issue with sweeping curves

table38

This is for a THT part making leads with sweep tool isn't working. Sketch 1 is guide path and Sketch 2 is profile. 

https://cad.onshape.com/documents/31d7342ed8cf5edf50bfe297/w/86318314347464ebab042339/e/ea24f76335a4b695a2a30c29

NeilCooke

You need to make the radii on the path bigger (or the profile smaller) to prevent the sweep from self-intersecting.

table38

NeilCooke said:

You need to make the radii on the path bigger (or the profile smaller) to prevent the sweep from self-intersecting.

CancelThe Intersect option doesn't work I rather it be intersecting.

NeilCooke

Not sure I understand? I am not referring to the Intersect option in the dialog. 

At at the bend in the path you are asking the sweep geometry to go inside itself (“self-intersecting”) which is physically impossible. 

table38

Changed the diameter of leads and the issue is the leads aren't solid body with rest of the part.

The sweep feature was made as Add and using Union to merge the 2 parts will still leave a gap between part and leads.

NeilCooke

That's because the diameter of the sweep is 0.01mm smaller than the ball shape. Change that to be bigger and make the R0.4 bigger in the path so that it doesn't self intersect - like this:

https://cad.onshape.com/documents/33ac0357d7e57ad543b9cc02/w/cb782a56667e53da5edfef95/e/265c2c8714d42495ede5bffa

table38

That resolved the issue, its a solid part with leads.