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# Difficult Sheet Metal Part

Member Posts: 68 PRO
edited May 27

Here is a tough one. I have the helix below I need to form from sheet metal. I can't roll this with any consistency. My plan is to (see the second picture) project these radial lines to the helicoid surface creating 11 segments onto the helicoid. Then, I'd like to make a line corner to corner in each of the segments to split the 11 segments into 22 triangles. I'd like to then split the surface into these 22 triangle. Then I'll take each triangle, create a plane from the 3 points of the triangle, and replace each face to with its corresponding plane, convert those facets to SM and place bends between the facets. Sounds easy, right? I'm sure it will be a lot of work. I'm having a hard time getting started with projecting lines onto the surface in order to proceed with the face splitting. Any ideas on how to make these projections?

The idea here is to form the features in the press break. The segments will start quite small at the top and end up quite large at the bottom so my radial will likely need to be progressive. I also wondered if having a cylindrical surface around the outside would allow me some advantage. I feel like if I can get the splits onto the surface I'd be home free.

• Member, OS Professional Posts: 423 PRO
This was fun to think about.  I think this is what you are attempting to do.

I tried first creating just a few triangulated surfaces and curve patterning them.  Not sure why but after the second pattern instance, they don't line up by a very small amount.  Ended up just using bridging curves to create flat triangle faces using the points from the curve patterned sketch
• Member, User Group Leader Posts: 515 ✭✭✭✭
Bryan Lagrange

• Member, OS Professional Posts: 423 PRO
@bryan_lagrange
Can you make you doc public?  I want to see your method.
• Member, User Group Leader Posts: 515 ✭✭✭✭
Bryan Lagrange

• Member Posts: 68 PRO
Shawn and Brian,

Thank you both for this excellent guidance. I have a lot to learn. Shawn, you're using Onshape tools I didn't know existed. It's going to take me a minute, but I'll go through both of these approaches feature-by-feature until I understand them. I can't thank you guys enough. This took real effort your part and I'll make good use of those efforts. I'll let you see the final project when we're all done.

Thank you,
Kent
• Member, User Group Leader Posts: 515 ✭✭✭✭