Fillet question

[Art5]

I'm working on a stamping die, and I wanted to put some large fillets around the edge of the die, but it will only let me go up to a certain radius before it gives me an error. Can someone help me understand why fusion won't let me put a fillet bigger than 6mm? Ideally, I was hoping to put around a 25mm fillet to help the material flow into the die. As always, any and all help is greatly appreciated.

6mm fillet works7+ m fillet does not

[jeff_strater]

Fillet does have limits to what it can do, primarily driven by the geometry of the edges you are trying to fillet.  Areas of high curvature, and "near tangencies" can all cause fillet to fail.  If you share your design here, we can take a look at it.

[Art5]

Here ya go

[jeff_strater]

thanks, @Art5 .  This design looks slightly different than the one in the above image - it looks like we have only part of the pocket:

or, am I missing something?  Thanks.

[TrippyLighting]

Past approximately 6.7 the fillet starts failing because it basically start collapsing.

So you need to make the vertical fillet larger.

[Art5]

@jeff_strater  We are a prototype shop, the designs are proprietary, so I'm not allowed to share the full die.  I did get permission to share partial designs, so I cut the die in half. I couldn't get the fillet to work on the partial die I provided either.

[Art5]

The "bottom" of the die is built to part, I can't change the design as it will change the shape of the part.

Where part is must remain the same, I can change my runoff to a certain extent though.

[wmhazzard]

Take a look at this file to see if it works for you. 

[laughingcreek]

another possibility if you can't change the geometry near the bottom would trim out some of the surfaces at the top and loft a fillet like surface at the top.  example attached.

[Art5]

I'm afraid that while this is the size of fillet I was hoping to achieve, this particular solution doesn't quite work for me since the part no longer matches  up with the die in a couple of places.

As you can see, in these locations the die either interferes with the part or doesn't contact it

[Art5]

@laughingcreek  This does appear to be a viable solution, although I'm not entirely sure how you achieved it.

[Art5]

@michallach81 Success!!! This is exactly what I was trying to achieve! Thanks a million!1" Radius Fillet successfully created!