Modeling with advanced techniques > Surfacing tools > Creo Elements/Direct Surfacing module > Round a face
  
Round a face
Create a chain of blend-like faces to connect two face part sets tangentially or curvature continuously.
1. Activate the Surfacing module.
a. Click File > Modules. The Modules dialog box opens.
b. On the Modules pane, click Surfacing under Licensed.
2. Click Surfacing and then, in the Advanced Surfacing group, click Face Round. The Face Round dialog box opens.
3. Type a name for the face part.
4. Click a point on the first face.
5. Click a point on the second face. The system will calculate an initial radius based on the position of the picked points and the face normals at those picked points.
6. Use the CoPilot arrows to modify the radius of the face.
7. Click Extend to create a chain of faces with edges tangent to the initial face. Use Stop Edges to stop the chain before the end of the tangent edge. Curv Cont provides smooth transitions at face boundaries. The face(s) are added with a curvature continuous connection.
8. Imprint will imprint the face onto the original part. It is on by default.
9. Click to complete the operation.
10. Delete unwanted faces in the original part.
11. Gather to integrate new faces into the model.
12. If you want to generate a solid part, use Grow or one of the other Surfacing tools to close any remaining gaps.
Advanced options
Convexity: The convexity of the face chain depends on the initial pick positions on the two faces. Change the shape of the face chain by choosing Auto, Convex, or Concave.
Stop Edges: Limit the length of the face chain with two stop edges.
Click Edge1, then select an edge on a face to shorten the chain of faces.
Click Edge2, then select an edge on a face to shorten the chain of faces.
Roll along Edges: Changes the shape of a rounded face when it meets another edge. This option adapts the new rounded surface to preserve the original edge.
Limitations
Rounding a face only works on faces of one single part. To use Face Round on two parts, transfer all faces of both parts into one single part. Use the Gather command with the Split Part option turned off.
All generated surfaces are freeform surfaces, even if the defining faces are analytics. There is no modification capability available with Face Round.
When using the Curv Cont option, the chain of faces will stop at any edges where it is not possible to generate curvature continuous faces. Usually this happens when the chain boundary rolls over a non-curvature continuous edge.