Sheet Metal Design Lessons

(Click highlighted lessons to watch them.)

Introduction
The Sheet Metal Environment
Styles and Templates
K-Factors
Creating Bend Tables
Using Bend Tables
The Flange Command
Corner Seams
Bend Reliefs and Remnants
Bend Transitions and Flat Patterns
Custom Sheet Metal Templates
The Contour Flange Command
Shells and Ripped Seams
Using the Hem Command
Multiple Plates in Assemblies
Extended Surfaces
Using the Punch Tool
Custom Punches
Custom Extruded Louver Punch
Dangling Geometry in Punches
Custom Extruded Dimple Punch
Custom Revolved Dimple Punch
Surfaces
Tabs
Double Bends and Bend Allowances
Knockouts
Flat Patterns on Drawings
Export-Import Flat Patterns
From Flat Pattern to Folded Model
Custom Sweep Punches
Rules for Complex Shapes
Lofting Conical Shapes
Sweeping Conical Shapes
Complex Shapes
More Complex Shapes
Frame Generator
Editing Frames
Preparations and Welds Part I
Preparations and Welds Part I
Post Weld Operations
Conclusion

Assemblies and Advanced Concepts Lessons

(Click highlighted lessons to watch them.)
Introduction
Using and Creating Templates
Creating Derived Parts
Editing Derived Parts
Intro to the Assy Environment
Degrees of Freedom
Driving Constraints
Adaptive Parts and Sketches
Creating Adaptive Parts I
Creating Adaptive Parts II
Constraining Adaptive Assemblies
Strategy for Adaptive Assemblies
Editing Adaptive Assemblies
Adaptive Subassemblies Part I
Adaptive Subassemblies Part II
Subassembly Constraints
The Content Center
Mirrored Assemblies
Flexible Assemblies
Copied Assemblies
Pattern Components
Advanced Viewing
Assembly Viewing
Motion Constraints
Animating Gears
Transitional Constraints
Collision Detection
Contact Solver
Checking for Interferences
Creating Compressible Springs
Driving Adaptive Springs
Positional Representations
Creating Presentations
Editing Tweaks
Creating iFeatures
Inserting iFeatures
Creating iFeatures from Parts
Creating iPart Factories
iPart Members
Editing the iPart Author
iMates and iParts
Custom iParts
Creating iPart Assemblies
Creating iAssemblies
Threaded iParts
iMates and the Content Center
Identifying and Using iMate Glyphs
Inferred iMates
Scaling Parts
Combining Parts
Subtracting and Splitting Parts
Deleting Faces
Trick for Measuring Interferences
Prep for Design Accelerator
Bolted Connections
Generating Bearings
Generating Shafts
Generating Gears
Generating Keyways
Parameter Driven Assemblies
Conclusion

http://area31.blogspot.com/2005_10_01_archive.html

1. Project the part origin or some other RELIABLE and LOGICAL geometry into each new sketch and
reference new sketch geometry to it.

2. Sketches should be fully constrained and related to the sketch origin. Avoid using the fix
constraint, it makes the sketch difficult to edit by another user.

3. Apply sketch constraints and dimensions carefully and logically so that the sketch geometry will
change in a predictable manner when a dimension is edited.

4. Avoid placing fillets and chamfers in sketches. If possible, make them the last thing added to the
part. Only add them earlier if there is a functional necessity.

5. Use construction lines to make sketch relationships easier to analyze.

6. Use cross part sketches only for strategic relationships. These are powerful in creating
associativity across parts but can add complexity to making changes in your design.

7. Use silhouettes only when absolutely necessary. These are highly depended on the sketch plane
and its orientation to the source geometry. Large changes can have unexpected results.

8. Turn off “show constraints” when done. The visibility setting of constraints is remembered and
you might surprise someone when they go edit a model of yours, activate a sketch and all the
constraints appear needlessly.

