Trying to make a airduct/funnel

[jpmxrider489]

I have been working on this air duct for my drag car. I have got the basic shape pretty much done but I'm getting stuck on the funnel part. I'm fairly new to fusion and just learned basic principles of sketches. Where before I was just doing a bunch of extrudes. Ill attach my current workflow. I was trying to use the loft feature on the shelled surface to make the funnel part. Also, just learned recently that all the lines on the sketch needs to be black. I am struggling to understand how to make them black. I add dimensions and constrains but sometimes it works and sometimes it doesn't. So I'm just not understanding something. In my workflow, you should see how messy the sketch is. Is this why the loft wont work on the shelled faces? The actual body is a little off and I need to push/pull. 

[jpmxrider489]

Did you go back to the original model to do that? Should I start this over? The furthest point of the pipe circle needs to be 2 inches from the locking tab. This is to be able to fit a clamp on the pipe end. The funnel side with the honey comb can be 1 inch away from from the locking tab. 

Are you able to give me a better starting point to attempt this better?  I think im messing up by using surface loft to fill edges? When I use the boundary fill, most of the time there is nothing to fill. When I go to thicken the inside, it cant calculate.

[jpmxrider489]

I have been using multiple printers. I printed this with my newest one and I agree, I definitely need to fine tune. 

[jpmxrider489]

Here is a fresh start. I haven't tested it. But I think this is the correct procedure?

[davebYYPCU]

I used your file, not sure which version, 

Started a new sketch, in the timeline, after your 3rd sketch.  This gave me some sketch outlines to follow but mainly needed a clean look at your 3 very good Mesh bodies.

Tracing the important outlines, from all those bodies meant that there were three distinct outlines and the pipe.  There are 2 straight lines in the bodies outline, so they go first.  Connect Splines Tangent to the straight lines, no creases,  2 point spline lower corner and 4 point spline to close the shape.  Adjust the shape to conform with tangent handles - angle / length.

Will check the new file, but intend to send your/mine back, will review the latest.  Will be using part of the grill sketch, for pattern of holes, not sketched grill.  Generally, if you can Pattern in a sketch, don’t, use modelling patterns.  Way less human work, easier for Fusion.

Might help....

[jpmxrider489]

If you can, use this one for you latest update. This has less on the timeline and is simpler for me to follow. If not, ill go back and try to follow you again.  In the pictures, you can see the fitment from the front side of the bumper.  I need to extrude it down more  off the top of the funnel side. Fitment is a bit tighter than I want. From pipe up to the middle loft ( just under the tabs is perfect. 

 

 

[davebYYPCU]

Sent PM message, here is my attempt without tabs.

[davebYYPCU]

Updated file, turn on eyeball for meshbody2, all will make sense.  

Might help.....

[jpmxrider489]

I added picture of the related bumper. 

 

[jpmxrider489]

I wasnt able add on to your duct for some reason. I think because I had to unstitch it.  But I attempted to recreate what you did by using your simple sketches and using patches. 

How did you get the tabs to look different? I tried a taper extrude but threw it off.

Is this what we were going for?

[jpmxrider489]

I tried to get the form correct. I found that the left/right loft further out than the top/bottom. When I go to thicken it to my 3mm, it wont let me. What is going on now? 

[davebYYPCU]

Best I can figure it out, you have these new outlines in the front area of the duct.

Shell / Thicken will fail when each of these intersections are not Tangent connections, in this sketch.

I would also worry about this blue ring, (would not be needed in my loft.)

Might help.....

[jpmxrider489]

I ended up and removed some constrains to add the tangents. Is this what you were referring to? Still having issues with the thickness of it. 

Ill address the ring I fix the tangents.  

[davebYYPCU]

If I make the Loft tangent to the pipe, then the Thicken fails, but as a connected set of profiles, the inside Thicken works.

I used Sketch 13, but not sure if that is correct.

That sketch has so many individual curves, that not many are tangent connected.  A cleaner sketch will make Fusion happier.  Black edges in this pic, are from curves not tangent.

Might help.....

[jpmxrider489]

That did help. Now when I added the tabs, it fits on the lip of the bumper as planned. However I believe the blue ring needs to be there as that is the form of the hole or else there is a large gap/empty space that needs filled. The blue rings the area that I believe keeps it firmly in place. Hope that makes sense. I wasn't able to grab pictures unfortunately.

[davebYYPCU]

Adding material inside the duct, is why the Shell / Thicken gets crankier.

You can Join that external spacing material to the tabs, and or the duct, but has nothing to do with inside the duct.

I am thinking a solid external filler spacer, will prevent the fibreglass tunnel from distorting for Assembly.  Just add holding material to the tabs.

Might help.....

[jpmxrider489]

You thinking two separate pieces physically? Or two assemblies in fusion to combine into one after?

[davebYYPCU]

No, just 1 piece print, push it in the hole and it’s done.  Clamp the pipe to it.

Might help....

[jpmxrider489]

Ill post progress.

[jpmxrider489]

I was able to get it to thicken to 2mm and tried two different types. Body 448 and 466. If body 466 was able to be thicken to 3mm, The fitment would be acceptable I believe. Not sure what I have to change in sketch 13 to make it calculate correctly?

[davebYYPCU]

Added my holding material, as it was hard to describe.  New sketch, Extrude Join to the tabs.

I see that the intermediates are changed, these 4 corners need to be altered to be tangent, but as I don't have your tunnel, I am not sure how much you can change.  

Might help...