ensure design for

Why do I need to know this?

Because of these characteristics, it is essential to the creation of a valid, usable

How to Use This Manual

The general format for lesson content is:

Step 1 Open part file xxx_topic_1.prt.

From the menu bar, select File.

DoubleĆclick on the parts subĆdirectory.

Select the file xxx_topic_1.prt and choose OK.

Obviously, it is always necessary for students to consider the classroom situation

Classroom System Information

Student Login: Username:

About Part File Naming

In order to facilitate the identification of design models without requiring the

part name revision

identifier configuration extension

Class Part File Naming

This course utilizes the following filenaming standard:

TIP Once a seed part is established, it should be writeĆprotected to avoid

The following colors are preset to indicate different object types:

Object Valid colors

Expression Name Intended Use

These expressions could be entered by the user in each file or could be a

Layers and Categories

Layers 1-100, Model Geometry (Category: MODEL)

Layers 1-14, Solid Geometry (Category: SOLIDS)

Layers 15-20, Linked Objects (Category: LINKED_OBJECTS)

Platform Specific Dialog Variance (Windows vs Unix)