Smoother Saddle Joint Profile with Ruled Surface

In the above video, I wanted to demonstrate how to create a frame tip in Solid Edge. The default method creates a standard saddle joint. The method I used creates a smoother profile on the edge.

Creating the Frame

Start by creating a new assembly and entering the Frame window. Create a 3D Sketch of the profile and in the next steps we'll turn it into some frame components. I created a mitered corner on the pipe. Then I use the same size pipe for the brace which creates the largest saddle profile on the geometry. We're going to clean this up.

Now starts the magic. Let's make some modifications to the geometry.

Save the individual components by going to File > Save As > Save Selected Model. Start a new assembly and populate it with those parts. Hit Shift, select all the items, then right click and select Occurrence Properties and set the X, Y, and Z values to zero. Save this and now it's linked to the original.

Apply a chamfer to the mitered corner to allow for a weld bead.

Ruled Surface Function

Now let's clean up the profile of where the brace connects to the frame. Double click and edit in place. Under Surfacing tab, select Ruled Surface. Select the option that works best for you. I tried out "Normal to Face" option which produced a cleaner profile. This creates a bit of interference which can be solved using the subtract feature.

On the other saddle, I applied the "Natural" option which also creates a clean result.

Finished Product

These ends are meant to be cut on a laser machine rather than just with a pipe profile. Below you see the end conditions on the actual pipe.

Hopefully this helped you create a laser cut, cleaner profile rather than the larger standard saddle profile.