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Fillet not ending at Parting line

Question asked by Sourabh Kumar on Sep 9, 2016
Latest reply on Sep 14, 2016 by Christian Chu

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I am trying to model a part for Die Casting. A fillet on a inside corner is not ending at the appropriate parting line. Is there any way to end the fillet at the parting line ?

This is before the fillet.

This is after.

One other problem I have is that a 3d sketch converted from a edge shows some deviation from the edge itself. If anyone has any suggestions about how to model this part in a better way please feel free to suggest. I am attaching the part too just in case.

I found the same question asked by someone before but none of the methods mentioned in the post works for me.

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BUCKLE REV.SLDPRT.zip793.8 KB

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Dwight Livingston Sep 9, 2016 10:03 AM
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Sourabh

If you can, first create a parting surface and the split the part in half. After you put in fillets, combine the two back together.

If the parting surface is too complex, see this thread: Ending fillets at the parting line

Dwight
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- Sourabh Kumar @ Dwight Livingston on Sep 10, 2016 5:57 AM
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  Thank you for your reply Dwight, I have tried the method you mentioned but that creates a extra face after combining two bodies. i have read the thread you mentioned but these methods don't work for me.
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Christian Chu Sep 9, 2016 10:46 AM
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It's hard to say since I'm not sure what you want to achieve from this part
it's a nice surfacing model until you added the Boss-Extrue1 - I'd recommended all should be done in surfacing until you've happy with the look before converting it to solid
Just a little bit out of the subject, why you want to add a small fillet at the parting line as it'd be hard for the tooling?
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- Sourabh Kumar @ Christian Chu on Sep 10, 2016 5:57 AM
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  Thank you for your reply Cristian, I would definitely try your advice about doing the whole model in surfaces and converting into solid at last.
  As for the utility of the fillet, to be honest I really don't know ! it's just something we do, I guess for aesthetic appearance of the model. If you have any suggestions about doing this core cavity design in a better way please feel free to reply.
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  - Christian Chu @ Sourabh Kumar on Sep 12, 2016 1:35 AM
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    If I design tooling, i'd definitely avoid the small radius at the parting line for 2 reasons:
    1)hard to make
    2)Reduce the life of the tooling (number of shots)
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    - Sourabh Kumar @ Christian Chu on Sep 12, 2016 7:57 AM
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      Christian I don't have much experience in Tooling Design but I understand your point about the fillet being hard to machine. If you don't mind me asking, why would it reduce the Tool life ?
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      - Christian Chu @ Sourabh Kumar on Sep 12, 2016 11:16 AM
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        Because the cavity or core will have a small round clip for the part - This small clip is not strong and will be damaged after a number of shots - see below image: which one will you pick: left or right?
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        Deepak Gupta @ Christian Chu on Sep 12, 2016 12:21 PM
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        Other than this, there would be material flowing into that fillet and this is not good.
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        Sourabh Kumar @ Christian Chu on Sep 14, 2016 7:43 AM
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        Christian maybe I am not understanding it right but I still don't see how it would reduce the tool life.
        This is the radius after core cavity extraction
        
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        Christian Chu @ Sourabh Kumar on Sep 14, 2016 10:37 AM
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        I don't know where is the parting line from the image you posted here
        Please see the image from my post. there is a little clip sticking out of the cavity or core and it's easy broken - usually the tooling can last for about 300,000 shots, but that clip might be survived after few thousand shots - which I mean reduce the life of the tooling
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Loganathan V. Sep 10, 2016 5:57 AM
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Sourabh

i had attached simple way of design, and solve your fillet problems.
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- BUCKLE REV-New.SLDPRT.zip376.1 KB
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- Sourabh Kumar @ Loganathan V. on Sep 10, 2016 9:08 AM
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  Thank you Loganathan, for the time and resources you put into this. I actually tried the same method as you previously. My main concern with this part is that I would really like to keep the parting surface along the curve in the side sketch of the model. This is possible if I don't add fillets but after adding fillets the parting line changes. I am just getting started in core cavity design so I apologize to everyone if this is a trivial question.
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Sourabh Kumar Sep 10, 2016 9:08 AM
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Thank you everyone. I have solved the problem finally. anyone having the same problem, feel free to ask me.
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Paul Salvador Sep 10, 2016 9:51 PM
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Sourabh,.. since you are basically there (splitline 2)... you could go forward and treat it as a split or two halves.. that is, you will make a mold of it anyhow.. so, you can solve the fillets on each side.. (see attached)
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- BUCKLE REV - zxys.zip1.0 MB
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- Sourabh Kumar @ Paul Salvador on Sep 12, 2016 7:58 AM
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  Thank you for your reply Paul. As I mentioned earlier splitting, filleting and then combining creates a extra face like this.
  Granted it's only 0.004 mm but it still irks me !
  
  But I found out what was causing the problem. The parting line I drew earlier had a spline which was preventing the fillet from ending at the parting line.
  
  I revised the Parting line around the problematic area to a straight line.
  
  and Voila !
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  - Paul Salvador @ Sourabh Kumar on Sep 12, 2016 10:37 AM
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    ..understand... just showed a practical option to do two things (moldsplt and blend) to reduce the overall work... and in my experience, the .004mm is well within any machinable/moldable tolerance... so, for all uses, it would be good to go,... ship it!
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    - Sourabh Kumar @ Paul Salvador on Sep 14, 2016 7:43 AM
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      Yes paul you are right but I am just getting started in this field, so I had no idea this would have on the final casting.
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Fillet not ending at Parting line

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