SHEET METAL

SHEET METAL CUTOUTS

 SHEET METAL WORKFLOW
Content : ESTABLISH BASIC PARTCHARACTERISTICS
DEFINE THE BASIC SHAPE OF THE PART
CONSTRUCTING BASE FEATURES
SHEET METAL CORNERS
SHEET METAL CUTOUTS
SHEET METAL DEFORM FEATURES
FLAT SOLID AND FLAT PATTERN
ADVANCED SHEET METAL COMMANDS
ANALYZE FORMABILITY – ONE STEP
AEROSPACE SHEET METAL
WORKING WITH NON-SHEETMETAL DATA
SHEET METAL CORNERS

Purpose
Creating different types of sheet metal cutouts is
an essential part of designing usable sheet metal
parts.
Objectives
Upon completion of this lesson, you will be able
to:
Identify the key elements and conditions needed
to create cutouts using the Normal Cutout and
Extrude commands.

Explain and use the options available in the

Normal Cutout dialog box.

Create Normal Cutout features.

 Normal Cutout
• Sheet Metal cutouts let you create unique shapes that define material to be removed from a formed
or flat solid sheet metal part.

• Cutout features are generally added to a sheet metal part after all bend geometry has been created.

• There are two methods for creating planar cutouts:

• Use Normal Cutout to create cuts by projecting a sketch onto the model and then cutting
perpendicular to the faces intersected by the projection. The thickness faces always maintain their
perpendicularity to the top and bottom faces of your part. You can create cutout profiles with planar
sketches or 3D curves.
 Normal Cutout

Normal cutouts are particularly useful when you want to make cuts
across bend regions The feature is also useful when you need to
unbend and rebend sheet metal parts, because non-perpendicular
thickness faces created with Extrude- Subtract may be deformed
during Unbend and Rebend operations.
 Normal Cutout

• Use Extrude to create a cutout that is normal to the plane or

surface the profile section curves were created on.

• The extruded body cutout allows you to create the extrusion in

two directions as well as to place draft on the tool solid.

• However, you will not be able to maintain a constant sheet

metal thickness if the section curves are not created parallel to
the faces you wish the cutout to go through.
 Normal Cutout

• Tips for creating Normal Cutout features

• Your section string profile can be either open or closed.

• You can create section curves or sketch on a plane other

than the face that will contain the cutout.

• Overbuild your cutout sections when removing material

that extends beyond the edge of the part. This will ensure
that the resulting edge will be clean.
 Normal Cutout

• Bend Parameter and Relief options are not available, so you should create sketch curves that include
all required radii for your part.

• Linear cutout edges can be used to create additional features such as Secondary Contour Flanges.

• You can use 3D curves and planar curves to create a Normal Cutout feature.
Normal Cutout dialog box
Normal Cutout dialog box
• Type Specifies the way the profile is created, using a planar sketch or 3D curves.

Sketch Specifies a sketch that you select or create on a planar face of the part.

3D Curves Specifies a profile created from three dimensional curves that lie on a part face.

• Section Select Curve Lets you select a sketch or create one when you select Sketch from the Type
list. The sketch must lie on a planar face of the part. If you create an open
profile, you can use the direction arrow to specify which portion is cut out,
and which is retained.

Lets you select 3D curves when you select 3D Curves from the Type list.
The profile can be created using a variety of Modeling tools, such as Curve
on Surface.
Normal Cutout dialog box

• Cutout Properties Cut Method

Thickness compensates for the material thickness of the part by
projecting the profile onto both layer faces, inner and outer (top/bottom),
then thickening the resulting surface into a solid tool, and removing the
tool from the base part.

Thickness cut Mid-Plane projects the profile onto the mid-plane of the sheet metal
part, then thickens the resulting surface into a tool body. Usually, the
Thickness option consumes more material than the Mid-Plane option.
 Normal Cutout dialog box

Limits

• Value lets you define the extent of the cutout manually, either by dragging the depth
handle or by entering the distance in the Depth box.

• Between lets you define the extent of the cutout by selecting two parallel planes or faces.

• Until Next extends the cutout to the first edge encountered.

• Through All extends the cutout through the whole part.

 Normal Cutout dialog box

• The Symmetric Depth check box is only available when you

select Value. This option creates a cut area symmetric in both
directions from the sketch plane.

• In the example below, a single internal sketch was created on a

mid-plane and the Normal Cutout was created using the Value
option, with Symmetric Depth selected.

• If the walls of the part move, the plane, and therefore the
sketch, adjusts accordingly.
Create a Normal Cutout using a sketch

1. Choose Home tab→Feature group→Normal Cutout .

2. In the Type list, select Sketch.

3. In the Section group, click Sketch Section and create the open
section on the XC-YC plane as shown in the following graphic.

4. Click Finish Sketch to exit the Sketch task environment.

Create a Normal Cutout using a sketch

5. In the Cutout Properties group, set the following:

Cut Method = Thickness

Limits = Through All

6. In the graphics window, double-click the section arrow to reverse

the direction of the cutout.

7. Click OK to create the normal cutout.

Summary: Sheet Metal cutouts

In this lesson, you:

• Identified the key elements and conditions needed to create cutout features and tapered bends.

• Became familiar with the options available for creating Normal Cutout and Bend Taper features.

• Created Normal Cutout and Bend Taper features.