Fillet feature on edges in Solidworks - Real Business Scenario

Scenario Mode

👤 Your Role: You are a product design analyst at a manufacturing company.

📋 Request: Your manager wants a report showing how applying fillet features on edges affects the production time and cost for different product parts.

📊 Data: You have data on product parts with and without fillet features, including edge count, fillet radius, production time (hours), and production cost (USD).

🎯 Deliverable: Create a dashboard that compares production time and cost between parts with fillet features and those without, grouped by product category.

Sample Data

Part ID	Product Category	Edges with Fillet	Fillet Radius (mm)	Production Time (hours)	Production Cost (USD)
P001	Housing	10	2	5	150
P002	Housing	0	0	4	130
P003	Bracket	5	1.5	3	90
P004	Bracket	0	0	2.5	80
P005	Cover	8	2.5	4.5	140
P006	Cover	0	0	3.8	120
P007	Housing	12	3	5.5	160
P008	Bracket	7	2	3.5	100

1

Step 1: Create a new column 'Has Fillet' that marks 'Yes' if 'Edges with Fillet' > 0, otherwise 'No'.

In your BI tool, add a calculated column: Has Fillet = IF([Edges with Fillet] > 0, "Yes", "No")

Expected Result

Parts with edges having fillets are marked 'Yes', others 'No'.

2

Step 2: Create a pivot table with rows as 'Product Category' and 'Has Fillet', values as average 'Production Time' and average 'Production Cost'.

Rows: Product Category, Has Fillet; Values: AVERAGE(Production Time), AVERAGE(Production Cost)

Expected Result

Table showing average production time and cost for parts with and without fillets per category.

3

Step 3: Create a bar chart to visualize average production time by 'Product Category' and 'Has Fillet'.

X-axis: Product Category; Legend: Has Fillet; Y-axis: Average Production Time

Expected Result

Bar chart comparing production time for parts with and without fillets across categories.

4

Step 4: Create a bar chart to visualize average production cost by 'Product Category' and 'Has Fillet'.

X-axis: Product Category; Legend: Has Fillet; Y-axis: Average Production Cost

Expected Result

Bar chart comparing production cost for parts with and without fillets across categories.

5

Step 5: Add clear titles and labels to charts and ensure color contrast for accessibility.

Title: 'Production Time by Fillet Feature and Category', 'Production Cost by Fillet Feature and Category'; Use distinct colors for 'Yes' and 'No' in legend.

Expected Result

Charts are easy to read and understand with accessible color choices.

Final Result

Production Time by Fillet Feature and Category

Housing: Yes ██████████ 5.25h
Housing: No  ██████ 4h
Bracket: Yes █████ 3.25h
Bracket: No  ████ 2.5h
Cover: Yes   ████████ 4.5h
Cover: No    ██████ 3.8h

Production Cost by Fillet Feature and Category

Housing: Yes ███████████ 153.33 USD
Housing: No  ███████ 130 USD
Bracket: Yes ██████ 96.67 USD
Bracket: No  █████ 80 USD
Cover: Yes   █████████ 140 USD
Cover: No    ██████ 120 USD

✓Parts with fillet features generally take more production time than those without.

✓Production cost is higher for parts with fillets across all product categories.

✓Housing parts show the largest increase in time and cost when fillets are applied.

✓Fillet features add complexity that impacts manufacturing efficiency and cost.

Bonus Challenge

Create a scatter plot showing the relationship between 'Fillet Radius' and 'Production Time' for parts with fillets.

Show Hint

Filter data to parts where 'Edges with Fillet' > 0, then plot 'Fillet Radius' on X-axis and 'Production Time' on Y-axis.

Practice

1. What is the main purpose of applying a fillet feature on edges in SolidWorks?

easy

A. To create holes in the part

B. To make the part heavier

C. To change the color of the edges

D. To round sharp edges for safety and strength

Solution

1. Step 1: Understand the function of fillets

   Fillets are used to round sharp edges on parts.

