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Lofted flange unbend, won't rebend

Legend
Legend

A coworker had mentioned this issue coming about when we upgraded to ST7 last year. Is there a different approach you folks take to make a similar round to square lofted flange? I've never really done a part like this before with Solid Edge, so I'm open to any suggestions.

 

All you have to do it take this part, flatten it out, and then when you try to rebend, it fails.

ST8 MP9
Go FAST, or go home.
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