Hi Vince, welcome!
Which version of Maya are you using? In 2015 and higher, booleans are a lot more forgiving than in previous versions.
There are a bunch of reasons why the operation might fail. First, try deleting the history of the objects before performing the operation. If that doesn't work, try another boolean method. Does it still fail? Another thing you could try is adding more divisions along the length of the cylinders, and then trying again.
I am using the 2015 version. Thanks for the advice! I'll work on these when I get back from my day job tonight.I have responded to quite a few posts in the past on Boolean operations. If you do a search you might find something helpful. As ND suggests always delete history before doing the Boolean. Also you want to avoid long thin polygons, so you should add divisions along the cylinder of both the wheel and the cutters. (this is what I would guess is causing the operation to fail).
Also use symmetry to your advantage. You can that wheel in half along z and quarter it along y and x and only have to work on 1/8 of the part.
After performing the boolean, if you intend to smooth you will have to do some clean up so try to align edges in the part being cut and the cutters to minimize the post boolean cleanup work.
I am recording a camtasia video to demonstrate and will post a link shortly.
I think I understand, so I need to delete the edge first and then the vertexes connecting to it? Or delete the edges and do the Cleanup Mesh command afterwards for the stray points?1. when you delete edge do not just hit the delete key. This leaves the verts and so the shape will not change and you will have orphaned verts in the middle of edges. I use marking menus so ICannot recall where the "delete edge" command lives in the tabbed menus.
2. Normal refers the the direction of the outward facing side of a polygon. Faces have a side that faces out and reflects light and a backside that does not. Under lighting tab you can turn off two-sided lighting and see one side will become black. If you see black faces it usually means you have flipped normals. This can lead to non-manifold geometry if two faces are facing opposite directions and connected by an edge.
There is a cleanup command and under remove geometry I usually select - lamina faces, non-manifold geo, edges with zero length, faces with zero geo area.
You can also highlight faces with more or less then 4-side and non-planar faces which can help to find surfacing issues.
As NextDesign said but instead of pressing enter use the "y" button to reuse last tool, should speed up the process a little............daveOne way to fix that would be to delete it, then use the Append to Polygon tool under Mesh Tools. Then, click on one edge, and then the one you want to create the polygon to, and press enter. Repeat for all other edges.