Step 1.
I created a flat piece of metal in Inventor's Sheet Metal tool. This serves as a 'generator' for my I-feature. I like to create parts who live only to create I-features for me. It allows me to go back and try again if I make a mistake the first time. Make sure you use a Point, Center Point in your sketch or the punch won't work!
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Step 2.
Next I draw my 'Footprint' for my punch. In this example, this is also going to be the simplified representation for my punch. You'll also note that I set the circle's offset to be equal to the material thickness. This will allow the emboss thickness to adjust to different sheet metal thicknesses.
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Step 3.
I'm going to use Inventor standard modeling tools to create my emboss, so I'm going to go to the Convert pulldown and switch to the Modeling environment.
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Step 4.
With this done, I can now start embossing the outer portion of my emboss.
In my example, I've made the emboss's depth 3 times the material thickness, with a taper angle of 15 degrees. Of course your values may be different!
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Step 5.
Now we need to 'hollow out' the emboss. I'm going to reuse the sketch I created back in Step 2, but first I need to use the 'Share Sketch' tool so I can access it for the next step.
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Step 6.
With the sketch available again, I can use the extrude tool to cut out the emboss. I use the same settings, but only cut 2 times the material thickness for the cut (so we don't cut out the bottom of our emboss).
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Step 7.
With the Emboss nearly completed, we can break the sharp edges with the fillet tool. Notice that I used the Thickness parameter again to keep my emboss thickness consistent.
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Step 8.
With this completed, I renamed my sketch to 'Footprint Sketch'. This isn't absolutely necessary, but it helps find the sketch when we need again a little later.
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Step 9.
Finally, we get to go to Tools>Extract I-feature and create the I-feature!
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Step 10.
Now that the Create I-feature dialog box is up, make sure to choose the punch option. Notice the following:
a) I added the diameter as one of my size parameters (so I can change the diameter of my emboss). You can add as many or as few parameters as you need.
b) I used the 'Footprint Sketch' in the foot print option.
c) Make sure you add all the features you need, in this case I have two extrustions and the fillets. You can also add the features by picking them from the browser. It may be easier that way.
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Step 11.
Save the punch, and now your ready to go use your punch in your designs!
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Happy Inventing! I hope everyone enjoyed the CAD Summit, and that this post is a useful extension to the event!