All
I often model plastic parts, and a common problem I have is getting a fillet to end correctly at a parting line. I really want it to end at the parting plane, but the easy standard fillet tool often pushes past or pulls short of the correct plane, so I've had to go through a lot of extra work to get it right.
I find by adding a tiny bit of geometry beforehand, the fillet will end correctly. The extra geometry gets consumed by the fillet, so it's a fairly painless workaround, at least compared to other stuff I have tried.
The images below show the story (I hope).
Dwight
WIthout the extra move:
HI Dwight,
yup - I've been there. for simplier parts I add the fillet to the separate parts (after they've been split ) but sometimes I have the case that you have where they need to be applied before the split. In this case I go ahead and split the part, apply the fillet and then combine them back together. In other cases where I cannot take this approach, I will use Delete Face and/or Replace face to remove the small face.
A Lot of the time the decrepancy is hidden because material is removed at the PL for an Appearance gap.
good luck
regards
Mark