Fillet or chamfer won't generate at fused bodies

[infoFU88V]

Hi everyone,

Hope there's someone here who can help me out. I have this weird problem that I've been struggling with now for days, and I can't get it resolved. I have this design where I combined some bodies into a complete structure, but at one intersection I just can't get a fillet or chamfer. I have no idea why this happens. The structure there is hollow, and I can get a fillet on the inside of it, just not on the outside. I've tried all the settings as the system suggests, but to no avail. Thanks in advance for your help!

Michel

[davebYYPCU]

The intersecting curve is not smooth, that body has no sketches, best guess is that the profile involved is not smooth / tangent, in the original.

Might help.....

[infoFU88V]

Hi @davebYYPCU,

Thanks for you help, mush appreciated! I'm still learning to do analysis like that. I had seen that the curve wasn't smooth, but without doing such an analysis I just hadn't realise it was that bad.

I've also found the cause as well. The curved part is basically two lofts to create the outer and inner shape (I needed varying wall thicknesses in the part). And I found that on the outer loft the rails were, well, off the rails so to say. After some adjustments making the rails symmetrical, redoing the loft and re-fusing the parts I had no problems generating a fillet between them. 

Every day is a learning day! 😉

[TheCADWhisperer]

Does CTRL b or CMD b return any unresolved issues?

Are all sketches fully defined (no blue lines or white dots)?

Should this line be horizontal?

Should this line have a Midpoint constraint to the Origin?

Some unusual stuff going on here...

Checked in Autodesk Inventor Professional -

This looks like a major issue...

Go into section view and examine this area too...