Facing Difficulty with a Punch Cavity Splitting in Fusion 360

[Navy9]

I am planning to make a cavity punch for a rubber part. It has a non planer profile. It also has come holes in the design of the part. I fill the holes with creating a surface on them. Then I crate a surface on the edge of the part which is our parting line. I create a solid box around the part and deduct the part from it, making it hollow in the areas where the part was present. Then I use the Boundary fill selecting all the surfaces created to cover the holes and the Splitting / parting profile surface to the solid box created but it does not work. Here is the download link to the file with the history. Download link
https://we.tl/t-7oTAudy18u

[g-andresen]

Hi,

Please use to share the way via
File > export > save as f3d on local drive > attach it to the next post
and not via an external source.

günther

[Navy9]

File Size is 96mb it wont allow me to attach, any solution to this ?

[TrippyLighting]

You'll have to offset the top faces ( I started and you cans ee the blue highlighted faces in the screenshot) and then stitch that and all the boundary faces into one surface body that can then be use as a single splitting surface. Good luck!

[Navy9]

Hi. Thank you for the solution.

While it worked to some extend but didn't actually yield the results I needed.

So here is the think. The Surface so created could split a solid block in two parts with the boundary fill tools.

But when I combined the Original model from the Solid Block (for punch cavity splitting purpose), the surface so created wouldn't split this and kept showing errors.

Here are some screen shot for your ref. I tried even the splitting tool but same results.

Please guide.

[Navy9]

btw Also the Attempts to Thicken or offset the surface created for splitting did not work.

[TrippyLighting]

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@Navy9 wrote:

btw Also the Attempts to Thicken or offset the surface created for splitting did not work.

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That does not surprise me and is what I would have expected. The model at hand was likely the result of a 3D scan that was re-meshed into a quad mesh and then converted into T-Spline.

There are some inherent problems with such models as their topology is not ideal.

[Navy9]

Your assessment of the situation is accurate, this actually a scanned model converted in solidworks.

Is there a work around this, since making the model all over again with its current geometry is bit difficult.