Sweep works on 1 hole but not on another one

[joshua.franklin]

Hello, I am running across a weird situation where I can make a sweep cut work on one hole but on 2 other ones it switches to a join instead of a cut and seems to just jump through the body. I have listed the holes 1, 2 and 3.

Hole 1 lets me go 0.010 mm deep and does a recess but holes 2 and 3 don't work. I even make separate sketches to separate them to see if that was the problem. I suspect it has something to do with the base body but I'm at a loss. I am sweeping it along the axis that is currently turned on.

 

[joshua.franklin]

Regarding the flange perpendicularity question, the face of the cases are not normal to the input shaft of the clutch so that is a question for the engineers at Kawasaki. From my experience flanges at angles in the motorcycle world are very common so it never occurred to me to be anything but that. At the end of the day I am just trying to design around the features provided . As you can see in the photo, this is not something that I'm not understanding, its a necessity due to the mating part design.

You can also now see why I'm designing this part based on the very apparent crack on our first try at modifying the OEM part.

[joshua.franklin]

Yes @davebYYPCU, I am working on correcting that as well. Thanks for your input.

[TheCADWhisperer]

@joshua.franklin 

That picture helps a lot in understanding the geometry.

Thanks for responding.

[joshua.franklin]

So how do I get the end feature to be a circle? If I am sweeping it a a certain angle then I am cutting the end at a 90 degree to the axis of extrusion and not making any angular adjustments, I would expect it to remain a circle. I tried to extrude a cylinder at the angle and created a tangent plane along a path. Then I split the body to get the desired length but I am still not perfect circle at the end of the opening. I think I'm missing something basic here. Any suggestions?

Thanks for everyone's help.

[TheCADWhisperer]

@joshua.franklin 

You can use Sweep or Extrude, but in either case the circular profile must be on a plane perpendicular to the axis.

(You could also use Revolve.)

Each time you experience an issue you should Attach the file at it's current state.

[joshua.franklin]

Ok makes sense. I think my issue is that I am trying to extrude along a path. Is there a way to perform that? If I sweep I can get the proper angle but the end of the cylinder is parallel the initial plane instead of being perpendicular to the axis/path. If I extrude I cant find how to do that along a path so I get a perpendicular face on the end. I'm sure there is a way to do this but maybe its through a sweep and that's a new tool to me.

[TheCADWhisperer]

@joshua.franklin 

Files?

[joshua.franklin]

Coming right up. I even turned on the Timeline lol. I think I may have figured out how to perform the revolve but now I need to be able to extend the end of it.

I need the lowest point on the cylinder to be 80 mm from the face but then I need to fill in the other side to make it complete. 

I wish there was a snap to face feature so that I can get an exact dimension without eyeballing it. 

[joshua.franklin]

 I figured it out, Just did an extrude off of the bottom face of the cylinder and now I can perform a split body and delete the remaining part that I don't need. Do you see any issues with that strategy?

@TheCADWhisperer You have been a huge help on this journey and I truly appreciate the insight as well as making me think about this whole thing differently

[joshua.franklin]

Any suggestions on how I would remove the inner area while keeping it uniform? Maybe some sort of another split body command? then another split to remove the excess sticking below the base flange?

[davebYYPCU]

Using the Move Tool, rings alarm bells.

The axis is constructed first, then you can do the Plane on Path that @g-andresen demonstrated.

The cylinder is then round and intersects with the flange.

Use the same circle sketch to cut the ellipse shape into the flange.

Might help....