9. When importing DXF and DWG (remember you can copy and paste in R11) data use the Auto
dimension command. Uncheck the dimension optional and then press the apply button until the
number of constraints needed stops changing. You might need to click apply three times for this to
happen. Now you should have a much better constrained sketch to start with and need fewer
dimensions to finish fully constraining you sketch.

10. Less is more. Don't overload a sketch too much. Think 20 sketch lines and 3 to 10 dimensions
per sketch. This helps break the model up into manageable pieces and makes editing the design
easier.

11. Rename key features in the feature tree. This makes it easier for another user to find and edit
features.
12. Use user defined parameters for common dimensions in a part where applicable. For example,
if a typical wall thickness is to be used in a casting design, define a parameter called "wall" and
assign that value to applicable dimensions. If during the design process a universal change in wall
thickness is required it becomes a simple change of one parameter and hitting the update button.
This can also make it easier for downstream users to quickly identify the key design parameters.
13. If the parameter has a value restriction (only + or - 1 or 0, 90, 180, or 270), make sure to
describe the proper use of the parameter in the comment field. If you use an external source, such
as a spreadsheet, to feed parameters to your model, make sure to note both the spreadsheet and
model so that they reference one another. Add tolerances to model parameter if you know them.
14. Use equations. For example, rib thickness is generally a percentage of wall thickness. Instead of
applying a discrete value to a rib's thickness, make it a function of the wall thickness dimension.
Better yet, create a parametric value to do this (see tip above) and use it for the rib thickness. By
doing so, if the wall thickness is changed, the rib thickness will change accordingly.
15. If the design is quite complex, use the Engineer's Notebook to document what/how/why
you've designed the way you have.

16. Avoid parent/child relationships between features. Unless necessary, avoid starting sketches on
part faces or projecting feature geometry. Instead, use the origin geometry or work geometry
based off the origin geometry. Critical relationships between features should be obvious and
logical so that changes to other parts behave in a predictable manner. Objects to avoid creating
relationships to:
- Faces and edges of chamfers and fillets
- Features in a pattern or mirror, unless it's the parent feature(s)
- Edges or seams of non-analytic surfaces (like swoopy curvy surfaces from loft)
- Non associative cross part projected sketch geometry that is fixed or grounded
- Grounded work geometry
17. Name your features if they are critical or commonly edited. Naming construction geometry will
make working with the model significantly easier and should be done as often as possible.
18. Add cosmetic features like decals and embossed text at the end of the feature tree.
19. If a group of features are all relative to a point other than the origin, or at an odd angle to the
origin planes, create a common set of work geometry (referenced from the origin) to act as a
pseudo-origin point. Build the features relative to this pseudo-origin
20. Avoid unnecessary features and work geometry. They increase file size, clutter the feature tree
and slow down the program. This is important when working with complex parts. Strive to have a
clean, efficient, stable and logically ordered part as your finished product. Downstream users
(sometimes, that's even yourself) should be able to understand and edit it as easily as possible. A
minimal investment of time and effort during model creation will pay off greatly downstream.
21. Don't take shortcuts. Edit features to make changes, use grips to help speed up finding the
feature and dimension to change. Common examples to avoid:
- Do not fill in holes to remove them. Delete the hole and repair if needed.
- Do not stack extrudes on top of one another to make a part longer. Edit the dimension.
22. When possible pattern features rather than sketches. these are easier to edit and understand
23. When making large sweeping design changes to a feature, drag the EOP to right below the
feature you are about to hack. Then progressively roll the EOP down and repair as needed. This
approach is faster and easier than letting the model fail massively. If the model does have massive
failures re-read these tips and try to create a more solid model and as you repair it.
24. When filleting difficult models, turn of chain edges to reduce the number of edges that you are
trying to round. Fillet corners with mixed radii and convex/concave solutions first then finish the
other edges after.
25. When e-mail a native Inventor part. Roll the end of part marker to the top of the browser and
save the part. This will decrease your model's size.

26.When possible keep the assembly aligned to the origin and as near as possible. Assemblies that
are far away from the origin or at odd angles can be difficult to work with.

