Explosion protrusion through metal

I’m trying to model the effect that an anti armor explosive might have on the exit side of a thick metal wall. The look I’m envisioning is like a bullet exiting, where the surrounding area of the affected area bulges out, with the middle section showing a hole torn and cracked around it. My approach to this is to create a bulge by revolviong a curve above a flat surface, and then drawing the cracked hole and makehole through that bulge… but I’m having some dificulty merging the revolved bulge with the side wall solid. I tried booleanunion but it just says failed… doesn’t say why? Ideas? Second question, how can I thicken the revolved bulge to match the wall so they look like the same material in section? Thank you. See attached.bulge.3dm (314.9 KB)

So the issue with the merge is that your bulge is an open polysurface and you want to union it with a closed polysurface. You need to make the whole thing closed polysurfaces if you want to union them that way.

I just exploded the shallow cylinder, deleted the front face, moved the bulge to replace that face, and then joined them. Then you can booleanunion that closed polysurface with your armor wall.

Thank you but I think this solution would make the entire bulge solid… I just need the bulge to be as thick as the wall it’s protruding from. Do you know what I mean? I tried extruding the surface but no luck… ideas?

Offset your revolve curve so the final revolution will be closed. Then you can join the polysurfaces together.

To reduce the number of isocurves, you can run rebuild on the offset curve you make to lower the amount of control points.

I realize that my explosion shape isn’t working with make hole…

Thank you @nagreste… that works. I must have been reading your mind as I discovered this just a moment ago myself. But now I’m seeing that the explosion hole I drew does not work with makehole… I tested a simple circle to makehole, and it does work, so it’s definitely a problem with the explosion drawing. Hm…

You can try wirecut instead. It’s like not working due to the outermost edges of your explosion curve. The curves are so close together at that point that they might not even be in tolerance.

Yep. Those little cracks at the outer edge of the explosion curve were the problem. Rhino doesn’t like it when a closed curve intersects on itself or has edges too close together. I trimmed off all the crack-like pieces at the very tips of your burst and rejoined the curve. It worked fine after that.

Ok I’ll give that a shot and report back

It worked. Thank you!

No problem! Glad you figured it out!