2. Step 2: Recognize the benefits of fillets

   Rounding edges improves safety and adds strength to the part.

3. Final Answer:

   To round sharp edges for safety and strength -> Option D

4. Quick Check:

   Fillets = Rounded edges for safety [OK]

Hint: Fillets always smooth sharp edges for safety [OK]

Common Mistakes:

• Thinking fillets create holes
• Confusing fillets with color changes
• Assuming fillets add weight

2. Which of the following is the correct way to start creating a fillet on edges in SolidWorks?

easy

A. Use the Hole Wizard to add a fillet

B. Select the Fillet tool, then select edges and set radius

C. Draw a circle on the edge and extrude it

D. Select edges and press Delete

Solution

1. Step 1: Identify the correct tool for fillets

   The Fillet tool is used to round edges by selecting them and setting a radius.

2. Step 2: Eliminate incorrect methods

   Drawing circles, using Hole Wizard, or deleting edges do not create fillets.

3. Final Answer:

   Select the Fillet tool, then select edges and set radius -> Option B

4. Quick Check:

   Fillet tool + edges + radius = correct method [OK]

Hint: Fillet tool + edges + radius = create fillet [OK]

Common Mistakes:

• Using Hole Wizard for fillets
• Deleting edges instead of rounding
• Trying to draw shapes to create fillets

3. Given a part with a sharp edge, you apply a fillet with a radius of 5 mm. What will be the visible result on the edge?

medium

A. The edge will change color but stay sharp

B. The edge will be removed completely leaving a gap

C. The edge will be replaced by a smooth curve with 5 mm radius

D. The edge will become thicker but remain sharp

Solution

1. Step 1: Understand fillet radius effect

   Applying a fillet rounds the edge with a smooth curve matching the radius.

2. Step 2: Recognize what does not happen

   Edges are not removed, thickened, or color-changed by fillets.

3. Final Answer:

   The edge will be replaced by a smooth curve with 5 mm radius -> Option C

4. Quick Check:

   Fillet radius = smooth curved edge [OK]

Hint: Fillet radius defines curve size on edge [OK]

Common Mistakes:

• Thinking fillet removes edges
• Assuming fillet thickens edges
• Believing fillet changes edge color

4. You tried to apply a fillet on an edge but SolidWorks shows an error. Which of these is the most likely cause?

medium

A. The fillet radius is larger than the edge length

B. You forgot to save the file before filleting

C. The part color is not set correctly

D. You selected a face instead of an edge

Solution

1. Step 1: Identify common fillet errors

   Fillet radius too large for the edge length causes errors in SolidWorks.

2. Step 2: Exclude unrelated causes

   File saving, part color, or selecting faces instead of edges do not cause fillet errors.

3. Final Answer:

   The fillet radius is larger than the edge length -> Option A

4. Quick Check:

   Radius > edge length = fillet error [OK]

Hint: Check fillet radius smaller than edge length [OK]

Common Mistakes:

• Ignoring radius size limits
• Blaming file save status
• Confusing face selection with edge

5. You need to prepare a part for 3D printing by smoothing all sharp edges with fillets. The part has edges of varying lengths. What is the best approach to apply fillets efficiently?

hard

A. Select all edges and apply a uniform fillet radius smaller than the shortest edge

B. Apply the largest possible fillet radius to all edges regardless of length

C. Apply fillets only to the longest edges

D. Skip fillets and print as is

Solution

1. Step 1: Consider edge length variation

   Edges vary in length, so fillet radius must fit the shortest edge to avoid errors.

2. Step 2: Apply uniform fillet radius safely

   Selecting all edges and applying a radius smaller than the shortest edge ensures smoothness without errors.

3. Final Answer:

   Select all edges and apply a uniform fillet radius smaller than the shortest edge -> Option A

4. Quick Check:

   Uniform radius < shortest edge = safe fillet [OK]

Hint: Use smallest edge length to set fillet radius [OK]

Common Mistakes:

• Using too large radius causing errors
• Ignoring short edges
• Skipping fillets before printing