What I would like to know is what is the limiting radius in the form tool? It seems that any inside radius that the form tool creates on the part has to be 2x the material thickness (which doesn't make sense because physically you can form the sheetmetal untill the ouside radius is the material thickness). Is this a glitch in the tool, or am I missing something.
I finally got the feature to work by defining the punch to have large radii (approx 4x the material thickness). I think that the problem was coming from the fold at the corner of the sm part failing with the radius on the punch. What I would like is to define the punch with no radius at that corner so it doesn't even bite into the sm at all. But the darn tool fails unless that radii is there. I don't think we are willing to sacrifice tight sm bends to get this feature in, so unless I'm totally screwing this up PTC needs to fix this tool.