Solid problem PLEASE HELP!

[racingjas]

Calling all Mastercam modeling wizards.

We are new to solid modeling and are struggling to complete this corner on this model. 

I have extruded the front portion, revolved a portion in the rear and am struggling to sweep the rads and have them join smoothly.

Ahhhhhh!

If you look from the rear view it appears that my surface actually goes beyond the outside diameter. 

Some please point me in the right direction. 

I have enclosed the mcam file and a couple of pics.any help would be GREATLY APPRECIATED! 

Thanks in advance.

 

 

 

 

NPD-0102 - 4.75in Panzarotti Rotary Die.mcam

[pullo]

that was just 2d...and even that is fragmentary ,  where's the 3d file?  Nothing to go on here.... You do understand there can be no output if there is no input ....

Gracjan

 

[pullo]

ok, i found the other stuff  on the turned off levels , but the solid you have made would help...

[jlw™]

Just by looking at their 2d you can tell it was generated from a solid.  Why not ask for a solid from them so you know you get exactly what they want?

[racingjas]

Hello guys, I haven’t finished the model....... that’s why I’m here. 

Jlw, the geometry was all created by me as per the drawing, not taken from a solid model.

there is no solid model available, that’s why I’m making one. The partial model I created was enclosed in the mcam file. 

85 people view this and no one can help?? Come on boys, someone must know what’s happening! 

[neurosis]

1 hour ago, racingjas said:

Hello guys, I haven’t finished the model....... that’s why I’m here. 

Jlw, the geometry was all created by me as per the drawing, not taken from a solid model.

there is no solid model available, that’s why I’m making one. The partial model I created was enclosed in the mcam file. 

85 people view this and no one can help?? Come on boys, someone must know what’s happening! 

 

I don't see a solid in your file.  Just a 2d drawing.

[racingjas]

Hi, I sorry guys but some of the levels may be turned off. Double check the level manager.

[Roger]

I have viewed it also.  ALL Levels turned on, NO SOLIDS!!

[crazy^millman]

19 minutes ago, racingjas said:

Hi, I sorry guys but some of the levels may be turned off. Double check the level manager.

Yes I checked it out and there is no solid in the file.

[#Rekd™]

14 hours ago, racingjas said:

?? Come on boys, someone must know what’s happening! 

You have not provided your “solid” file, that is what’s happening. 

[racingjas]

Panzarotti Rotary Die.mcam

 

sorry guys,not sure what happened with my previous file

I uploaded another so I hope that works this time 

[Leigh @ Kodiak]

Make a second curve and use the "two rails" in surface sweep. See how that works for you.

 

 

 

[crazy^millman]

I took your flat pattern and I made it the complete pattern. I then rolled it to the 9.072 Diameter. I then Dynamically transformed it to put on top of your solid. From there I would use it to road map the Solid you need to make. Roll Dies are sometimes best left in the flat pattern and machined that way verse trying to make the solid that represents it. That is not an easy solid to do in a good professional level CAD software IMHO. Might could spend a day and figure out a way to make the solid, but I would just leave it a flat pattern and machine it from there.

I would like to see what a good Solidworks, SpaceClaim or other CAD guy could do with this. I am not saying it cannot be done in Mastercam, just will be some work to make it the correct solid.

[ajmer]

take a look at this file

I used the 2 rail method that leigh mentioned

I did it in 2018 so I saved it as a step aswell

ajmer_ihs_rotary die.stp

ajmer_ihs_rotary die.mcam

[crazy^millman]

40 minutes ago, ajmer said:

take a look at this file

I used the 2 rail method that leigh mentioned

I did it in 2018 so I saved it as a step aswell

ajmer_ihs_rotary die.stp

ajmer_ihs_rotary die.mcam

Good work sir, but do you think you can make a solid of it?

[pullo]

as you seem to have 2017 , I am sending the corner solid as a step . It  is ready to rock just use boolean. As you can see  from the yellow pick color it is one  entity.  all done in mcam. took about half an hour to  invent the strategy. Here  is also the 2018 file just in case. I had to raise the solid 0.001 otherwise it would not add...

 

 

corner.stp

Panzarotti Rotary Die 2018 pullo.mcam

[pullo]

I thought I'd leave the gaper behind the corner solid for You guys

Gracjan

[pullo]

 

 

Panzarotti Rotary Die 2018 pullo2.X_B

[crazy^millman]

4 hours ago, pullo said:

Good work sir.

