How Can I Combine Two Faces that Are Aligned on a Solid Body?

[Fab_Things]

I am trying to figure out how to eliminate the horizontal boundary line between the two highlighted faces.  This line went away on the sides when I got the faces aligned but, the highlighted one and the one on the opposite side still have this line.  I've tried zooming in to see if the faces are slightly off but when using 'measure' it never highlights a second line to select.  How can I combine two adjacent faces like the ones highlighted?  (design file attached)

[Fab_Things]

@TheCADWhisperer,

Yes, the dimensions match my design intent.

What is the reason to use Reference Dimensions for four of the dimensions?

Thank you for offering to make a video - I am so looking forward to seeing it!

You are amazing - thank you for all this help!  👍

[TheCADWhisperer · Accepted solution]

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@Fab_Things wrote:

Thank you for offering to make a video - I am so looking forward to seeing it!

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@Fab_Things 

[Fab_Things]

@TheCADWhisperer  Thank you for posting this video!  I will be watching it - multiple times I'm sure 🙂  Been out an event most of the day.  Will be studying this later tonight or early tomorrow morning!! 👍

[Fab_Things]

@TheCADWhisperer 

Thank you for this great explanatory video - it is very easy to follow! 👍  I watched it a couple of times already and have it bookmarked to reference as needed in the future.  The dimensions and alignment in my design are a bit peculiar because they are for a specific arbor press - I was surprised when I took the measurements of the arbor press myself.  I triple checked them and even 3D printed test-fit pieces to further confirm the measurements. 🙂

The last design feature I'd like to understand the proper way to design, is the fillets on the top surface of the bending die.  It is currently filleted on all 8 edges.  I need it to be on just 2 edges as in this screenshot:

The way I did it in the screenshot is to split the body into 3.  Then fillet the 2 edges you see above on the middle body.  Then combine the 3 bodies back together into 1.  Is this process the correct way?

[TheCADWhisperer]

@Fab_Things 

I will not be at my Fusion machine for several hours, but rather than Fillet, I would do an Extrude -Cut of the profile needed to remove that material.

The question arises “How will you manufacture that feather?”  Might have to also Revolve the ends to replicate the cutter.

[Fab_Things]

@TheCADWhisperer 

Yes, understanding the tooling limitations to factor into a design is an area I need to study.  Can you recommend a good website or book that covers this?  I enrolled in an online course that I am half-way through at the moment but, I am seeing some disconnects between what is being taught and what is best practices when designing parts.

When you have the time, can you teach me how to do the extrude -Cut method vs. the Fillet tool?  Would you create the sketch profile above the area to be cut, extrude that sketch to the width of the cut you want to make, then extrude (-cut) it down to the surface of the cutting die to remove the necessary material to achieve the intended radius?

I am not sure what to consider regarding "replicating the cutter" as any designs I do, I send out to have made.  Are there certain standard questions I should ask the manufacturer I send them to, to get an understanding of what needs to be considered?

And, of course, I am curious about "revolve the ends" and how to do that!  I have used the Revolve tool when designing wheel spacers - that is my only exposure thus far to that specific tool.

[TheCADWhisperer · Accepted solution]

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@Fab_Things wrote:

When you have the time, can you teach me how to do the extrude -Cut method vs. the Fillet tool? 

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Examine the Attached by going step-by-step through the timeline.

I also converted the pin to a separate component.

[Fab_Things]

@TheCADWhisperer 

Thank you!  I followed what you did in the new file.  What is the benefit of having the pin be its own component vs. the way it was initially designed?

[TheCADWhisperer]

@Fab_Things 

Will this part be machined from metal, or will it be injection molded from plastic?

It is very easy (cheap) to drill a hole and press in a dowel pin.

It would be very difficult to machine a cylindrical feature (prohibitively expensive).

I recommend that you take a beginner machine shop class at local technical school.

I just realized that I made the pin slightly larger for a press fit.  Assuming your pin has to be a certain diameter it would be better to make hole slightly smaller instead.

If possible, use an off-the-shelf pin size.

[Fab_Things]

@TheCADWhisperer,

It will be machined from tool-grade steel.

Thanks for the recommendation on the machine class.

When you design a component to be press fit, do you need to make the
press-fit component the identical diameter as the hole or 0.001 bigger with
ribs where it will mate with the component it's being pressed into?

[Fab_Things]

@TheCADWhisperer 

Thanks for the clarification 👍

I truly appreciate your help with my questions on this post and others - thank you! 👍👍