PTC Global Services

Designing Sheetmetal Products with

Pro/ENGINEER Wildfire 2.0
T1709-340-01
Training Agenda
Designing Sheetmetal Products with Pro/ENGINEER Wildfire 2.0
Day 1
Getting Started with Sheetmetal Design
Building Sheetmetal Geometry
Unbending Sheetmetal Parts
Adding Features to Sheetmetal Parts
Project Laboratory Day 1

Day 2
Forming Sheetmetal Parts
Bending Sheetmetal Parts
Documenting and Validating Sheetmetal Design
Project Laboratory Day 2
Table of Contents
Designing Sheetmetal Products with Pro/ENGINEER Wildfire 2.0

GETTING STARTED WITH SHEETMETAL DESIGN 1-1

Introduction ............................................................................................................1-1
Objectives ..............................................................................................................1-1
Module 1 Lecture Notes ..................................................................................... 1-2
Overview of the Sheetmetal Design.......................................................................1-3
Defining the Typical Design Approach and Workflow............................................1-4
Tools to Create the Sheetmetal Parts....................................................................1-6
Defining Attributes of Sheetmetal Parts .................................................................1-8
Creating Initial Sheetmetal Geometry....................................................................1-9
Creating Primary Walls ........................................................................................1-11
Sketching for Sheetmetal Walls ...........................................................................1-12
Joining Walls ........................................................................................................1-13
Creating Sheetmetal Parts From Solid Parts .......................................................1-14
Module 1 Lab Exercises ................................................................................... 1-16
Exercise 1: Creating Side Panels of the Toaster .................................................1-16
Exercise 2: Creating the Toaster Body – I ...........................................................1-25
Exercise 3: Creating the Toaster Body – II ..........................................................1-28
Exercise 4 (Optional): Creating a Blended Wall ..................................................1-32
Summary.......................................................................................................... 1-36

BUILDING SHEETMETAL GEOMETRY 2-1

Introduction ............................................................................................................2-1
Objectives ..............................................................................................................2-1
Module 2 Lecture Notes ..................................................................................... 2-2
Creating Secondary Walls – Overview ..................................................................2-3
Creating Attached Secondary Walls – Flat Wall ....................................................2-4
Creating Attached Secondary Wall – Sketch.........................................................2-6
Creating Attached Secondary Walls – Flange Wall ...............................................2-7
Creating Attached Secondary Walls – Options......................................................2-9
Creating Attached Secondary Walls – Without Bend ..........................................2-10
Creating Attached Secondary Walls – Partial Walls ............................................2-11
Creating Attached Secondary Walls – Twist........................................................2-12
 Creating Attached Secondary Walls – Extending Walls...................................... 2-13
Creating Walls With Reliefs ................................................................................. 2-14
Creating a Flat Pattern ........................................................................................ 2-15
Module 2 Lab Exercises ....................................................................................2-16
Exercise 1: Adding Walls to Side Panel .............................................................. 2-16
Exercise 2: Adding Walls to Carriage Binder ...................................................... 2-29
Exercise 3: Building the Carriage Lever .............................................................. 2-36
Exercise 4 (Optional): Building the Toaster Body................................................ 2-39
Summary...........................................................................................................2-42

UNBENDING SHEETMETAL PARTS 3-1

Introduction ............................................................................................................ 3-1
Objectives .............................................................................................................. 3-1
Module 3 Lecture Notes ..................................................................................... 3-2
Unbending Sheetmetal Parts - Overview .............................................................. 3-3
Unbending Developable Surfaces ......................................................................... 3-5
Unbending Undevelopable Geometry ................................................................... 3-7
Creating Developable Geometry ........................................................................... 3-9
Adding Rips to the Geometry .............................................................................. 3-10
Creating Deformation Areas ................................................................................ 3-11
Using SMT Conversion Tool................................................................................ 3-12
Creating A Flat Pattern Feature........................................................................... 3-13
Creating a Bend Back Feature ............................................................................ 3-14
Module 3 Lab Exercises ....................................................................................3-15
Exercise 1: Unbending the Toaster Body Part .................................................... 3-15
Exercise 2: Unbending the Crumbs Tray Part..................................................... 3-22
Exercise 3: Creating a Developable Part ............................................................ 3-28
Summary...........................................................................................................3-37

ADDING FEATURES TO SHEETMETAL PARTS 4-1

Introduction ............................................................................................................ 4-1
Objectives .............................................................................................................. 4-1
Module 4 Lecture Notes ..................................................................................... 4-2
Creating Cuts......................................................................................................... 4-3
Creating Cuts in Design State ............................................................................... 4-5
Creating Cuts in Unbent State............................................................................... 4-6
Using Notches and Punches ................................................................................. 4-7
Using Notches to Create Reliefs ........................................................................... 4-9
Module 4 Lab Exercises ....................................................................................4-10
Exercise 1: Adding Features to Side Panel – I.................................................... 4-10
 Exercise 2: (Optional) Adding Features to Side Panel – II ..................................4-27
Summary.......................................................................................................... 4-32