[racingjas]

18 hours ago, ajmer said:

take a look at this file

I used the 2 rail method that leigh mentioned

I did it in 2018 so I saved it as a step aswell

ajmer_ihs_rotary die.stp

ajmer_ihs_rotary die.mcam

thank you very much for all your help!

one question,how did you greate the upper arc? projection?

[racingjas]

6 hours ago, pullo said:

 

 

Panzarotti Rotary Die 2018 pullo2.X_B

nice job pullo!!! thanks so much for all your help!

[racingjas]

20 hours ago, C^Millman said:

I took your flat pattern and I made it the complete pattern. I then rolled it to the 9.072 Diameter. I then Dynamically transformed it to put on top of your solid. From there I would use it to road map the Solid you need to make. Roll Dies are sometimes best left in the flat pattern and machined that way verse trying to make the solid that represents it. That is not an easy solid to do in a good professional level CAD software IMHO. Might could spend a day and figure out a way to make the solid, but I would just leave it a flat pattern and machine it from there.

I would like to see what a good Solidworks, SpaceClaim or other CAD guy could do with this. I am not saying it cannot be done in Mastercam, just will be some work to make it the correct solid.

thanks so much for all your input!

[crazy^millman]

I noticed no one modeled the serration sections.

[pullo]

If the  guys  don't sweat  a little  , it'll be even harder the next time . You have to ease yourself into it

I first created the  upper rail using Xform Roll die , onto a d= 9.072 , just like C^man  and them  using  Xform project I projected a line  pic 1)  to get the second cross section.

 

 

 

 

 

 

 

 

And now it gets tricky ,  because if you now use boolean , you'll get a myriad of answers why it's not a good idea.  For one , the first problem was  non-manifold.  I filleted 

the underlying sharp inner crease  with 0.02 and that took care of that. The other most common problem is "FACE IMPRINTING OPERATION FAILED".  

As a parasolid modeler works with some tolerance , if you try to Boolean add bricks which have free surf  topology  Mcam , SW and the rest of the bunch will say "no way".

So  you have to nudge one of the blocks a little off and then it works . I moved my corner block 0.001 in the Z direction. I know  that this is the part that all people with  psychological disorders  will hate ( )  , but hey that's how I did it and moved on....  Otherwise you are stuck , Boolean add won't work  and I do not know any other solution to this problem.

Gracjan

[crazy^millman]

9 hours ago, pullo said:

If the  guys  don't sweat  a little  , it'll be even harder the next time . You have to ease yourself into it

I first created the  upper rail using Xform Roll die , onto a d= 9.072 , just like C^man  and them  using  Xform project I projected a line  pic 1)  to get the second cross section.

 

 

 

 

 

 

 

 

And now it gets tricky ,  because if you now use boolean , you'll get a myriad of answers why it's not a good idea.  For one , the first problem was  non-manifold.  I filleted 

the underlying sharp inner crease  with 0.02 and that took care of that. The other most common problem is "FACE IMPRINTING OPERATION FAILED".  

As a parasolid modeler works with some tolerance , if you try to Boolean add bricks which have free surf  topology  Mcam , SW and the rest of the bunch will say "no way".

So  you have to nudge one of the blocks a little off and then it works . I moved my corner block 0.001 in the Z direction. I know  that this is the part that all people with  psychological disorders  will hate ( )  , but hey that's how I did it and moved on....  Otherwise you are stuck , Boolean add won't work  and I do not know any other solution to this problem.

Gracjan

I was thinking that was how you cheated the solid in and thank you for confirming my thoughts as the method and all the issues you would run into. The real issue here is it is roll die and the shape must wrap from an un-wrapped shape. I did these for years with pencil and paper and this one like I said originally I would do old school and program it all 2D with the unwrapped geometry and machine it. End of the day making the best part possible is the end game here and to many keep looking for the fancy easy button when the easy button is the simple as a 2D program just wrapped using axis sub. I have made custom form tools and machine use the .25R with a 1/2 endmill stepping down and leaving .002" for a finish pass. I would make a form tool that goes from the 10 degree wall to meet the .25R that has the .093R on it. I would contour cut that and step down doing the same thing. It would look like new money printed when I was done 25 years ago doing it that way so today I think I could make it even nicer then back then.

A possible solution to the problem is to make square corner pockets and then once you have made the square corner pockets you go back and put 10 degree chamfer and then the fillets in. That will do the work you need with the blends. You need the corner fillets 1st then come back and apply the .093 and .25 Fillet to the corners from the walls to the floor. The other way would be to make the males to remove from the round part creating the female shape. Do all the work on the reverse part that you want to Boolean remove from the roll die part and that might be the best way to achieve the solid. Work in reverse verses trying to work like you are.