3 tube intersection, notch

[dwoodville]

I'm trying to build a chassis for an offroad vehicle and have multiple locations where there will be 3 tubes intersecting each other. Since I want to send my files to get laser cut and bent I need to notch the tubes for welding. I cannot seem to get the attached scenario to notch properly. Normally I split the face of the tubes and then press/pull the wall thickness where I split the face and I've got a nice notch. I've been scratching my head and trying for about an hour now and can't seem to get this to work. In the attached example there are 2 tubes that are mitered at a 90* angle and those are fine. The 3rd tube that is intersecting those ones is what I'm trying to notch. Help! Please!

[davebYYPCU]

Cutting is not the hard part, the result may not be what you wanted.

Might help....

[dwoodville]

I've attached a photo of how the cut should be in order for the tube to eventually be laser cut. So while yours achieves a cut it wouldn't work in the end. 

[davebYYPCU]

Ok.  Not Pipe. 

Extrude Surface to object (body2), @ inside diametre, thicken for wall thickness.

Might help

[dwoodville]

I'm having a tough time following along with that. Any chance you can do a screencast? Or provide a few more in depth steps. 

Thank you for the help!

[davebYYPCU]

I have now removed the 1st and 3rd pipes from your timeline.

Created a sketch on the vertical line, for the inside diameter (the other pipe, is 1.51mm?)

With  Surface Extrude, extrude the circle to Object and object selected is body 2. (colour reversed for demo)

Thicken this surface 0.12mm to finish as 1.75 diametre.

All bodies are visible, you can hide or remove the surface body now.

Might help....

[dwoodville]

I really appreciate the help you've provided me and the solution. Some of the tubes I'm trying to notch are already existing, already extruded and they are intersecting other tubes already. I suppose I might be able to press/pull the tube back, then try doing what you suggested. 

[dwoodville]

Ok I tried doing it but now what I'm running into is that my intersections contain multiple components or bodies. In the example you provided the Body you extruded to was just one body. When I'm extruding the surface it only allows me to choose one body and not multiple. 

[davebYYPCU]

Then you make dummies that are combine joined to a single object and remove / split them afterwards.

If simple repeating geometry there may be other methods.

(body 2 was a single pipe as supplied)

[noneyabidness]

I did hundreds of these joints with Solidworks for a handrail project using the Ruled Surface command twice on the pipe edge and then using those surfaces to cut the pipe. I accomplished the same thing with Fusion and the tools were nearly identical except in Solidworks it would allow me to not just trim the body into two pieces but delete the portion of the body that I no longer wanted in the same feature. Solidworks Weldments is a tool sent by the gods. Frame Generator in Inventor didn't even compare. Take notes Fusion team...

See the attached file but beware that the rollback in the timeline seems buggy and breaks the features sometimes? roll back the timeline and take it step by step and see how the trim body creates multiple bodies and leaves you with the one that you want. This created beautiful perfect fit-up joints that the welders loved.

The ruled surface feature is creating a plane that is perpendicular at all times to the tube axis using the selected edge. This has to be done twice to get the desired result. 

If you think it's tedious, try several hundred joints...

[davebYYPCU]

I'm confused, you do this for a 45 degree mitre cut?

How was that face manufactured in real life?

[noneyabidness]

I'm not sure what you're asking. I use this method for modeling any copes and miters on the project. 

I only created that file to demonstrate how to do the ruled surface trimming to represent how some lasers or high def plasma tube cutters can only cut perpendicular to the tube axis. I then sent all of the step files for all of the individual tube bodies to the vendor who needed it model this way so they can use the outer edges of the miters and the copes to drive their toolpaths..

I am only trying to show you how to modify the final real-world final product for laser or plasma tube cutting.

[davebYYPCU]

I know what you did, and why, 

I did not see a need for a mitre Cut, 

but you answered the other question, vertical cutter and rotary axis.  Thanks.