PROJECT LABORATORY DAY 1 5-1

Introduction ............................................................................................................5-1
Objectives ..............................................................................................................5-1
Module 5 Lecture Notes ..................................................................................... 5-2
Project – Designing a Stapler ................................................................................5-3
Project – Designing a Stapler ............................................................................. 5-5
Project Day 5 Lab Exercises............................................................................... 5-6
Exercise 1: Creating the Stapler Base ...................................................................5-6
Exercise 2: Creating the Stapler Handle..............................................................5-13
Exercise 3: Creating the Stapler Magazine .........................................................5-17
Summary.......................................................................................................... 5-19

FORMING SHEETMETAL PARTS 6-1

Introduction ............................................................................................................6-1
Objectives ..............................................................................................................6-1
Module 6 Lecture Notes ..................................................................................... 6-2
Overview of Creating Form Features.....................................................................6-3
Creating and Using Reference Parts .....................................................................6-5
Creating Rips in the Geometry...............................................................................6-6
Using Multiple Forms .............................................................................................6-7
Returning the Model to the Flat..............................................................................6-8
Flattening Edges with Features .............................................................................6-9
Module 6 Lab Exercises ................................................................................... 6-10
Exercise 1: Adding Emboss to Carriage Binder...................................................6-10
Exercise 2: Adding Louvers to Side Panel...........................................................6-17
Summary.......................................................................................................... 6-22

BENDING SHEETMETAL PARTS 7-1

Introduction ............................................................................................................7-1
Objectives ..............................................................................................................7-1
Module 7 Lecture Notes ..................................................................................... 7-2
Creating Bend Features .........................................................................................7-3
Using Bend Options ...............................................................................................7-5
Calculating Developed Length ...............................................................................7-7
Defining Bend Line...............................................................................................7-12
Adding Bend Line Adjustment..............................................................................7-14
 Defining Default Bend Radius ............................................................................. 7-15
Defining Fixed Geometry..................................................................................... 7-16
Module 7 Lab Exercises ....................................................................................7-17
Exercise 1: Creating the Electrical Contact ......................................................... 7-17
Exercise 2: (Optional) Adding Flange to Toaster Body ....................................... 7-27
Exercise 3: Calculating the Developed Length of Carriage Lever....................... 7-32
Exercise 4: Using Defaults to Bend and Unbend Carriage Lever ....................... 7-36
Exercise 5: Adjusting Bend Line.......................................................................... 7-43
Summary...........................................................................................................7-49

DOCUMENTING AND VALIDATING SHEETMETAL DESIGN 8-1

Introduction ............................................................................................................ 8-1
Objectives .............................................................................................................. 8-1
Module 8 Lecture Notes ..................................................................................... 8-2
Documenting Bend Order ...................................................................................... 8-3
Setting Up Design Rules ....................................................................................... 8-5
Generating Sheetmetal Reports ............................................................................ 8-7
Creating Sheetmetal Drawings............................................................................ 8-11
Module 8 Lab Exercises ....................................................................................8-12
Exercise 1: Documenting the Side Panel Model ................................................. 8-12
Exercise 2: Using Sheetmetal Information Tools ................................................ 8-28
Summary...........................................................................................................8-34

PROJECT LABORATORY DAY 2 9-1

Introduction ............................................................................................................ 9-1
Objectives .............................................................................................................. 9-1
Module 9 Lecture Notes ..................................................................................... 9-2
Project – Designing a Stapler ................................................................................ 9-3
Project – Designing a Stapler (continued.) ......................................................... 9-4
Project Day 9 Lab Exercises .............................................................................. 9-5
Exercise 1: Building the Stapler Base ................................................................... 9-5
Exercise 2: Building the Stapler Magazine .......................................................... 9-15
Exercise 3: Creating Bend Order Table for Stapler Plunger ............................... 9-24
Summary...........................................................................................................9-32

TOP-DOWN DESIGN PROCESS A-1

Introduction ............................................................................................................A-1
Objectives ..............................................................................................................A-1
Module A Lecture Notes..................................................................................... A-2
 Describing Top-Down Design Process ................................................................. A-3
Creating Layouts ................................................................................................... A-5
Creating Assembly Structures .............................................................................. A-6
Creating and Using Skeletons .............................................................................. A-7
Sharing Geometry and References ...................................................................... A-9
Summary.......................................................................................................... A-10

USING PTC HELP B-1

Overview of Pro/ENGINEER Wildfire 2.0 Help.................................................... B-2
Using Pro/ENGINEER Wildfire 2.0 Help ............................................................. B-2
Accessing Pro/ENGINEER Wildfire 2.0 Help from the Main Menu ...................... B-2
Accessing Context-Sensitive Pro/ENGINEER Wildfire 2.0 Help .......................... B-3
Using the Pro/ENGINEER Wildfire 2.0 Menu Manager ........................................ B-5