I have this small part that has several 'T' junctions. It's 1mm thick but the thickness analysis gives about 1.2mm at T junctions. Does anyone know the right way to design T junctions so that it has a uniform thickness?
If you have a 90 degree corner with no internal radius, the only way to maintain a constant thickness is a fillet radius equal to the material thickness.
If you start with the outside of the corner and shell the corner the inner corner will not be able to have same equal matl thickness. The same thing happens if you have an external corner with less radius than the material thickness of the shell operation. When it shells inward, the outer radius cannot be maintained if it is less than matl thickness - it just disappears and becomes a sharp corner in which you cannot have equal matl thickness.
You need to either accept the varied thickness or design appropriate radii into the part.
Thanks. With a part like mine, if the junction between the rib and the outer wall has internal radii, then the gap between the two radii would be too small to be manufactured, right? It's 1mm thick, so if I have the rib-wall junction a 1mm fillet on each face, then the 'outer' fillet would be too tiny to make. Am I right?
I guess I can't risk having varied thickness, given the cost of having bad shrinkages. Redesign entirely to avoid T-junctions?
I don't know if the top has to be flat all over, but if not I think this type of T junction maintains constant wall thickness.
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