Fusion fail

[emjtech]

Hi
I am new to FreeCAD.
I made various designs and printed them OK however I sometimes stuck with errors that seems like bugs, for example I cant get the Fusion between the Pad002 and Cut006 (on the attached file) to work

What is the problem?
How can I solve that (other than redrawing from start)

OS: Windows 7
Word size of OS: 64-bit
Word size of FreeCAD: 64-bit
Version: 0.16.6704 (Git)
Build type: Release
Branch: releases/FreeCAD-0-16
Hash: 0c449d7e8f9b2b1fb93e3f8d1865e2f59d7ed253
Python version: 2.7.8
Qt version: 4.8.7
Coin version: 4.0.0a
OCC version: 6.8.0.oce-0.17

Thanks
Eli

[NormandC]

Use Check geometry (Part workbench) on Cut006. You will see that it is invalid (you need to set Tools > Edit parameters... > Preferences > Mod > Part >CheckGometery > RunBOPCheck > Value = true).

You need to go back and check each operation before it to locate when the error starts.

[NormandC]

The problem starts with Fillet002. It is bad practice to apply fillets so early in the modelling of a part. They should be applied only when the basic shape of the part is done.

Also, rather than apply multiple cuts with single objects (box, cylinder) you can fuse them together beforehand then apply a single cut on your main shape. That way you do not get a tree with so many levels.

[NormandC]

I've deleted all the Cuts and both Fillets, fused the primitives together then applied 2 cuts. The solid seems fine, it's ready to get fillets. But you should look into Pad002, it interferes with the cutouts made in the main shape.

[emjtech]

Thank you very much

[emjtech]

Hi
As you did I deleted all the cuts and fillets, and then make a Fusion of all the material and a Fusion of all the holes
Then I made a Cut of the Fusion with the FusionHoles
It worked but I got something strange:
1- One of the holes looks as a hole in one look and a material cylinder on the other
2- I have the Fillets.. but I didn't apply them!

How can that be?

[NormandC]

You broke your model history. The Boolean operation "Cut" contains only a single object, Pad001. Pad, which should be included in the Cut, is on its own, unused. The result is that the "Cut" object has broken history, and shows the last saved state, which included fillets.

You can find that out using the Dependency graph from the Tools menu. It requires installation of Graphviz. More info: Std DependencyGraph

[emjtech]

Thanks again,
FreeCAD is great, in the end I will learn it

[NormandC]

Glad to help.

A hint: when deleting objects or Part Design features, start from the end, in reverse order of creation. This should prevent breaking the leftover operations.

[emjtech]

Hi
Now it should be OK, but I still have the hole-cylinder problem.
I tried he cut's and fusions various times, but still this hole is always in conflict as you see in GLOBSDwinBoxB.FCStd.
The only way to correct that was moving the holes further from the support. See finished box GLOBSDwinBox.FCStd.
This is OK for me, however is that a bug? How should I prevent it?
Thanks,
Eli