180 curve connecting two different sized discs. Tried loft but just get errors

jonathan_stewart160

I'm trying to create a custom 18650 battery holder using contacts I already have and I'm trying to model the contact as a way to check fit in the end and learn the tool with a defined end goal. It's two disks with a screw thread pole on one side and an integral leaf spring. An earlier revision of the contact can be seen in the lower right of this image https://www.electricbike.com/wp-content/uploads/2017/06/BPBK10.png

I tried doing a loft to create the curved spring portion of the contact but that didn't work at all. The linked model below I used the 3 point arc tool but the transitions are clearly wrong. I tried a tangent curve as well but couldn't figure out how to make it symmetrical. 

https://cad.onshape.com/documents/1be1fb84bdbdd444be241913/w/1f7a0b5bef531286e21a17b6/e/75ce751f508cae7cf4a1f8f8?renderMode=0&uiState=6372e9f140f45b657850bc41

As a secondary question the smaller disk is actually "humped" to create a slightly protruding center. Would two more extrusions one to add the hump and then one to subtract the back with fillets be a reasonable way to model that?

steve_shubin

@jonathan_stewart160

is this what you were looking for ?

https://cad.onshape.com/documents/96a689ae37de09fd6ceba86d/w/b0820d4393b1d2d0c0fbe926/e/3150ef98c9eb55417a492733

eric_pesty

@jonathan_stewart160
Another option to consider for something like this would be to use a shell. I also started with a revolve to create most of the shape in one go:

https://cad.onshape.com/documents/dceafb616ad02ade926333d9/w/5b9e7b596c304af828eb7a5f/e/9d52cdb866bb0d2c149260c9

steve_shubin

@jonathan_stewart160

is this what you were looking for ?

https://cad.onshape.com/documents/96a689ae37de09fd6ceba86d/w/b0820d4393b1d2d0c0fbe926/e/3150ef98c9eb55417a492733

mahir

@jonathan_stewart160
Another slightly simpler method would be to start with a U shaped sketch and either use an sketch offset to extrude it directly, or extrude a surface and then thicken. This is similar to what @steve_shubin did but without the need for an additional boolean at the end. The specific contact shapes can be added/removed via extrudes.

steve_shubin

@jonathan_stewart160

https://cad.onshape.com/documents/96a689ae37de09fd6ceba86d/w/b0820d4393b1d2d0c0fbe926/e/3150ef98c9eb55417a492733

Rearranged the features to eliminate the boolean feature

Could’ve also eliminated the thicken feature by doing offset within sketch one, but I don’t like working that way. Meaning, I definitely don’t like working with lines real close together. Hard on the old eyes.

I like a simpler sketch. So I prefer to use single lines, and then get my end result by using something like Thicken or Thin Feature within Extrude when possible

Onshape gives you a ton of ways of going about things. Now along those lines, you should certainly keep best practices in mind. But like the famous golfer Arnold Palmer used to say — Swing your swing. In other words, with all things considered, you still have to find out and pursue what works for you

But if you have those good eyes, you might want to go the Mahir route

eric_pesty

@jonathan_stewart160
Another option to consider for something like this would be to use a shell. I also started with a revolve to create most of the shape in one go:

https://cad.onshape.com/documents/dceafb616ad02ade926333d9/w/5b9e7b596c304af828eb7a5f/e/9d52cdb866bb0d2c149260c9

jonathan_stewart160

Thank you all! I'm honestly blown away by the amount of help my question got. A far better beginning experience here than I've had in many other forums.