I'm working on a cart that has UHMW bumper strips on the side. I would like to combine the 3 pieces (2 red and 1 green) into a single piece to create a smooth transition and reduce part count. My plan is to add a groove at the bend locations to create something like a living hinge. I will need to show the part in the flat for the drawing. So I've got some options but would like to get some feedback from others to see how you would do it. The strips are 1/4" thick. Here are some of my initial ideas (I haven't tried anything yet so the methods may or may not work):
1. Model the part in sheet metal (1/4"), maybe a contour flange, use unbend, add grooves, rebend.
2. Model in Synchronous and use its tools to bend/unbend faces. I will need a way to show both conditions
3. Model a 1/8" strip in sheet metal then use part to add additional 1/8" thick "pads" to bring it back up to thickness.
One thing I learned is that I had to:
1. Sketch the inside the bend profile
2. Then offset it back the gauge of material I'm using (.125),
3. Create the contour flange
4. Switch to part
5. Place planes offset to the full thickness of the material (.25)
6. Create protrusions from the planes to "next" - the face of the sheet metal
I had to use sheet metal and part because SE doesn't like it when you try to create grooves that cut parallel through the bends. I created the planes in part at the full thickness becuase I could then play with the material gauge which is really .250 minus the notch depth. This will allow me to change the notch depth and have the overall material stay at .250 thick.