Increasing performance on a complex 3D part
I have been modeling a part that is a cylinder ~500mm dia x 1100 that has a complex surface geometry. It has a bunch of helical slots approx 120mm long that are repeated as a polar array then are reversed and off set half the polar array angle. The result is like a herring bone pattern of overlapping slots in the surface of the cylinder. There then need to be 360 angled groove across the width to form teeth.
My approach was to:
1 - model a piece of the cylinder 120mm wide, draw a helix as path and rectangle as profile and sweep it to form an intersecting solid where the slot is required, use fillet to round the ends of the solid.
2 - Polar array the swept solid to give 24 similar solids around the circumference.
3 - 3D mirror both the cylinder and array to give the next section of cylinder with the twist of the sweeps reversed. The mirrored body is offset less than width of the cylinder so the mirrored solids intersect about 10mm. I then 3d rotate the mirrored solid by half the angle of the array. This process is repeated until I have built up the full width of the required cylinder.
4 - I then union the 120mm section of cylinder for form a single body, Then subtract all the helical sweeps to cut the slots in the surface.
5 - I model the negative form of the teeth, constrain it to the cylinder surface, again polar array to give 360 solids around the circumference intersecting with the surface.
6 - I start subtracting these from the cylinder to 'cut' the profile into the surface.
The problem I have, is the dwg is now over 14MB, takes ~5 minutes to save, I can't SU the teeth forms in one go Brics refuses to do that. So I am doing them 20~30 at a time works but the SU is taking 10~15 minutes to process. My question is is there a bitter way to do this? I have still got a reasonable amount of features to add and the processing time is killing my productivity.
Brics is running on a reasonable spec PC Dell workstation with 3Ghz 6 core xeon, 16Gb memory, graphics could be more powerful being a NVIDIA Quadro FX 580. Brics is using 1 gig of memory & 100% of one core.
PNG image attached as the DWG is too big!!
I am hoping either a better approach to modeling or some system setting can be suggested to speed thing up.