Fusion of multiple cavities into a single one

Good morning,
I need some help with an issue I’m encountering regarding the Boolean union between two tube cavities that converge into the single cavity of another tube with the same radius as the intersecting ones.

I’ve tried everything — adjusting the tolerance both higher and lower, using Sweep1, creating tubular shapes and hollow cylinders — but I can’t get the resulting cavity to merge correctly. It always ends up as if the walls of the intersecting tubes penetrate into the other cavity instead of forming a single continuous one.

Does anyone know what I might be doing wrong, or if there’s another way to achieve this?
Thanks a lot in advance.

_Split on tube with the other tube and remove the interior sides.

Alternatively, _Loft this cross-sections:

Model the tubes as closed solids and the cavities as (smaller) closed solids. Use _BooleanUnion on the tubes, and then _BooleanDifference with both cavity solids.

Your issue is related to collinearity of both pipes at their end. Build your pipes to the same diameter as the tube. Move their seam to the side with SrfSeam. Split both pipes by isocurve. Intersect. Draw the last bit of intersection that Rhino refuses to find. Trim.

No nasty booleans needed, only good old surfaces.
Collinear pipes.3dm (2.5 MB)

Then, you could also use FilletSrf without a problem.

this is the way ^^

nicely done as usual-