Inside Fillet Doesn't Work Right

Note that I tried to fillet the inside corner and ended up with a hole there. What went wrong?

thanks, rex

snip

Hi rex - impossible to say without the file but just at a guess, it may pay to MergeAllCoplanarFaces (`MergeAllFacesa’ if your Rhino version < 7) before the fillet.

-Pascal

Pascal, here’s the file.
I am using Rhino 7 on Windows 10.
thanks,
rex

TruckLowerCross.3dm (828.3 KB)

TruckLowerCross_PG.3dm (631.6 KB)
Hi rex - see if this makes any sense with what you need - all the coplanar faces are merged before the fillet. You can make a bigger fillets if you make that and then pop the hole through.

-Pascal

Pascal, your result is what I’m looking for, but I’m not able to reproduce it.

I start with the part as a single closed polysurface.

I then execute MergeAllCoplanarFaces. Then I go to Solid/Filet Edge/Filet Edge and select the internal edge between the vertical and horizontal surface.

I still get the same result I was getting which has an opening where the filet should be.

Thanks,

rex

Hi rex - does your part look like my pre-fillet part, in how the faces are arranged?

-Pascal

Oh, I just understood what you were saying. The filet I’m trying to make interferes with the hole.

OK, I’ll work with that.

Thanks,

rex

Pascal, I did get it to work after I noticed that you reduced the filet size to miss the hole.

Thanks much!

rex

OK, I got it to work with a .25 radius after plugging the holes.

Odd though that one end required me to mergecoplanarfaces, while the other one didn’t’.

Thanks,

rex

The “take away” here is you can not use a fillet radius that spans wider than the surfaces it is following.
You had a couple coplanar faces. Merging them made a single wider surface.
The hole was the same problem. The fillet ball was rolling along the crease the ran into the hole. Make a smaller hole, smaller fillet radius, or cut the hole after making the fillet surfaces.

If I have two 1/4" wide surfaces that meet at 90º, my fillet radius must be smaller than 1/4".

Yep, thanks John. I learned something today; always a good thing!