Attached is my attempt at creating a cruciform join between two beams. The idea is that the horizontal beam has two vertical inserts which make it appear that the vertical beam carries on through. It has been designed in such a way that the vertical inserts are inserted from the back and then welded so the final result is seamless. Some beams have already been fabricated in this way so I am trying to produce drawings to ensure future results are consistent. I plan on inserted each weldment into a new part and converting to sheet metal in order to get the flat pattern of the vertical inserts and also the beams.
What I would like to know is:
- Is there a better approach to get the result I'm looking?
- Is using weldments and then converting to sheet metal the correct approach for getting the flat patterns?
- How do I tidy up what I've already done? The vertical inserts have a step in them (see picture attached), and there isn't much of a weld seam on the back (picture attached). I think what I've done so far is ok for a visual, but it's not ready for a fabricator.
Any advice, recommendations etc are appreciated.