If you could upload your part someone might be able to identify the specific problem.
Without it I can only offer two alternate approaches
- Cut With Surface
In both cases you may have to do some additional work ie a CopyBody (with Delete Face for Surface cut)
Just to clarify, I'm not looking to cut through the target (e.g. a through-hole opening) but to indent the plastic around the tool body region as per the pic below.
I've uploaded some simplified versions of my parts and it still shows the same erroneous behaviour. Right now the "test lanyard" part has the feature "end rounds" suppressed and the indent feature works (this is where the picture above comes from). If you unsuppress the feature "end rounds" then rebuild, the indent feature fails with the message "Indent cannot handle this case. Please try different geometry or enter a smaller thickness value."
I have not found any thickness value that will make this feature work.
Im on 2016 so I could not see your feature tree and had to work with an imported body.
I have no idea how you rounded the edges so I just guessed but it worked for me.
I probably simplified something somewhere.
As I said before, you can do anything indent can do with other features. In this case you would have to copy body / move face.. combine add and combine subtract
Rob,, I know you are curious.. Here is an .x_t of the lanyard... the plate is 2.5 mm thick.
test lanyard.x_t.zip 3.9 KB
Thanks Dennis.. I have SP5 so I can open 2017 files and save as x_t..
Tyler,,, if you cannot offset the surfaces of the tool it will not work for an indent tool. Since I was not able to offset the surfaces (all of them) in the test lanyard I made a small .2mm fillet all around then tested it in the indent feature and it works. You could alter you geom a tad so you don't have the odd intersections and use the tool for indenting also.
These surfaces don't behave with an offset no mater how small.
This is with .2mm filleted edges and a 2.5 offset.
Dennis Bacon you can (move) offset the surfaces but lets put it in a similar context of delete patch surfaces you often see.
If you move offset the end two radius first and then in a second feature move offset the rest of the surfaces it works fine. No need to add any fillets or do it in surfacing. Much similar to problems encountered with delete patch. The end result is the same but SW can't handle doing it all in one feature with the given geometry on this occasion.
Obviously this still means indent won't work as a primary solution because the move offset faces needs to be done in two features.
I think it's some peculiar "singularity" if we can call it that, that Rob Edwards, Dennis Bacon, and myself found 3 different ways around. I'll summarize below.
When he recreated the end rounds, the cutting arc was wider than the lanyard body, so no tangent conditions to the edge. If I do that on my files, it also works.
Adding the fillet is maybe making every edge have a tangent condition(?) where before they didn't.
Then I noticed this:
If I create the end rounds by a fillet, if I go small radius or big radius, I get the close to the shape I want and indent works:
If I bring the radius just about to the full round condition but there's a tiny flat, indent works and is essentially the shape I want:
If I go past this, I get into an almost ball-end shape. Not what I want but at least indent works properly (see cross section - uniform thickness):
But if I bump the fillet radius from 5.5 mm to 5.6 mm, the tool shape looks the same ball-end shape, however look at the cross section - no longer a uniform thickness. Some weird glitch when these 3 surfaces collide I guess. Now in this case, indent still technically worked, but it's behaving oddly.