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fearthebeard - 9/18/2020 2:16:53 PM
   
Cosmetic Diamond Knurling

Hiya,

I'm working on a project that includes a long cylindrical(-ish) part that is diamond knurled. I've done custom diamond knurling on lots of parts in KeyCreator before, but I've never had great success with the process. The parts have always taken a very long time to create, the file sizes are enormous, the solids are difficult to manipulate/unite, and using the file eats up all my computer RAM.  

I'm wondering if there is a different, possibly faster way to create accurate, clear diamond knurls other than the way I'm currently working.

What I typically do is create a helical spline running around the length of my part, and then create a 2D "tooth" profile that I sweep along the helical spline. I mirror the new solid spline shape, and then copy the two new solid splines as many times as there are teeth around the diameter of the part. 

All good so far, but then I run into trouble when I want to subtract the solids from my cylinder. The operation can take several minutes, sometimes hours. There is also no guarantee that the operation will even be successful, as sometimes I will get some sort of face intersection error. I'd say this happens like 30% of the time. I've tried uniting all of the solids together before subtracting them from the cylinder, but this takes longer and is more likely to fail.

Has anyone had more success with this type of operation that would be willing to share their wisdom?

Thank you!! :)

 

 


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Hans_Winkler - 9/18/2020 4:13:52 PM
   
RE:Cosmetic Diamond Knurling
The only thing I can think of with the creations of the helical spline and the 2D profile is to make sure the spline reaches beyond both sides of the cylinder end, and the 2D profile reaches above the cylinder, not tangent.
I agree that KC is slow when it comes to the type of stuff you are trying to do.
Hans

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fearthebeard - 9/18/2020 5:00:15 PM
   
RE:Cosmetic Diamond Knurling
Good points on both, thanks! :) much appreciated.

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Dana - 9/21/2020 7:56:17 AM
   
RE:Cosmetic Diamond Knurling
If I just want the knurling to show in a HLR layout, I use crosshatching (alloys pattern, usually about 1/16" spacing, angle as appropriate).  For a shaded image you can use a surface texture, if the supplied texture images don't work for you you can use your own image files.
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fearthebeard - 9/21/2020 11:07:35 AM
   
RE:Cosmetic Diamond Knurling
Great points! I do end up having to do both of those things, and they are helpful; unfortunately I also need to create a 3D-printable solid, which is why I have to do this exercise. 
Thank you for the reply, take care!

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