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There's a lot to say here. Spend 4 hours in the car, and you miss all kinds of stuff....
First: @Anonymous - yes, this is a bug. I will log it. Not sure what is happening that makes it forget or ignore the twist. It's a strange one. Yes, this should report a failure in this case (if it is a valid failure, otherwise it should succeed), and we'll have to see what is causing that. Many kudos to @laughingcreek for the super detective work on finding the center hole as the source of the problem. Never would have gotten that in days of staring at this one.
Second: The other advice being offered here is all good advice. You would be wise to pay attention to it. Of course, no one will force you to do so, and you are welcome to model however you want, but the community is here to help, and offer guidance and opinions based on lots of experience in Fusion and in other CAD systems. People like @TrippyLighting , @HughesTooling , @laughingcreek and @g-andresen are experts, they know more about 3D modeling than I ever will. You are getting this advice for free. Again, your choice here. But, here is one example: All the comments about "complexity" and "near tangencies" are all based on experience with Fusion and other CAD tools. Your sketch tries to model a smooth curve with lots of line segments. Presumably, that came from some 3rd party tool to generate gear tooth profiles. And yes, I agree with you: In an ideal world, Sweep should "just work" no matter what you throw at it. But, what those folks are trying to tell you is: Fusion (and any CAD program) will always work better if you use techniques that are known to work well with that modeling kernel. In this case, using splines that are constrained to be tangent to the next curve will work better. Using a profile such as the one in this model produces a solid with lots of unnecessary faces and edges (from the end of each line segment):
This is bad for a number of reasons: First, it is slow to compute. But second, even when this does work, these little faces can cause problems down the road for you: If you 3D print or machine this, those non-tangencies will be visible and tangible. But, also, these can cause modeling problems as well. For instance, Fillet can sometimes fail just because its input edges are almost, but not quite tangent. For instance, if you try to fillet the top edge of this gear. No one expects you to know this, of course, but that is part of the reason why the advice here was to clean this up. It may or may not affect the results of the sweep itself (in this case I don't think it does), but that does not mean that it is bad advice. Perhaps that was not clear from the discussion, but that is what is running around these folks' minds when they offer advice.
Finally, and don't take this the wrong way, but we try to keep this forum as professional and cordial as we can. In general, we try to just help each other, and new users, and keep it enjoyable to do so. I understand frustration, and admit that we all sometimes react in ways we should shouldn't in situations where we are frustrated (me on my evening commute...), but, typing in all caps, reacting aggressively to advice, etc disrupts that nice environment we try to keep here. This is not Twitter. People are more likely to want to help someone who is positive and objective. I admit that there are certain users of this forum that I hesitate to respond to questions for, based on their past interactions. Again, advice you are free to ignore...
Thanks for sharing the model. I'll create the bug and have the team look at it. It is very helpful to report these things. We appreciate it.
[edit] The bug is FUS-58612
Jeff Strater
Engineering Director
@Anonymous wrote:
The issue here was that I wasn't asking for help. I was reporting a bug.
I could have just ignored it and created a new sketch on my own.
Acknowledged!
Bug has been reported!
Now leave!
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