Im making a twisted iron bar. I have added array modifier and with the help of empty i have twisted. After adding array modifier the edges been seen. How can i remove that edges of the array to look a continious mesh. After adding the sub division modifier the mesh look odd. How can i make a smooth mesh and plz suggest me is this method right or can i go with other method
Atek, I try here to describe what you could do as an altenative.
1) I suppose you have 7 revolving bars around your cylinder, so in front view I add a 28 vertex simple circle, then I take a 2 vertex segment, duplicate and separate it. Then I extrude it along normal Z (press ZZ), here I extruded using 0.2 value.
Then I also added to the extruded "square" a screw modifier, with the settings below.
In the picture above I also extruded the original 28 vertex circle to get the cylinder: you can obviously smooth/subdivide/bevel the cylinder as you want to make it look "perfect". To smooth/subdivide/bevel the "bar", though, you could need "real geometry", so you could need to apply the screw modifier first.
2) then, to get the other "bars", set the pivot for rotating/scaling around the cursor, put the cursor at circle center, activate snapping to vertices, as you see below, then duplicate the first "bar", and rotate it around the circle centre, and snap it to the fourth vertices you have clockwise on the circle.
As you see in the picture, your "bar" is duplicated and fits nicely around the "cylinder".
3) to get all the bars, you need to repeat the "bar duplication" step other 5 times, to get this:
This is what I had in mind, I hope it is explained simply enough, and gives you another idea.
You need to delete all faces that are going to be hidden by the Array modifier (selected on the screenshot, delete them on both sides of the object). Then enable the "merge" option in the modifier settings.
Normally, this is the way I'd be going for. Sadly, I can't tell you why the subsurf modifier messes up in this mesh. But if you put a fairly high Crease amount on most of the edges (except those that should be smoothed) it works fine.
If you are looking from your object from a distance, the Edge split modifier will do the trick. If you have some spare render time, go for a Subsurf and eventually then a Bevel modifier.