Solid flanges along a curved body

[usafak]

Hey all. Learning Fusion from scratch using exclusively online resources and I have just hit my rock bottom while attempting to model this F-16 main wheel bay for the purpose of 3D SLA printing.

What is really twisting my head are those flanges. I have tried extrude, sweep and loft, all of it creating a new body which is strangely not connected with the mainbody. This results in having issues with the perpendicular flange - loft is not working there as the loft guide rails do not intersect loft face, sweep does not properly match the surface and while trying to use surface as a guide it returns an error. Using project and project to surface to create the guides so my first guess would be it should be properly lined up. Extruding from the main body does not seem to be an option as the extruded body will be incorrectly shaped due to the uneven surface and I was not satisfied with it. There has to be a better way to do this and to do it correctly.

As a second thing, I would really appreciate your advice on how to properly constraint curves and 3D sketches - I remember blue line is not correct and my model is full of them. I would also guess that it may be a reason behind the above errors.

Attaching my model and a photo of what I am trying to achieve. (Note: Without those cables and hydraulics.)

[Pradipio]

Hi @usafak ,

Thank you for posting on Fusion Forum.

I take a look in to the model and images, I understand that it's a bit complicated for you.

However we can fix it but it need some references to create a model. Do we have any other images for parts only?

The image you have attached I am not families with this stuff,  if you give some more clear picture I can help.

Or just add some markups on your created model. that will also helps. 

[Pradipio]

Hi @usafak ,

I did try to create a model with some of the your sketch as a references.

Please let me know in which portion you had a difficulty to create. 

You can download a file from this link https://a360.co/2xR8oNc

[usafak]

Dear @Pradipio ,

thank you so much for your help. There is an incredibly supportive community here on the Autodesk forum.

Your model helped me a lot, still one question remains outstanding. What would be the best way to create those flanges which are perpendicular to the central flange? I was trying the same solution and have used your original sketch and extrude operation to do this. Though I am still getting an error while trying to extend the flange between both surfaces. For that matter, I have made my sketch object shorter to not extend over the projection surface. How can I get the flange connected to the side accurately?

Model and a simple sketch attached.

Kind regards,

David

[Pradipio]

Hi @usafak ,

Here I have created the mirror body as yours on the lofted body.

To create this extrude I did curve projection on the surface and create end profiles.

Then create a loft option to get the exact solid as required.

Please check the attachments and find the f3d model here. 

Please accept the solution if you get it done. 

[usafak]

Dear @Pradipio ,

thank you for your help. Now with the extruded center flange, the loft seem to be working. Thank you very much for resolving that.

Eventually, what I was trying to achieve and understand is to how to get rid of these minor imperfections. E.g. as seen on the below screenshot - they seem to just pop out anytime when using projections. In fact in this case, when reviewing the sketch of this face, everything seems to be fine -> out of sketch, this gap is appearing.

Can you help shed some light into it please?

Kind regards,

DavidImperfection as shownSame corner in the sketch which is reference for the loft tool

[laughingcreek]

just using extrudes, or using lofts, aren't going to keep the thickness of the flange consistent as it travels around the curves.  you can see this rather glaringly in the previous example posted.  I think the easiest most straight forward way is to over extrude the flanges, and trim them to an offset face.  this will keep the cross section thickness consistent over the part.  and make sure all those corners align. example of the process is attached.