I've look at quite a few posts on here, watched a few YouTube videos, but none seem to cover the problems I've been encountering. I am converting some parts over, and they have small cooling channels. I've been using secondary planes and cut-sweep to make the channels, but when I come to the small corners, weither they be square or round, I keep on getting errors. I've tried using a right angle, then a small radius, then a larger radius than the diameter of the tube, to no avail.
I tried a second approach, using multiple planes, and it looks like it was able to get the first curve swept, but hangs up on the rest.
I'm out of ideas. Very frustrating.
OK.....a few issues:
1) if you are doing this with a sweep cut, I would say that this would be easier to create your path as a 3D sketch rather than 3 different 2d sketches. You can even use the planes to constrain your sketch (easily using the "3D Sketch on plane" function).
2) You only need 1 profile sketch unless you are doing this as a loft (not recommended unless the diameter of the channels are changing as they move along (expensive and maybe impossible!!)
3) The other issue is that the diameter of the profile needs to be less than the diameter of the fillets in the corner, otherwise you are going to get self intersection issues.
4) Manufacturability. If you want to make life easier, then create this as 5 drilled holes. 2 blind ones on the bottom. Then 2 more blind ones coming from the surface opposite your front plane that cross your first two. Then one more from the side of the part that crosses your 3rd and 4th holes. Then just plug the ends of the holes somehow. (I see that this might be problematic because this part is VERY small).
See the attached video for Part5 and how I created your cooling channels using a sweep feature. I created it with the cooling channel diameter to be .08" If you want it bigger, you are probably going to have to increase your fillet radius size.