27.Think about what the first part should be in an assembly before inserting parts - better yet go
ahead and mate the logical grounded part to the assembly planes.

28.Group parts in the browser to organize them and make for a logical structure. Rename
components when needed. Be aware that names will not carry if you do component replace. Some
users are confused with browser names that don't match part number or file name. Decide what
you will use in your company and standardize on it.

29.Use assembly construction geometry only when necessary. If you find that you need a large
number of assembly construction geometry than consider learning master modeling techniques.

30.Use assembly features only when necessary. If you find you are creating a large number of
assembly features reevaluate you design approach or confer with an Inventor expert to see if there
is an alternate approach.

31.Minimize the use of tangent constraints. While useful, they can be geometrically difficult to
maintain and can add to unstable constraint solutions.

32.Use the select and find tools to your advantage. Save frequently used views a design views. If
working in a workgroup consider saving you views as a private design view.

33.Use the Degree of freedom tools to help identify under constrained parts that might make a
mechanism not work as intended. The find tools allow you to search for components with more
than x number of degrees of freedom. A good search to have saved is "Find all components with
two or more degrees of freedom."

34.Turn off adaptivity as soon as you no longer need it.

35.For speedier interference checks use the all content center suppressed LOD Rep before running
an interference analysis. It will ignore any tapped interferences and speed up the simulation. If you
only need to check two parts use measure to find the minimum distance between parts, if the
interfere the measure too, will alert you.

36.If a face or axis is a key mating surface Create a workplane or workaxis to assemble to rather
than using the faces. Make these in the part not the assembly. This will allow you to make more
changes later and not worry about assembly constraint problems. It also will allow you more
flexibility when working with advanced techniques like LOD or derive part base master modeling
approaches.

37.If a component is frequently reused and constrained in the same way(s) consider using iMates
or composite iMates to capture these mating conditions. This will save time latter.

38.Turn off contact solver after analyzing contact motion.

39.When mating things that are symmetrical, mate to your center planes, go back to the assembly
plane when practical.

40.Standardize on component properties and be disciplined in keeping them accurate and filled
out. This will make sorting, searching and finding components easier. It will also make filling out
BOM columns more automatic.

41.Create design views and LODs for use when making drawings and presentations. A little up front
work will save a lot of headaches later. Use these reps associatively in your drawings and
presentations.

42.Use the global visibility overrides for quick visibility changes only. Leaving these on can cause
planes, sketches, welds and other critical design features to not display causing confusion. A better
alternative is to use public or private design views.

43.Align views to one another to make moving views easy

44.Whenever possible use associative design views. When creating views.

45.Recover work geometry and dimensions to save you time annotating. The work you put into the
model and tolerances is most valuable on the drawing and saves you time.

46.If you need to create construction views, place them on a non printing sheet rather than off the
border, or on a hidden layer. It makes working with the drawing easier.

47.Spend the time to make and keep up to date your style library. Ensure you have styles for your
most frequent types of annotations.

48.Unless you have a company standard that requires otherwise, try to keep one part or assembly
to one sheet in one IDW. This simplifies the relationships between drawing and part and protects
you should a drawing get lost or damaged. You will have significantly better performance too.

49.Create a library of symbols and add these to your template. Saves you time having to redraw
them every time.
50.Fully constrain your section and breakout view sketches. This will ensure that they update
correctly.

51. Always anchor your detail views. This will ensure that they update correctly and move with the
important geometry. (Thanks Quinn)

51.If you are making many changes to a part design, open the drawing and leave it in the
background. You will find that the drawing may update faster and more reliably then having the
drawing go through one massive update when you open it later.

53.When creating leaderless annotation or notes on a view, make sure that you first create it inside
the view border. This will associate the annotation with the view and it will move with the view.

54.Use property values in Title blocks rather than prompted text. It makes the drawing title block
much smarter in the long run.

55. For drawings that you are archiving, set defer updates to on to be sure that the drawing does
not update.