Error Message When combining bodies - inconsistent graph vertices

[oldtbone55]

@cekuhnen

Hello Class, hope this message finds you and your family doing well. I need your help with a problem I've run into. I'm getting an error message when I try to combine two bodies to perform a cut. I'm using one body as tool that I created from a Setup in CAM as my die to create a jig for a second operation for the guitar neck that I was working on. The original imported mesh file was an .stl. I edited the mesh file to reduce the number of faces to under 10,000 before I converted it to a b-rep. I did have to move this body over in order to align it with the jig stock I wanted to combine it with. I've attached a screen shot as well as the file. I know you are extremely busy but I would greatly appreciate any help you could provide. I'm so close to finally making this guitar neck a reality and could really use some help.

Best Regards. 

[daniel_lyall]

Just take a guess use the presspull command to move the faces out, then jump back to cam simulate it if it needs more move it out some more. 

Have it so it looks like just to much at each end, (the other end you use the move command to do it by selecting move faces) then if it's too much do a 2D contour to take some of when you make it.

If your design does not change you should only have to make it once.

[oldtbone55]

@daniel_lyall

Hey Daniel, I've resized the jig so the clearances between it and the Op2 are much smaller. I came up with a way to do it that I think gives you a bit of an easier way to do it. I saved the Op2 stock as an stl file and imported it. I was then able to take a measurement of the length of the remaining end stock and use it to extrude the end stock of the jig the same distance plus another 0.005 to provide enough clearance. Before I did any of this I put the jig stock back to it's original length. The other end of the jig was done in the same way. This method gave me a lot more precision. I've attached my file. I hope you find this useful.

Best Regards.

[daniel_lyall]

If you zoom in close it's overlapping a little bit, what is what you wont if it's the other way it's scrap.

It will be close to bang on you may just need to take a hair more of it what you can use a contour cut to do in one go but make sure you measure the cutter first and walk it in if it takes 5 goes to get it correct so be it, you don't wont instant scrap.

[oldtbone55]

@daniel_lyall

Hey Daniel, been playing around with the file a bit more trying to make the jig better. I decided to try another approach and created a new jig stock then projected the top of the neck onto it and used the Op2 stock stl file to get the clearances and the shape I needed. It did take a bit longer this way than just using the jig stock and the neck body together but it allowed me to get the clearances closer as well as the shape of the jig closer to the Op2 stock, just like the original file. I'd appreciate you having a look at my file and giving it a once over. Another set of eyes is always good. 

Thanks.

[daniel_lyall]

There's a slight gap at the heel end between the two bodies with the light bulbs on

And there's some crashes that need attention 

 

This one it's rapiding down it may not affect anything but just incase.

I would not cut it myself with the gap and the rapids hitting the jig.

[oldtbone55]

@daniel_lyall

Hey Daniel, thanks for the review. I can fix the gap no problem. I wasn't getting any crashes when I ran my sim. I noticed that you run the sim using the Fast mode (3 axis) whereas I use the Standard mode. Is this why I'm not getting any crashes and should I be using the Fast mode instead? 

[oldtbone55]

@daniel_lyall

Hi Daniel, I've closed the gap between the jig and the neck and remove some material where the crash was occurring. I ran the sim in both modes (Fast & Standard) and didn't get any crashes. I think it's good to go but would like you to give it a once over.

Thanks Kindly.

[daniel_lyall]

I can not see anything that will be a problem, I do the sim in standard for some reasion whenever I open a file from you other than this one it's on fast 3 axis.

Just rember to measure the tool you dont wont over size, if it is you will have to compensate for it