How to model sheet metal part in different bend states

[rhudd]

Certain bends of a sheet metal part will take different angles depending on if it is pre or post installation. I want to model and draw both states. 

I don't want a family table as this will create two part models when in reality there is only one part.

I tried simplified reps. I modeled the pre-installed state, then an 'unbend' feature, then add new bend features to set the installed angles. I planned to use simp reps to enable/disable these features as required. However, I'm unable to add new bends in the same location as unbent ones.

Any ideas how I could tackle this would be appreciated. 

[tbraxton · Accepted solution]

Having a single model as a constraint would lead me to suggest using a flexible component. Be advised there are potential issues with flexible components so do some testing before implementing it in production.

Flexible components:

https://www.ptc.com/en/support/article/CS28948 

It is common to have two or more models for this type of scenario. Inheritance features are another option to consider and were designed to deal with manufacturing states such as cast and as machined model variants. Inheritance features supports varied dimensions. This would work to have a single design model driving both variants in your case.

Changing the bend angle in your scenario seems to be the simplest way to manage this rather than adding features.

[rhudd]

Thank you 😀 I wasn't aware of flexible components, they appear promising. I will test before implementing. 

[StephenW]

I would agree with @tbraxton. This is the primary purpose of flexible modeling and is pretty much your only "one model" solution.

Just to be clear, family tables are "one model" but in windchill they apprear as 2 objects (and file open depending on your settings). I don't like family tables much either but they occasionally come in handy for certain scenarios (mostly families of parts).

Using simplified reps for variations are a recipe for a growing level of frustration. You have to actively manage them and then you have to make sure all your coworkers or "others" who use your models have to know what each simplified rep means and does. Simplified reps are good tool for large assy management and now an alternative tool for sheet metal flat states but not so much for other things.