Having a Boolean Difference problem

 From: davidb45 26 May 2011  (1 of 10)
 I am trying to cut out slots in a wheel that I created. The operation deletes the cutting object but does not cut the base object. 3dm file is attached. Thanks in advance for the help. Attachments:

 From: BurrMan 26 May 2011  (2 of 10)
 4302.2 In reply to 4302.1 Hi David, Your wheel revolve is kindof twisted... Luckily that the history is still enabled on it, so you can fix it by doing this. Go to your front view and view this curve and turn on points. Select those 2 points that I have circled and run transform/align/horizontal and pick your line there to align them with it. The revolve will update and the boolean operation will succeed now. EDITED: 19 Jun 2012 by BURRMAN

 From: BurrMan 26 May 2011  (3 of 10)
 4302.3 In reply to 4302.2 Here's an updated version where I did that and it's ready to boolean. EDITED: 19 Jun 2012 by BURRMAN

 From: BurrMan 26 May 2011  (4 of 10)
 4302.4 In reply to 4302.3 You may have to re-array the cutters as they may be arrayed to the skewed revolve and not work... I deleted all but the top one and did another array of 9, being sure to pick the center of the new revolve.. FYI

 From: Michael Gibson 26 May 2011  (5 of 10)
 4302.5 In reply to 4302.1 Hi David, yup Burr's got it nailed above - because that little segment that Burr circled above is not quite fully horizontal, you end up with a kind of irregularity at the center area of your revolve. It's very small in size so you have to zoom in very closely to see it: It's not quite a regular hole, it kind of collapses on the other side of it. The other collapsed side probably makes it into a self-intersecting object, and there can be various problems with doing intersection calculations on an object that has self-intersecting pieces in it. - Michael Attachments:

 From: davidb45 26 May 2011  (6 of 10)
 I think I did everything you suggested. It did get rid of the mico-hole in the center of the wheel. I went back to the basic shape of the slot cutter and did a new array, this time picking the center of the wheel Revolve and not the slightly off center of the slot cutter. I then did an Extrude on one of the new cutters, then a Boolean Difference. Unfortunately, it still did not cut holes in the wheel. I have attached a new 3dm file. I could just use the corrected files you sent me, but I need to understand my mistakes. Thanks for you help. Attachments:

 From: BurrMan 26 May 2011  (7 of 10)
 4302.7 In reply to 4302.6 Hi David, I arrayed the cutter at center by nine and it booleaned ok here. Select the large wheel, then boolean difference and then select all the cutters and right clcik.