4-1 Merge Collector Not Coming Out Properly

[mmicciolo]

Hello All,

I am trying to create a 4-1 merge collector. I can create the individual pieces. I am using 6" long pipe, 2" diameter, 11 degree intersection angle and cutting 270 degrees off of each pipe so that 4 x 90 = 360.

The pieces come out fine, but for some reason when trying to join them together into the collector, the last one never fits correctly.

Measuring each individual piece i get 90 degrees, but when two are aligned it reads 148 instead of 180.

Im not sure what I am doing wrong? Is it just an alignment issue?

Attached is a screencast as well as an attachment of the project.

[davebYYPCU]

They fit, but no idea if the angles are the required angles.

Mirror, twice.

measured angle is 149.8, but certainly misalignment for the cutting plane.  

Might help....

[mmicciolo]

Thanks for the help!

So you're saying that my cutting plane (one created from the hypotenuse of the triangle in the drawing) is misaligned and causing the cuts to be incorrect and thus causing it not to fit together correctly?

[davebYYPCU · Accepted solution]

Yes, it is in the setting out, and or the way you are misusing the end face of the tube to measure.

This file has the mirrors working correctly, Origin planes used for the splitting.  Neat and tidy, edit the angle in Sketch one to the angle you need, and all will update.

Currently it's set at 160, it looks a bit narrow.  Play the timeline....

File attached, 

[chrisplyler]

I humbly submit that geometrically, the 90-deg angle you measure here...

...is not desired. I made a collector that fits correctly, and I did not get 90-deg at the same place.

You want the 90-deg between the CUT FACES, which angle measurement is on a different plane than the one you made at the end of the tube.

I'm attaching my file. Follow the time line.

[mmicciolo]

Thank you everyone for the help!

My end goal was to make a 5 cyl collector, but I wanted to learn a 4 cyl first and now after seeing how a 4 cyl is done I was able to make a perfect 5 cyl one!

Thanks!

[davebYYPCU]

Sweet, we like success stories.

[tomas.fober]

Hello, found this topic. I want to made something similar as mmicciolo, . Could someone please just write what is the correct procedure how to design it? 

Thanks in advance

[davebYYPCU]

Download my previous file, follow the steps I took, while you substitute your own dimensions.

If that doesn’t work, you need to stop when stuck, and explain why you are stuck.

Might help....

[tomas.fober]

I have it, but why is there an 160 angle and 45 degree angle, whilst 4 cylinder has 90 degree between each cut on the band saw. On 5 cylinder it should be around 72+-. Or you mean it as 45degree + 45 degree = 90 ?

I already change diameter on pipe to 38mm and 3mm thick and change lenght of the tube to 100mm. But i cant add another 5 tube...

[TheCADWhisperer]

@tomas.fober 

Can you File>Export your *.f3d file to your local drive and then Attach it here to a Reply?

BTW - when a thread has already been marked as Solved - it is probably best to start a new thread discussion with a link back to the Solved discussion as reference.  And always, always , always Attach *.f3d files, image files, and Screencast Recordings to illustrate your issue.  We are probably more geometry driven than mere word driven around here.

[tomas.fober]

I use both files. One from davebYYPCU and second from chrisplyler. The second one is now actually 5 cylinder but inside merge it looks kinda wierd 😄 

[davebYYPCU]

Yes kinda weird, cutting a 5 way pipe with 4 way cutter.

This sketch is 72 degrees, on origin plane.  

Cut Component 2 with this sketch (Split Body) remove inside piece, then pattern.

(Picture is timed out - not uploading)

Might help.....

[kostas_kritikos]

Hello, I am working on a 4-1 merge collector design, with the intention of CNC producing 2-3 of them.

This is part of my Fusion 360 self learning. As you can see in my attached files, my draft is far away from final.

My biggest issues are:

• The 4 pipes that merge together have their top sides all flat on the same plane.
• Unrealistic to cut in a CNC machine for obvious reasons

I know how to do the threads in the holes, I know how to do a pipe at an angle. But I am not sure how to get 4 planes at the top 4 corners of an imaginary rectangular, in a way that would be like the finished product I am attaching as an example. Also the design has to be what realistically can be cut from a piece of steel, so any suggestions on how to achieve something like that one in the photo?

Thanks in advance

[davebYYPCU]

The example photo, the top faces are square to the straight pipe centre line.

draw the centre line at the angle the pipe has to be, and Pipe Tool will do the example.

Your attempt looks like a Lofted pipe, bent or swollen, not sure.  If you have a centre line, use Plane on that path, to split body the top section.  Doesn’t like good for a thread on your attempt, should be round.

Attach the file for more accurate instructions.

Might help.....

[kostas_kritikos]

I have made some progress. Thanks for the advice.

I am using "loft" as the opening in the flange is oval.

When I tried the "pipe" function it would leave some gaps between the pipe and the oval opening.

Not sure if there is another way to do it.

Now ideally I should fill in the deep point between the 4 pipes merging, for easier CNC machining.

Question is how?

[davebYYPCU]

Did you really want to shell the inside of the plate?

Not sure how you would fill the the centre intersection, depends on the fluid flow intentions.

Might help...

[kostas_kritikos]

Not sure how I managed to do this. I noticed it earlier myself.

I will try correct it tonight.

Any ideas on how to fill the area between the 4 pipes on the top?

Also with this design, is it possible to change easily the angle of the merge pipes, without having to edit the sketch of the top plane in order to change the size of the "imaginary" square that defines the centers of the merge pipes?

[davebYYPCU]

Edit the pipes as you need it, and make one of the pipes first, as new body then

I would use 2 mirrors on the first loft. (Join)

Make the plate as New Body,

and Combine cut the pipes out of the plate. 

Then shell top and bottom faces of the pipes,

combine Join the plate to the pipes.

Fill the top with a Boundary Fill, for a plane on top face, but not sure it is what you mean. 

Fillet as you wish.

Might help....

[kostas_kritikos]

Hello, I am back to working on this turbo exhaust manifold.

I am using standard dimension pipe parts (90 degree elbow long & short radius, 45 degree elbow), which I modelled myself from available drawings.

Is there a way to automatically adjust the angles of the joints on the header so that these 2 pipe surfaces become parallel?

I tried to manually adjust both sides, but it could take forever! Too many combinations of relative angles between each pair of jointed pipes.

If this is not possible, then I will have to design the merge collector against the 4 pipes coming down.

Just wanted to know before I go down this path.