Applying Fillets to Intersecting Edges

[tedbradley314]

Hi, I'm creating a sandcast part and therefore need fillets. I'd like my fillets to be 3.175mm.

I'd like to apply fillets to the highlighted edges shown below but I receive an error. File attached. 

 

At a high level I'm aware that it's likely caused by the fact that the 5 edges don't meet at a single point, even though it looks like they do when zoomed out.

I created this approximation using the 0.995" dimension in the "Foundation" sketch. 

 

What's a better way to construct this part such that I can apply fillets? 

Thanks

[davebYYPCU · Accepted solution]

See if this is what you are after.

You have mirrored the Loft, and I will hedge the bet that loft faces don't play well with fillet.

Might help....

[tedbradley314]

Hi Dave, thanks very much for sending this. I looked at the file you sent and the fillets look great just like in the screenshot. However, after spending a bunch of time trying to reproduce your solution, I found that I could reproduce the original fillet problem with your revolve solution (see screenshot 1 below). And I was able to reproduce your fillet solution using the loft (see screenshot 2 below).

The key that made the whole thing work, interestingly, is not loft vs revolve but rather the order the fillets were applied. When you apply the fillet first to the circular edge (1) and then the semi-vertical edges (2) it works just fine. Reverse that and it doesn't work. 

FILLET PROBLEM WITH REVOLVE CONSTRUCTION: 

FILLET SOLUTION WITH LOFT CONSTRUCTION:

 

 

[TrippyLighting · Accepted solution]

Here is another approach:

[tedbradley314]

Yes! That made the fillet cleaner. Learnings:

- order definitely matters in applying fillets

- adding even a small fillet (0.25) between two edges that intersect at sharp angles will produce a smoother/rounder fillet when you apply fillet to those edges