SURFACE BLEND OF DIFFERENT CONTOURS

[AIRMAN_DILLARD]

I need assistance with connecting 2 different surfaces, please see the attached video.  Your help and suggestions is greatly appreciated

[tbraxton]

Post your model and what version of Creo you are using.

[AIRMAN_DILLARD]

I use Version 10.  I get this message when I try to upload the file??  File type (.3) is not supported?  The file is only 2Mb

[AIRMAN_DILLARD]

I had to upload as a zip file.  Let me know if this will not open

[tbraxton]

Is this what you need shown in red? I used your existing geometry to create this by extending the swept blend shape into the "U" and then trimming it using the intersection curve present on the "U" channel. I had to use Creo 11 as I do not have 10 available but the picture shows how to do it.

On a side note, if this is intended to go to production there are some issues with some of the sweep trajectories and sections bending too sharply. The geometries are less than optimal for fluid flow and may cause downstream issues with the CAD model. What would be the method of manufacturing these channels?

 

[AIRMAN_DILLARD · Accepted solution]

tbraxton,

Thank you for your help.  I've attached a video

[tbraxton]

Depending on how you will make the part with the channels you may have much more flexibility with the geometry you can use for this type of design. Don't constrain your thinking to straight pipes and elbows if that is not actually a manufacturing constraint.

Here is an example of a liquid cooled manifold design for the cylinder head of a single cylinder of an internal combustion engine. This geometry is a closed quilt representing the fluid volume inside a cast part and was used for CFD and thermal analysis to optimize the performance of the cooling component. Once the cooling performance was satisfied by this geometry then a solid shell was built around this control volume for an aluminum sand casting to create the parts. 

For designs that have a primary function of fluid handling or thermal management using fluid containment in a control volume, I would design them from the inside out when possible.

[Patriot_1776]

'Sup Tom!  Yikes!  There's a lot going on there for a single cylinder engine!  Is this an engine for TESTING combustion efficiency or something?  Looks like a lot of ports for knock sensors, thermocouples, strain gages, etc.  Does this sit on top of the normal cylinder head then?  Looks like a 2-stroke (no provisions for a valvetrain), and the head on my Olde '91 KX500 is a LOT simpler.  The cool thing about sand casting is that you don't have to worry much about draft angles because you can destroy the mold afterwards, as long as you can get the cores out you're good.

[tbraxton]

@Patriot_1776 . The design was used on a two-stroke horizontally opposed boxer engine with multiple cylinders. This specific cooling system was designed for use on a dyno for development purposes. The design evolved to a version that was used for flight testing.

[Patriot_1776]

'Sup Tom!  I figured it was 2-stroke and for testing.  Interesting that they're using a 2-stroke for aircraft, since it looks like a piston port design instead of a forced induction and/or forced scavenge poppet valve design (no shape for cams/followers/valves).  I would think long term reliability with the rings would be a concern.  Rings aren't a major concern on a motorcycle like my Olde KX, but in a plane...  Continental, perhaps?