Variable Fillet modeling failure

[PuLsar_11]

I've been trying to create a variable fillet between two objects and I just keep getting errors.

I attached the file, I'm sure that that will be the best way to troubleshoot.

All of these approaches have failed.

Workflow one:

1. copy both parts from assembly to new part file (create new solid)
2. delete undesired faces (with heal checked)
3. create fillet

Workflow two:

1. copy both parts from assembly to new part file (create new multiple solids)
2. combine both parts
3. delete undesired faces (with heal checked)
4. create fillet

Workflow three:

1. create the files from scratch as one solid
2. delete problematic faces (with heal checked)
3. create fillet

[MSD_takaseh · Accepted solution]

Hello PuLsar_11,
How about a way here?
It should be needed same way for opposite side.
Thanks,

[PuLsar_11]

Worked great, thanks!

[johnsonshiue]

Hi! Here is another solution using Surface Modeling technique. Please take a look and see if it works for you.

Many thanks!

[Anonymous]

Mr. Takesh any way you can explain to me why the creation of this fourth and last fillet is failing? 

I tried everything descripted in forums plus the aproach shown by you and those taken by pulsar. Im about to throw my comouter to the wall 

Thanks in advance

[VChampDK · Accepted solution]

There's a very tiny groove between the two faces. Delete/Heal it and you're fine 🙂

[Anonymous]

I tried but it wont work! you can see from the left side that i tried patching healing and stitching to no success...   😞

Please help me 

[johnsonshiue]

Hi Juanita,

I am sorry I have to say I don't understand the design intent of Extrusion 8 and also the rest of Delete Face + Boundary Patch + Stitch. Why does Extrusion 8 create two holes? Shouldn't the profile be smaller? Why do you need to delete planar faces and then add boundary patches?

Many thanks!

[Anonymous]

HI Johnson,

The design in question is show bicycle stem. Extrusion 8 is just a weight reduction that also serves as a hole fore aerodynamic cable routing.

The last steps in the piece were just intents to heal the part as above was described to have a tiny gap... but i failed.

If anybody can help me out to carry out that last fillet would be great; either through solving it and leaving the file for me to examine the route taken or though teaching me! anything works and I´d appreaciate both. 

Thanks in advance!

[VChampDK · Accepted solution]

Here you go 🙂