I want to design a channel that have a rectangular shape in the start and circular section at the end with a complex trajectory and some geometrical constraint (e.g. bolt boss). I used swept blend command with 6 sections and a trajectory. Then I used round command to remove sharp edges .The problem is that the channel is not smooth and the round command created extra sections which is not suitable for flow analysis software.
How I can have a better geometry without extra edges and also smooth shape?
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The boundary blend was pretty messy so I opted for two sweep/blends. The 1st is the round section, the second is the tube. I used the external copy geometry to make sections with the radius already included. The final blend you can see is a copy of the circle using 8 segments instead of 4. Blending worked best to enlarge the radius rather than pinch it. This is a matter or preference, of course. I did choose to join one end to the previous blend.
Some observations on the sweep/blend; note that there are definite transitions where the sweep origin has endpoints. Making this a continuous spline may smooth a feature such as this tube. Otherwise, a blend section should be included at those vertices along the origin to better manage transitions.
Anyway, this is what I ended up with using the external copy feature:
The notch wasn't included in the model. I don't think that was the issue in the original post.
