Trouble with fuse, freecad crash on step export

[crobar]

Hello,

Im having trouble with boolean union on some shapes. I have managed o boil the problem dow to two solids, see the attached file. Running checkgeometry on these shapes says they have no problems. When I fuse then, the resulting shape also has no errors according to checkgeometry, however, it does not render correctly, and if I export to step FreeCAD crashes, with the following error in the terminal:

Code: Select all

*** Abort *** an exception was raised, but no catch was found.
	... The exception is:SIGSEGV 'segmentation violation' detected. Address 28

would be nice to know if this works in dev version with newer OCC

OS: Linux Mint 17.3 Rosa
Word size of OS: 64-bit
Word size of FreeCAD: 64-bit
Version: 0.16.6710 (Git)
Build type: None
Branch: releases/FreeCAD-0-16
Hash: f8eca0f9311f07c125dd6742a607724c1fa0b77c
Python version: 2.7.6
Qt version: 4.8.6
Coin version: 4.0.0a
OCC version: 6.8.0.oce-0.17

[NormandC]

It does work in 0.17-dev with OCC 7.1.0.

OS: Ubuntu 16.04.2 LTS
Word size of OS: 64-bit
Word size of FreeCAD: 64-bit
Version: 0.17.10980 (Git)
Build type: None
Branch: master
Hash: d02a34c03b0c14342151a4343250b571a603ece9
Python version: 2.7.12
Qt version: 4.8.7
Coin version: 4.0.0a
OCC version: 7.1.0

would be nice to know if this works in dev version with newer OCC

You can install it from the daily builds PPA, the name of the package is freecad-daily, we changed it last year so both 0.16 and 0.17 could be installed. Prior to it, it was one or the other.

[NormandC]

I spoke too soon. The union succeeds, the object appears OK in the 3D view, but check geometry reports it as invalid with a "tolerance value invalid" error. This may be fine, or cause problems later on...

Here's an alternative: cut one of the shapes' end so it perfectly matches the other. Then the fusion succeeds in 0.16.

What I did:

1. Map a sketch on the bottom face of Shape008
2. Sketch a closed profile; use the external geometry tool to pick two vertices of the face and apply point on object constraints between them and the profile
3. Close the sketch, then go to Part Design --> Detach Sketch
4. At the prompt "do you want to detach sketch", click Yes
5. Cancel the Sketch orientation dialog (the sketch will be detached, but will keep its placement)
6. Pad the sketch
7. Apply a Part Cut with the Pad on the Shape007
8. Fuse the Cut with Shape008.

OS: Ubuntu 16.04.2 LTS
Word size of OS: 64-bit
Word size of FreeCAD: 64-bit
Version: 0.16.6710 (Git)
Build type: None
Branch: releases/FreeCAD-0-16
Hash: f8eca0f9311f07c125dd6742a607724c1fa0b77c
Python version: 2.7.12
Qt version: 4.8.7
Coin version: 4.0.0a
OCC version: 6.8.0.oce-0.17