Making a "Port Tool" in Fusion 360

The finished housing

Earlier this week I finished my sequence valve housing in Fusion 360.  And I learned a quite a bit doing it.

Many of my challenges were learning to use Fusion 360, partially because it's a tool I'm still new to, and there are different ways to do things in Fusion.

But the challenge I'm going to focus on is more one of process, than one of creating shapes in Fusion

The ports where fittings attach

One of the challenges I faced was how to easily model the 6 ports that were located in the housing.

They're all based on the AND-10050 standard.  That means that the ports are similar.  And when I say similar, I mean they're all similar geometry, varying only by size.

Take away the dimensions, and they're the exact same shape

I also recalled that there are special tools for drilling these ports.


In other words, where things can be standardized, they are as standardized as possible

So why do the same thing in Fusion?

We'll, here's how I did it, at least in brief.

First, create a new part in Fusion, locate the parameters, and entered the dimensions from the table found in the standard into the User Parameters section.

The user parameters

Why enter them first as User Parameters?  I can enter them in an orderly fashion, as they're seen in the table, and then enter them as I built, instead of trying to do both at the same time.  I think it's easier, personally.

The cross section for the "port tool".

Next, I built the port, using standard Fusion tools, and calling the user parameters I entered above.  In my case, I created the cross section for the port as a revolved feature.

It's interesting, at least I think, to point out that the finished "port tool" is a solid.  But I'll use this to remove material from the base casting that will be receiving the port I need.

The port tool, as a solid.

So what were the benefits I found to doing it this way?

First of all, I had a tool that was easily reusable and repeatable across as many places, and designs as I needed.

Second, since the AND-10050 port comes in multiple sizes, I could copy the port, change those user
parameters that I created earlier, and create a new port in a matter of minutes.

Inserting into the current design

And since there were several different port sizes in the casting I was reproducing, this proved to be a big time saver.

I effectively created a "template" for the port that I would use as a standard design feature.

Those benefits alone were enough to get me to bite on this method.

Now, all that was left to do was to open the design that needed the port, and insert the solid.

With a little magic from the move and combine command, I was able to subtract the port tool from the casting I needed, and end up with the right port.

But I'll save that one for a post a little later.

I hope this port helped, and if you have any tips on how you've tackled a similar challenge, feel free to leave a comment!

Inserting and moving the solid

Good luck!

Acknowledgements.

The print I used to create this valve body was provided via my subscription to AirCorps Library.  Thanks for the awesome work preserving vintage aircraft drawings!

A Friday Fusion 360 Tip - Going Off on a Tangent

My first try at the sequence valve housing.
After a few mistakes, I decided to try again. 

Just today I was working on a model in Fusion 360 of a small valve housing for the hydraulic system in an F4U Corsair.  Call it a self imposed design challenge.

This is actually my second try.  I had a first iteration, but I wasn't happy with it so I just decided to start again with a clean slate.

What can I say?  Life happens!  But I learned, and the new model will be better than its predecessor.

But in the process, I was cleaning some excess material with  the sweep command, and ran into something that left me with a combination of surprise, puzzlement, with a touch of frustration.  

The model path that I chose for my sweep wasn't complete.  The cut I was intending to make came up short.

The sweep coming up short, it should continue around the back
of the part.

I hope this isn't a bug.  I told myself.

I mean, I couldn't have made a mistake, right?  Right....  Of course not.....

Thankfully, I have years of 3D modeling experience behind me.  And when I say "years of 3D modeling experience", I mean "years of recovering from making mistakes building 3D models"!

So once my initial feeling of frustration passed, my troubleshooting brain kicked in and my experience told me to check the tangency of the sketch.

The arrow shows where I missed a tangent

Nothing will stop a path dead in it's tracks like a non tangent edge.

So I went ahead and checked the tangency of the path. Sure enough.  I had missed a tangent constraint.

You can see it in the image to the right.  On the left side of the highlighted area, there's a tangent constraint.  On the right, not so much....

So I added that in, and tried it again..  

Guess what!  It worked like a charm!  A small thing, but an important one.

So remember, whether your using Fusion 360, Autodesk Inventor, Solidworks, or another CAD tool, remember that one of the best set of tools you can have is a good set of troubleshooting steps!

Victory! 

And remember.... Watch those tangents!

Aircraft Maintenance Class - A Milestone Reached... But Why?

The instructional airframes that taught me many lessons.

June 16th 2017 marked a big date for me.  I completed the airframe portion of my aircraft maintenance curriculum.  It's been a long time in coming for sure!

In the 750 hours the FAA required of me, I've covered everything from safety wire, to hydraulic to safety wire, and everything in between.

Now I'm not racing through 18 hour days between work and school, I have time to answer a few questions I seem to be asked.

"Why are you taking aircraft maintenance classes?"

I know I'm supposed to have some sort of awe inspiring, motivational answer.

But the truth of the matter is, I did it because I like airplanes, and when the time came to expand my skill set, I decided to accomplish that by jumping feet first into something I've always liked.

And what resulted was an ongoing journey that has been difficult, exhausting, frustrating, and most of all, rewarding.

I learned many lessons that I've been able to apply to my work as a mechanical designer.

So that's my story.  I'm hoping to find a little time to blog about my ongoing lessons, as well as dive back into Fusion 360 and share a few of those lessons there as well!

The Amazon Web Service Outage of 2017

Earlier this week, Amazon Web Services suffered a service disruption.  For me personally, that meant disruption in Autodesk Fusion 360 (which I thankfully wasn't using at the time), and Fusion Lifecycle, which I was.  Fortunately, while Fusion Lifecycle was disrupted, it wasn't offline.

So, what happened?!?!

Several sites were affected.  My girlfriend sent me an instant message to let me know their CRM (Contact Resource Management) was down.  According to NPR, Gizmodo and Apple iCloud were affected.

The amazing, and perhaps disconcerting part of this is how easily the service was disrupted.  It seems that a technician was troubleshooting, and took off more servers than intended with a typographical error.

That's right, a typo, fat fingers as us techies call them, were the cause of the disruption.

Added to that, there didn't seem to enough redundancy, or possibly any, to absorb the lost servers while they were brought back online.

Now I'm no expert on Internet architecture. I imagine I know more than some, less than others.  I'm not going to prognosticate on what Amazon could have, and should have done, or should be doing.

There are plenty of people smarter than I who can do that better than I can.

But what I will say, is what I learned, relearned, and what I can do in the future.

What I learned and (relearned)

• The cloud is a great tool, it's saved my class grades when I didn't print it out by mistake.  But the technology is new, and new technology is often developing systems, and developing systems can be prone to failure.  
• As a whole, the cloud is pretty robust, but when it fails, it can fail spectacularly.  Many can be affected, and word can get out quick!

What can I do in the future

• I can't make Autodesk, Amazon, or anyone else change their system, at least not directly.  But I've heard rumors that improved offline capabilities are on their way.  I hope they're true, and that after this outage, the efforts have been increased.  I'll be keeping my eyes out for that development! 
• To this end, I'll be doing a better job of backing things up locally.  That's right, in a 180 degree turn, I'll be working in the cloud and backing up locally.  Just in case. 

I won't be abandoning the cloud, what I will be doing is approaching it more cautiously, and more diligently.  

In many ways, the cloud is a new frontier filled with pioneers, and pioneers must face the hazards of a new frontier to pave the way for others.  

For my part, I'll choose to stay on that frontier, but I will make sure I'm planning ahead! 

On into the brave new world!

photo credit: NPS Park Cultural Landscapes Program Chilkoot Trail via photopin (license)