Hi there,
Following a Boolean Subtract of a Swept feature (single closed profile along a helix), I'm left with what I am calling a 'sliver'... basically a thin undesirable area of geometry. As shown on attached jpg "sweep-leftovers-01", you can see the sketch profile I'm sweeping, and the resulting solid after having the sweep subtracted.
FYI the sliver is highlighted orange; the section cap is light blue; resultant solid body green.
It looks to me that there's a gap appearing in between the swept volume, causing the boolean subtract to leave the sliver.
To try to remedy this, I measured the gap between the 'coils' of the swept volume (shown in attachment "sweep-leftovers-02-measure"). I then adjusted the width of the swept sketch by the same amount, thinking that would eliminate the gap right?
Unfortunately the result is shown in attachment "sweep-leftovers-03-adjusted". It appears the boolean subtract is now resulting in an undesirably large solid volume (I guess because the profile is now overlapping?)
I have tried nudging the swept sketch width a little either way, but whatever happens, I either get a sliver or a big solid!
Currently I have worked around the issue by using surfacing techniques to delete and trim the sliver away, then rebuild using Filled Surface. However I'd be grateful of any suggestions to prevent the sliver happening in the first place, since I'm still at a stage of making design changes. And due to the form of the custom thread, every time I make a change, I have to re-do the surface editing. That's not a problem in itself but it just seems like there must be a better way of doing this!
I'm limited to what I can show in the images, as the design contains proprietry information. Hopefully the images give enough info to understand the core problem I'm having, but if you need more detail, I'll try to help.