Sweep problem, not cutting as planned

[AJ_12152667]

I'm having an issue with Sweep in a channel. I'm not sure why it doesn't cut as much on sides following walls.

You can easily guess what the intent was. I'm not sure what went wrong with my idea of how to cut the shape actually.

Also, it doesn't generate some rounds around as planned.

EDIT: it sems like the cut sketch follows YZ plane in normal instead being normal to the intersect. I'm not sure how to force it to follow the intersection's normal.

[tbraxton]

Try an alternate approach to creation of the swept cut using two trajectories. It looks like the trajectories exist in the model before you would create the sweep. Use the normal to trajectory option with the second trajectory set as the X-direction reference in the sweep feature.

[AJ_12152667]

That's an one interesting suggestion @tbraxton, thank you.

I'll try to do this way and reply about the result.

[AJ_12152667]

@tbraxton I have tried your suggestion and it moved me forward. Please see the model attached.

However, it seems like cutting sketch follows both paths nicely, creating a proper cut. Problem is, that the cutting sketch doesn't stay vertical, but goes normal to paths.

As you can see below, the cutting is not too perfect, as some walls are not properly aligned:

My intent is, that the shape should be achieved with a ball point drill on a 3-axis milling machine. With the current shape, it requires 5-axis machine unfortunately...

I suppose I'd need another path to keep the cutting plane vertically. The question is where and how?

[rzukowski]

Sometimes the sweep tool can a bit tricky to get the geometry that you want.  An old school way of creating your geometry would be:

• Extrude a closed surface the same profile as the existing groove.
• Sweep an open surface to create the floor of the new groove.
• Merge the two surfaces together.
• Solidify / remove material to cut the geometry from the original.

Sure, this requires more feature, but it might be more robust if the parent geometry should change later on.  Just a thought.

[AJ_12152667]

@rzukowski thank you for the suggestion.

I've never tried that approach before. Would you mind to expand on the example? Are you able to share a model perhaps?

[tbraxton · Accepted solution]

You can control the sweep section orientation such that it matches the Z axis for the milling set up. This should make it possible to avoid any undercuts.

[AJ_12152667]

BRILLIANT, as usual 👏👏👏. Thank You @tbraxton