Merge, blend, or fillet? Unsure of what to do!

[Rewati.K]

Hi, PTC community! Really hoping someone can help me out with this operation sequencing problem.

In the first image here's what the letters represent w.r.t my model tree:

A. Surface has been swept to remove material and enforce a 1 deg. draft on it.

B. As part of the same sweep from A, the the rectangular cell feature has a fillet of 1 mm.

C. This section of the model also has a 1 degree draft and 1 mm fillet, but the height of my swept section is far lesser than the one used for A+B (as is obvious from the image).

Now, due to the sweep from C, I'm left with a weird material condition as indicated by D.

What I eventually want to do is the following:

E. Apply a fillet of 1 mm to this continuous edge.

F. Have this surface drafted by 1 deg. as well.

What I've tried so far:

1. Sweeping the highlighted edge did nothing, and ended up cutting into the drafted surface A.

2. I then changed my sweep sketch and removed the top fillet from it. This lead to adding many more rounds individually to all the edges left after the sweep, but it seems to have fixed the issue (ish).

I'd like to know if there's a more efficient way to go about fixing this, because this is an issue for at least 20 more instances in my model, and adding a set of 5 operations to achieve a smooth draft/fillet transition seems a bit redundant to me, not to mention way too process-intensive on my computer. Will surfacing tools help me out better?

[tbraxton]

As with most geometry there are multiple ways to create it. With your goal in mind I created a quick model to demonstrate one approach to deal with it. The geometry is a rectangular prismatic and can be quickly modeled with simple features. As you add complexity to the model make sure to push the drafts and rounds (except for round 1) to end of the model tree as a best practice.

Creo 4 model enclosed as an example. There is a saved draft analysis in the model to show the core side drafts.

Draft and round on core features

[Rewati.K]

Thanks for your response, and for taking the time to make that CAD part! Although I can't really use the sequence of operations per your model tree, on my current model (most of the cavity features and ribs have already been created and there are other features dependent on them subsequently), this is good information nevertheless for future designs that I will be working on, in the same vein.

[tbraxton]

If you are stuck with modifying a model I would suggest posting it here for review. If it is an educational license then most here will not be able to open it. Depending on the legacy features already in your model you may find it faster to rebuild it in a way that supports the design intent rather than modifying it.