Aha! YES! Exactly what I was thinking of.... a jelly roll for a Li-Ion battery. I sincerely hope you're not working for the same company I used to work for... egad yuck! 
For my demonstration model, I made a long flat strip with some terminal tabs sticking out the top and bottom. The roll-up should show how the tabs align in the cylindrical state.
I have some images to share and I'm trying to document what I'm doing but I keep getting sidetracked. Stay tuned!
Thanks!
-Brian
Cool! I often get off on tangents like that......with the same result. Too bad we don't have the opportunity to work together......yet.
What was the problem you solved, and how?
As a NASA Engineer once told me: ""Thinking out of the box" does not describe you.....you're not even on the same planet!" I liked working with Paul. 
P.S. So, do I get a beer for helping you solve your problem?
But......I thought we were never supposed to cross the threads????
Who ya gonna call?
Ok, so he owes us beers!
Yeah Frank... it's the exact technique I've been trying to document since yesterday. Thanks for letting the cat out of the bag!
The giveaway to how you did it is in the center. Looks alot like a wrap!
Hah! Sorry for stealing your thunder bro. Well, all this spiral talk got me thinking, and since I'd wrapped all those spring trajectories I'd sent you around a cylinder, combined with all that talk about "jelly-rolls", I got to thinking about how I'd never tried it on a spiral of Archimedes and all, and, bada-boom, bada-BING! I was pretty happy, I got the example done in like 10 min. I've never had a use for it, but, I can imagine now people could. He threw me when he said "cylinder", which to me meant exactly that, not a spiral of Archimedes.
Cool! I'll be eager to see the write up, and glad I could help!
P.S. They still owe us some beers though!
Edit test
Note: Editing the reply changes the date of the "original" reply, which confused the hell out of me, especially when you changed your reply above to detail the method. I was like, whaaaa????? Most forums give a separate "edit" date/time, not changing the original. Ok, for a minute I thought you'd designed a time machine instead of simply a large marshmallow-man killer raygun.....
P.P.S. One issue Pro/E has is that the surface must be at least a little bigger than the developed curve you're trying to wrap. If it "falls off", it'll fail usually. This might be the problem you mentioned.
Hah! Beating me up with my own technique.....irony?
Yeah, I'd imagine that with rounding errors wrapping thin sheets where, essentially, the solid created touches itself (in a bad way.....CADsturbation??) as it wraps around could cause failures. If it's layered, perhaps make it a family table where the insulating layer (instance) and the "plate" layer 9instance) don't exist at the same time in the .prt file, but do only at assembly? That way, the solid isn't touching itself (or it'll grow hairy palms and go blind..). Without seeing the actual geometry he wants to create, I'm just guessing, but......
I also, before I created any geometry, set my accuracy to absolute and to the most accurate setting.
Best of luck!
Sorry, I should have been more precise in my question. I have two problems. This is my first.
I need to "fold" the circular ridge onto the rounded cap (basically crimp the cap into place with the circular ridge). I could do this manually, but I'm sure there must be an easier way.
Hi Pum...
I feel like I've been doing battle with the software today. Everything I try seems to have some oddball twist that makes the problem harder than it should be. First, let's deal with the folded edge you need to crimp the rounded cap into place.
Now that I'm writing this, I wonder if I've even done what you need. If you truly needed to FOLD the edge (what's known as a HEM edge in sheet metal), I completely went in another direction. Ugh. We'll cover that in a minute. Here's what I came up with...
First I suggested using a Warp feature to create this geometry. Many of the Warp Tools have a "Marquee" which allows you to select an area of your model to affect with the tools. For instance, you can twist an entire model using the Warp Twist tool... or you could twist just a small area of the model selected using the marquee. I saw at least 3 or 4 of the warp tools that would probably work.
I tried the main Warp tool (which is confusingly also called "Warp"). This could produce a quick estimate of the geometry shown above. However, this tool lacks a marquee feature so it kept wanting to modify the entire model and there was no way to stop it. I had to eliminate this tool.
Next I tried the Warp Sculpt tool. This produced good results... and makes a very realistic crimp. The downside is that required an intensely manual manipulation process to achieve these results. The effort required to produce the effect was not worth the time spent. I had to eliminate this tool, too.
Next up, the Warp Spine tool. This allowed me to pick the rim of the tube and manipulate the edge by pulling it inward to the center of the tube while "crimping". Very nice... and it did have a marquee control to limit the crimp zone. However the tool could not be automated. It, too, required heavy manual manipulation and wasn't worth the time spent. I eliminated this tool, too.
I briefly tried the Warp Stretch tool but this did not provide a control to shrink the rim inward (as if it were rolled or bent around the inner cap). Therefore this was the wrong tool for the job and was eliminated.
Finally, I tried the Warp Bend tool which was my original idea for this feature. No matter which way I manipulated the marquee, I couldn't get the right options to fold the edge the way I hoped. Ironically, if I wanted to roll a flat sheet into a tube with a bent edge, I could DO that. I couldn't bend the edge of an already formed cylinder, though. Amazingly, I had to eliminate this tool, too.
By this point I was pretty frustrated. I wanted a simple, easy, parametrically controlled solution. I wanted a solution that could easily be used in a family table OR as a flexible feature. Either of these would provide you with a method of showing the edge before AND after the fold. I assumed you'd need this for drawing and documentation purposes.
As it turns out, there is one pretty easily solution which creates the entire fold in two features. With a simple table or flexible feature, you can show the cylinder before and after the fold. This seemed ideal so I went with it. To achieve the effect, I used a Solidify with Surface Replace option.
Surface Replace has always been (in my opinion) one of the coolest features Pro/E had. It's been around for at least 20 years. What makes this feature unique is that is can both ADD and REMOVE material from the model simultaneously.
I began with a simple cylinder. Next, I added a revolved surface representing the folded/crimped geometry. Note that this was a surface, not a regular revolved solid. The edges of the new surface touched the edges of the cylinder (this is a requirement for a surface replacement to succeed). Finally, I created a Solidify feature with the Replace option turned on. Most people use Solidify to turn a surface into a solid extrusion to add material or a solid cut to remove it. The fact that there's a replace option at all often goes unnoticed. By using this option, I was able to trim off the last .25" or so of the straight cylinder and replace it with an equal amount of folded/crimped cylinder all at one time.
Before I go through the slides to demonstrate each step, I figured I'd see if this is even close to what you wanted. If its not going to be of any benefit, it's probably not worth the effort to make the slides. It's still cool... but I want to do something to help you with your problem, not just post tons of slides that don't really offer anything useful.
Let me know if the images above are close... or if you needed something different.
Thanks!
-Brian
