Fillet on Sweep

[tfirth1]

I need someone to let me know what I'm doing wrong with this model.

Try as I might, I cannot get a fillet onto any of the spiral tangents between the cylinder and the swept rectangular profile.

Ideally, I would like to have a 2mm fillet on one side of the rectangle at the union with the cylinder and an 8mm fillet on the other side of the rectangle at the union with the cylinder. Then two small 0,25mm fillets on the top edges of the rectangle.

I've tried everything.

Any help much appreciated.

[TrippyLighting]

Like this?

The crosssection of the helical profile is not precisely 10x8mm in this simplest attempt, but that can also be done if needed.

[tfirth1]

Thanks for your quick response.

Unfortunately, that won't work.

The actual profile that I want to fillet is shown in the attached picture.

I really do need to sweep the profile; coiling won't do it.

Anyone get any ideas?

[TrippyLighting · Accepted solution]

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@tfirth1 wrote:

I really do need to sweep the profile; coiling won't do it.

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Sweeping is what leads to the problem with the filets as it creates the segmented geometry in your model.

 

[tfirth1]

That's great, thanks!

I would never have thought to use surfaces to achieve the result.

Been wrestling with solid modeling for ages on this.

I definitely need to familiarize myself with the surface modeling functions.

Again. Many thanks.