Another day, Another problem, shell/fillet

[ruudmolenaar]

Hi, it's me again;)

Something is not working out. 

I've included my current model. 

Shelling the bodie is my end goal (+/- 4mm), all kind of errors come up when I am trying this (also big thicknesses won't work). Probably because of some nasty edges. 

So I wanted to use the fillet tool for these edges, I'm used to, that this won't be a big problem (with SW). 

But I'm having a hard time at the moment to get it done.

So to conclude, I've two questions:

1. Is the shelling not working because of these small edges and stuff?

2. What kind of fix do you suggest? 

Hoping for some feedback, will be much appreciated!

Thanks in advance!

[jeff_strater]

I suspect that the problem is the "side bumps" on this body.  Specifically the area where they almost meet.  Some of the geometry here looks pretty small, and likely to give Shell problems:

I did test rolling back before Combine3 and I can successfully shell the main body, so that is OK:

I'll play around a bit more to see if I can make some adjustments that will let Shell succeed

[ruudmolenaar]

"I'll play around a bit more to see if I can make some adjustments that will let Shell succeed"

Thanks a lot! I'm also trying stuff, but didn't worked out yet. 

Hope to hear!

[jeff_strater]

@ruudmolenaar ,

I did find that if I introduced a gap between the side bodies, I could shell the result:

I don't know if that is an option for your design.

The other approach I looked at, but is very complex to do is to shell the side bodies separately, and then try to join the whole thing together, but it requires a lot of body splits to make it work:

[ruudmolenaar]

Thanks Jeff,

Really appreaciate it.

I'm going to choose one of your options.

Thanks again!

[JamieGilchrist]

Hi ruudmolenaar,

I think I may have figured out another way.  if Jeffs approach work for you, great.

Two things I did different.

1.  I built the "dentils" as straight extrusions, but built them between two objects, an offset plane and your main body.

   (built them one at a time with the outer fillets between each extrusion, if you look at the attached f3d, I think you'll see how I did it.).  This gave a nice, clean intersection/join with the main body.

2.  The problem area is where the rounds at each "finger" intersect to a point and the shell command does not like this geometry, so I put a filet in there at those sharp creases of .05 mm and the shell worked at 4mm

I've attached a file with my approach interjected within your timeline.  Take a look at the 15 or so features before the end of the timeline marker to see how I approached this.  (arguably I did not optimize my approach for the most efficient modeling practice, but you should see where this is going.)

now, whether or not the interior of the shell meets your design intent or needs is a question I have?

[ruudmolenaar]

Legendary mate!

Works like a charm! 

Thanks!

[ruudmolenaar]

Your solution worked out pretty good. 

But sometimes there where still errors.

In the end it work out the best if I did it like this:

1. I built the "dentils" as straight extrusions, but built them between two objects, an offset plane and your main body

(like you did)

2. Each extrusions is a new body

3. Shelled each new body

4. Combined all new bodies ("the dentils") and the main body.

 

5. Extruded cut to combine shelled main body and the shelled dentils

Thanks all for the help.