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Removing extra parts of extrusions

harry_keithharry_keith Member Posts: 10

I am trying to make a simple right angle pipe fitting. The actual project is more complex, but this is the fundamental problem. I've made a working document of the issue:

https://cad.onshape.com/documents/845c24a0bdec92a6bb4dc7b9/w/5025293a4ec839078403bda7/e/64e748aa4768085ddeee1444?renderMode=0&uiState=69165cdf3cdc2c1c1be9beb0

Here's the problem. Take two circles at right angles, extrude them to make an elbow. This is done in manufacturing all the time, and even mass produced items (a PVC elbow at a big box store) are essentially done this way. My sketch, as initially extruded, has each part extend past the other, and there is no open passage. Some efforts:

  • Make the second extrusion from "away" and extrude "toward" the first extrusion. Then do a removal extrusion on the inside to the middle of the first extrusion. This works fairly well, but the first extrusion is still a mess. And horribly complicated.
  • Use a loft. This actually works well if you want to use two identical sections. In my current project, I want to then taper one side (by means of a draft), and it fails. It also would fail if it were a reducing elbow (1" on one side, 3/4" on the other).
  • Build a 45-degree plane, then extrude each side to the plane. This works well, but is a bit of a hassle (and won't work on mis-matched size/shape parts).
  • I read about splits, and can't get anywhere
  • Frames seemed like a route, but couldn't get anywhere
  • Boolean almost seems to want to be an answer, but I think not.

In a prior project (I worked around this) I was basically building an igloo. A dome shaped housing, with a half-pipe shaped pipe protruding out one side. The basic shapes were easy, getting a clean merge of the two into one part wasn't clean (my solution was fine for my application). If you want to see it, it's here:

https://cad.onshape.com/documents/fa79761ed5c4cc30f33ce288/w/bf00fb19378620770cbe346b/e/101bbec2b6c3fed1a3753fe4?renderMode=0&uiState=6916602727762b9c94587c66

This has to be such a common design feature that I keep looking for it to be built in, or at least a custom feature. If it exists, my searches are letting me down.

Thanks!

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