How can I only fillet the edge between these two intersecting holes?

james_mitchell836

Hi guys, hope you're all well. I am pretty much brand new to CAD and after watching a bunch of tutorials I have started to create some parts to print in my 3D printer.

I have been playing around with creating a tool holder for my bench and have run into an issue that I can't seem to google my way out of.
I have two intersecting holes that I have created with remove extrusions in order to slot some allen keys in, when trying to fillet the edge between the two, it appears to also fillet the top layer edge as seen on the left picture. Is there another function I can use to create only the fillet that isn't highlighted? Or am I going about this the wrong way using extrusions.

             

Here is a link to the mentioned file; https://cad.onshape.com/documents/dc30d83daba3f937d606f607/w/e6e0d9bc8b445909300dbab0/e/a3f0e94da1b903d50e7fc7d7.

Cheers guys.

rafael_telgmann

Hi, you'll need to use a variable fillet with a radius of zero on the vertices.
Take a look at the last feature to see what I mean.

https://cad.onshape.com/documents/0cabc7ccdc899e107ef41004/w/f62a44c2a1f166d780cce585/e/a04e76c1d6bb14d7b21baf4c?renderMode=0&tangentEdgeStyle=1&uiState=666df667bf9efc1d9082fe2d

rafael_telgmann

Hi, you'll need to use a variable fillet with a radius of zero on the vertices.
Take a look at the last feature to see what I mean.

https://cad.onshape.com/documents/0cabc7ccdc899e107ef41004/w/f62a44c2a1f166d780cce585/e/a04e76c1d6bb14d7b21baf4c?renderMode=0&tangentEdgeStyle=1&uiState=666df667bf9efc1d9082fe2d

james_mitchell836

Thanks again mate that has done it! I tried playing around with variable fillet as well and had a similar thought to your solution, but I also didn't understand the tangent propagation feature of the fillet and had it left on, which makes sense as we don't want the fillet to be continuous all the way to the edges. Cheers again

james_mitchell836

Also I found that when extruding the top holes, rather than having the extrusion set to 'blind' at the correct manual distance, I could set it to 'face' and click the vertical hole. This meant that no variable fillet was needed. Hope that helps anyone else with the same issue.