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Accepted answer
Since designs are most often trade offs, I'll offer up another way, kind of.
It's really just how you did it in the first place, which left unwanted little slivers of geometry.
All I did was "delete face" on the slivers and presto. The only trick was it had to be done in two steps, which sometimes is the case when dealing with tangency scenarios.
The advantage to this method, for me, is the rib geometry becomes self adjusting to design changes to the underlying cylinders.
The trade-off is, now the big cylinder extends up the rib a little, and the rib extends up the top cylinder a little, but, it leaves the face of the rib "planar", which may present fewer tooling challenges to somebody. This is where I'd talk to the mold-maker and ask "would you rather..."
This might go a little further than you care to with a beginner/class situation, but I like to pitch the "delete face" tool when the chance arises, it's such a versatile tool.
4 Other answers
I would just shorten the length of the rib on the bottom, so it doesn't extend to the edge of the flange.
There's a similar situation on the top of the rib. In this case, I would probably make the rib extend outside of the collar.
You can create the triangle in respective plane the just extrude it symmetrically.
I thought about it last night, and while there are several solutions, I think this might be the easiest:
- Instead of sketching the side (triangular) profile of the rib, I've started from the top. This allows me to sketch arcs for ends of the sketch instead of lines.
- Extrude the shape to the desired height
- Create the desired slope with a really long Chamfer feature. In this case I used the asymmetric distance/distance option, but it would have worked fine with the symmetric option.
I know students are going to try and use the Rib tool, and will mess this up, but at least it will be a good opportunity to discuss making features in different ways.
I like this option because it just uses an extrusion, and a chamfer. Other solutions I have seen get into lofts, boundary tools, surface cuts, 3D sketches... I like those tools, just not in a basic level class.
Maybe you could find some physical parts with ribs like this, just to show your students what really happens with molded or cast parts.
