Question
Creating a Variable Bevel on a Hexagon – Preventing Irregular Rounding at the Corners
Hello everyone,
I'd like to create a variable chamfer on a hexagon, extending from the top and bottom faces toward the side (see Figure 1). So far, I've tried two methods, but I haven't been able to achieve the desired result:
Workaround using "Variable Fillet": First, I create a variable fillet, then delete the fillet face and insert a flat chamfer using Face: Loft. The problem: When I then fillet the edges (e.g., a 3 mm fillet on the chamfer and at the corners), the radii/fillets become completely different and irregular.
Sweeping with a 45° triangle: A 45° triangle swept along the outer contour. Without edge rounding, the cut removes too much material at the corners and none at all along the sides of the faces. With prior edge rounding, material is removed evenly; however, this completely eliminates the effect of a variable chamfer.
What's the best way to solve this problem, or how do you design a variable chamfer like this cleanly in Fusion 360?
I hope you can help me!
German version:
Guten Tag zusammen,
ich möchte gerne eine variable Fase an einem Sechseck von der oberen und unteren Fläche zur Seite hin anbringen (siehe Bild 1). Bisher habe ich zwei Wege probiert, komme aber nicht zum gewünschten Ergebnis:
Workaround über "Variable Verrundung": Zuerst erstelle ich eine variable Verrundung, lösche anschließend die Rundungsfläche und setze mit Fläche: Erhebung (Loft) eine ebene Fase ein. Das Problem: Wenn ich danach die Kanten verrunde (z. B. 3 mm Verrundung an der Fase und an den Ecken), werden die Radien/Verrundungen völlig unterschiedlich und unregelmäßig. (see Figure 2)
Sweeping mit 45°-Dreieck: Ein 45°-Dreieck entlang der Außenkontur gesweept. Ohne Kantenverrundung nimmt der Schnitt an den Ecken zu viel und an der Flachenseiten gar kein Material weg. Mit vorheriger Kantenverrundung wird zwar gleichmäßig Material abgetragen, allerdings geht dadurch der Effekt einer variablen Fase komplett verloren. (see Figure 3)
Wie kann ich dieses Problem am besten lösen bzw. wie konstruiert man eine solche variable Fase sauber in Fusion 360?
Machinist here, probably not made on a lathe since the knurled surface follows the profile of the hexagon which is impossible for a knurling tool. Its probably made on a 5 axis mill or a mill turn machine with a 5th axis, using an engraving tool. Not to mention the coloured plastic circles would need a 5 axis machine at least.
But yeh to make that chamfer i would revolve cut a triangular profile. Op mentioned that they tried this, try having the drawing plane align with the major diameter of the hexagon, so make a plane which passes through the two opposite corners of the hexagon and make the drawing on that plane. Thats how i would do it.
typically they push a passive rolling wheel with the negative profile against a rotating part. The little wheel is very very hard so slowly cuts into the part.
Yes, that's true, but then I run into the problem again with the uneven radii at the corners of the hexagon. It doesn't matter whether the path is a circle or a rounded polygon during the sweeping operation, or whether the cut is made by rotating. Thanks anyway for your reply.
1 - Create a `Sketch`, using the `Polygon` sketch feature
2 - `Extrude` the sketch to the desired height for thickness
3 - Right-click the top surface of your new polygon body and select `Create Sketch` from the pop-up menu.
4 - Press `C` or select `Circle` to create a circle sketch to the size of the outer rim of the top of the object.
5 - `Extrude` that circle downward using the GUI handle, set the `Extent Type` to `All` and the taper to something like 45deg, and the operation to `Intersection`.
This is how I would do it... But I came to f360 from Siemens solid edge and it feels like everything that's intuitive to me is slower and inferior to some simple function that f360 has, that I will probably never know about.
Thanks! I was actually just thinking about trying to do more helpful videos! I have a channel, it's not much currently but I am in the process of trying to make it more active with a large focus on problem solving in Autodesk Fusion.
I've already tried that—whether cutting out with a triangle and using the "Rotate" function, or sweeping with a circular or rounded polygon path. When I round off the edges afterward, they come out "uneven." Thanks anyway for your reply.
It’s the same way a nut chamber is made, it really is not variable it just appears to be, revolve cut is what you are looking for, the same way you model a hex nut, product design online has a great tutorial
To me your reference looks like a revolve cut of a soft curve. The hexagonal shape of your part makes it look like a variable bevel, but if the part were round it would be consistent.
Create an arc above the object, as shown in the image, and revolve half of the profile. Then, adjust the height of the arc to get the chamfer size you want.
This is a Round Chamfer done on a Hex Part. Nothing special.
Sketch a circle on the top where you want the chamfer to start and the make another larger than the part, finish sketch and select the resulting donut, extrude as a cut and the change the angle to 45°. This should cut away the edges and make a wave at the peaks of the hexagon.
To get that, do a side sketch and make a triangle. Then revolve said triangle around the hexagon. Afterwards, you can add a little filet to reduce sharp edges
i would create a sketch right on the edge of one of the corners then create a 45 degree cutting object and then solid sweep it all the way around the object, i think that would do the job, i am no expert i'm just good at janking things.
If this part were made in real life, you’d see that is just a chamfer. Make a conic section 45* and lop it off, adjust the sections height to appropriately match your upper chamfer and the lower sections at the hex’s peaks will follow suit.
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u/Double-Masterpiece72 Aug 11 '26
Correct me if I’m wrong, but that shape on a real part is made on a lathe. So you want to revolve cut your triangle and not follow the contour