Filletedge or filletSrf fail

Hi, V5
0.75 rad fillet bar to cylinder , all four places, yet FilletEdge fails, then explode and try for FilletSrf, it wont let me pick the bars surface, only part of it..
mergeSrf shows the surface as one, but FilletSrf says no it isnt.

I can never get on with FilletSrf as what appears a surface only sees part of it get selected then the next pick is the ‘mating surface’ so thats no use.
here is the rhino file.
fillet 0.75 fails edge or srf.3dm (3.5 MB)

Steve

you won’t be able to fit 0.75 here, the upper radius is 0.629” and the lower is 0.703”

If you fit in a 0.6 radius, you could, with some manual intervention create it:

Delete the upper surface of the fillet chain:

Split the small fillet and delete

create a plane

Match it in the direction of the top surface

Extend the surface

Join and MergeAllCoplanarFaces with the top surface:

FilletSrf to 0.05:

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btw there is a lot more going on in that file that needs fixing.

These kind of surfaces with singularities should be avoided:

Something like this could work for that area:

I’ve used your model to test out some of the new features in Rhino 9 WIP, such as FilletSrf chains and Patch, the attached is a closed polysurface:

fillet 0.75 fails edge or srf_SG.3dm (3.6 MB)

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Here is a couple more possibilities.

One even has a .75 Radius where the sides of the bar meet the cylinder.

fillet 0.75x.3dm (1.5 MB)