Fillet After Boolean Problem

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 From:  Skwerm
7086.1 
I'm attempting to model a street light pole base that has vertical grooves (See Attached Image).

After creating the base via a loft and then removing the groove objects using a boolean subtract, I need to be able to fillet the edges of the grooves. So far I've been unable to do so successfully.

To create the groove objects I projected a vertical line to the surface of the base object. I then swept a circle along the projected curve and added spheres to either end, which I then boolean-unioned to create the groove objects. I then did a polar array to create the group and then removed those from the base object.

It's probable that there is a better way to accomplish this, but I can't think of another method. Could someone have a look at the attached 3dm and let me know how I can accomplish what I'm attempting to do?

Thanks!

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 From:  PaQ
7086.2 In reply to 7086.1 
Hi Skwerm,

Here's how I would resolve the problem, but others might probably come with better solutions.
My guess is that the sphere seams will create trouble for the boolean subtraction.



So I rebuild the groove, using half sphere (but taking care to avoid seams)



I have attached the .3dm file too (without the fillet operation)

-- EDIT

Ok, looks like the groove need to be build a little bit more carefully, because while the fillet operation works, it generates naked edges :S

EDITED: 3 Dec 2015 by PAQ

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 From:  PaQ
7086.3 
Hi Skwerm,

Better result using a little different method to build the groove, using the deform tool.
But the idea is the same, avoiding sphere seams to help the fillet operation after the subtracting boolean.

EDITED: 3 Dec 2015 by PAQ

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 From:  Skwerm
7086.4 In reply to 7086.3 
Looked through help for "Deform Tool" and didn't find it.

I'm not upgraded to v3 yet. Is that a new tool?
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 From:  Skwerm
7086.5 In reply to 7086.2 
Thanks for the response!

I've tried a number of ways to get a hemisphere without a seam but can't create one. How did you do it?

--EDIT-- Okay, by boolean subtracting a cube aligned with the sphere's original seam worked. Is there a better way?

EDITED: 28 Nov 2014 by SKWERM

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 From:  BurrMan
7086.6 In reply to 7086.5 
Hey skwerm,
Although you don't have the newer V3 and deform-flow, I thought I would show it anyway.......

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 From:  Skwerm
7086.7 In reply to 7086.6 
Oooo! Snazzy!

I have been planning to upgrade to v3. I guess now I've got a good reason!

Thanks for the video.

Cheers!
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 From:  Michael Gibson
7086.8 In reply to 7086.7 
Hi Skwerm, were you able to get your piece finished up how you need?

Something in the filleting system seems to be getting pretty confused in your original case. One way to get it done still is to use the "lower level" surface/surface filleting which can be done between 2 separated surfaces. It can give a fillet surface result in cases where the edge based one gets messed up.

I've attached a model where I constructed a pocket that way - I did a boolean with your piece (I rotated the spheres around so that everything had their seams in one side), then did a boolean to cut, but then to do the fillets I used Edit > Separate on the model to break it into individual surfaces and selected 2 surfaces at a time and then did a Fillet. The surface/surface fillet that was then generated can be used.

To finish it you would need to array the current filleted fragment (which is sunken down into the main object now) around again, then use Edit > Trim to trim the main object by the set of fillet pieces, then join the pieces together. This kind of low level surfacing approach (using surface/surface fillet and trimming) is not as convenient as booelans and edge-based fillets but it can get the job done when the regular filleter is being cranky about something.

- Michael

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