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tube cutting for weldments
I have a problem that overlaps a question about how to and what I see as an error. I plan to post this on the forum as well to see if anyone else has run into the same concern and may have an answer.
I’m fitting tubes together for a weldment. Initially leaving supplier to take care of trimming tube ends since that is what they do to manufacture parts for us. The supplier cuts tubes using a machine that takes my extruded parts and cuts normal to the part axis which eliminates feathered edges that don’t work well for welding. We want to do this operation ourselves to save some time. I have not been able to work out the means. Tried a remove swept profile but the tracking has to change from outer to inner curve. My difficulty is determining where that transition has to happen so I can use 2 curves with a sweep remove.
Also tried using sheet metal parts since they have a normal cut as I need. The sheet metal tool doesn’t seem to know any better than me where the transition from inner to outer is and just follows the outer edge. The attached file has an example. It leaves material that produces interference fit. Also as shown on example is a cut where a secondary tube has to fit over primary. In sample provided it mostly works but leaves residual ‘parts’ not wanted. Some of the trimming of secondary cut out works but gives an error on about 50%. I don’t know why and no messages indicating what’s wrong.
Am thinking to provide paper flat layouts to our shop during development to save time by providing a wrap around template for tube cuts.This would require accurate flat patterns not always available when errors occur. Getting a flat pattern suitably sized for the diameter as a wrap around is no trouble when K facture of 1 is used.
Thanks to anyone that can help with this.