Fillet not making perfect half circle

[tyroneXJ9TF]

The height of this part is 2.05625" and width is 4.1125". I put a 2.05625"  fillet on the edges but it doesn't make a perfect half circle. 

What am I missing?

[ryan.bales]

Hard to say without seeing the design. You could try a full round fillet but the shape of the object looks tapered slightly.

[tyroneXJ9TF]

This is what the part looks like. The end with one outlet has a height of 2.05625" and the 4 outlet end has a height of 1.6". I am using a variable fillet. 

You can see that the single outlet was extruded before the fillet was applied and is the same width as the middle body but slightly higher.  

[ryan.bales]

I'm not able to see that from the image. Can you upload the design for us to look over? I'll be stuck speculating a lot without it. Full round might work but it cannot be variable.

[jhackney1972]

If you do not know how to attach your Fusion 360 model follow these easy steps. Open the model in Fusion 360, select the File menu, then Export and save as a F3D or F3Z file to your hard drive. Then use the Attachments section of a forum post to attach it.

[davebYYPCU]

Fillet has done what you asked for.  Fillet radius is normal to the Path.

The intersecting faces for that filleted area is elliptical at the duct face.

For a concise curved boundary between outlets on that model, you will need a sweep with Guide rail, or Loft.

Might help....

[tyroneXJ9TF]

Attached is the drawing.

Thanks

[davebYYPCU]

Split body the larger end, then Loft both ends together.

One way to get there, may not be what you want.

Might help....

[TheCADWhisperer · Accepted solution]

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@tyroneXJ9TF wrote:

Attached is the drawing.

Thanks

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A drawing is 2D - that which is printed on a sheet of paper.

You attached a 3D model.

I made some changes to your design - see Attached...

First thing I noticed is that your Sketch1 was not fully defined or making use of obvious symmetry about the Origin...

Version 2 with different Loft weights and Fillet.

[ryan.bales]

I kept the straighter edges and leaned on surface tool to erase, patch and stitch. This is very close to the original shape.

[tyroneXJ9TF]

I need a variable fillet on the sides.
Thanks for the idea though. Being new to CAD this will help further down the road.

[tyroneXJ9TF]

Oh wow! Thanks

[tyroneXJ9TF]

The original issue is still there though. It's not as bad as it was at the start.

Thanks

[davebYYPCU]

I need a variable fillet on the sides.

Considering you can’t use a variable fillet for the result desired, do you have a plan B?

[TheCADWhisperer]

How will you manufacture the real part?

Stamped Metal?

Bent and soldered Metal?

Injection molded?

3D printed?

I would base my design on manufacturability as well as functionality.

Is flow important to you, do you intend to do flow tests?

What do the mating parts look like?

In isolation the design doesn’t reveal much information about intent.

[tyroneXJ9TF]

This part is to be injection molded. Some snap fits will also be put in place. One side of the part's snap fits will be the opposite from the other side as I am only making one part, aside from one part with the hooks and another with a loops. If that makes sense.  

[TheCADWhisperer]

Will the snaps be on the inside or will they be on the outside?

What about Lips and Grooves for sealing?

Will you need the Lips?

[tyroneXJ9TF]

Snap Fits will be on the outside in these general areas. Evenly spaced. 

[tyroneXJ9TF]

Saw that last question after my previous reply. Yes there will be a lip needed. 

Thanks

[TheCADWhisperer]

Are you still going with the triangular planar face design rather than a more smooth flowing design?

(In my latest example - I used only one simple sketch.)

I should tie the Feature parameters to the sketch parameters so that everything updates on edits.