Cuts on Sheet Metal Cylinder

I am trying to add straight cuts down the sides of a rolled cylinder.
The cuts go straight down the length of the cylinder and do not go
through the material. The outside would be similar to full length
splines on a shaft, but much shallower. The cuts are only about .002
into the sheet metal.

I've tried adding the cuts in both the formed and flattened states and
neither works. The rest of the project is done in SW 2005, but I've
tried this using SW 2006 as well with the same results.

How do I add the cuts, or additional material in between, and still get
it to roll/unroll?

Thanks for your help.
dp

 

Copy the outer surface using offset (offset of "0"). Trim the surface
to the shape of the cut, then Cut-Thicken with the trimmed surface.

-OR-
Use an offset surface to define the depth of the cut, the Cut-Extrude
up to the offset surface.

 

That's the damndest thing...I just tried every way I could think of
(unfold, offset from..., etc.), and I either end up with no cut
whatsoever, or it goes through no matter what depth I specify. Maybe
it's just too early in the morning and my coffee hasn't kicked in
yet...

Jeff Mirisola, CSWP
CAD Administrator
HySecurity Gate Operators

 

That's the damndest thing...I just tried every way I could think of
(unfold, offset from..., etc.), and I either end up with no cut
whatsoever, or it goes through no matter what depth I specify. Maybe
it's just too early in the morning and my coffee hasn't kicked in
yet...

Jeff Mirisola, CSWP
CAD Administrator
HySecurity Gate Operators

 

That's the damndest thing...I just tried every way I could think of
(unfold, offset from..., etc.), and I either end up with no cut
whatsoever, or it goes through no matter what depth I specify. Maybe
it's just too early in the morning and my coffee hasn't kicked in
yet...

Jeff Mirisola, CSWP
CAD Administrator
HySecurity Gate Operators

 

The reason it won't work is pretty simple - by adding a shallow cut and
asking SW to "flatten it", you're asking the software to "deform" a
material plastically, which falls outside the scope of what the
Sheetmetal functionality is capable of at the present moment. It's
kind of like designing a stamped part (for example, a cooking pot).
You can design the shape of the part just fine, but getting the correct
flat pattern is impossible without some other software which can
calculate true material defomation.

You could try a surface approach as That70sTick suggested, or creating
two features separately - one in the "rolled" config and one in the
"flat" config.

 

I tried using a surface with zero offset but when the part is
flattened, the surface remains rolled. Am I doing something wrong?