Spline Design Generator - Internal Involute Spline Error

[SeanFountain]

We are generating a splined connection between a hub and a shaft.  The shaft side of the spline generator always generates without issue, however no combination of dimensions will result in successful generation of the hub groove in one pulley part, yet it always generates successfully with identical features on a different pulley part.

If a more detailed explanation could be provided of what the spline generator needs in order to generate the hub groove, it would tremendously boost the effectiveness of Inventor in our company.

It is useless to be able to get a fix for only just one iteration of this part, I need to be able to change the pulleys as needed for customers without having to spend days fiddling with sketch dimensions just to get the spline generator to work (sometimes with an identical set of sketch dimensions that didn't work a day before).

Sketches are fully constrained, all faces involved are parallel or perpendicular as necessary.  There is only material removal, no generation.

Spline specification is irrelevant to generating this problem.  Spline length is being set to 9mm or 11mm and out radius to 0 (Inventor is setting an actual out radius of 3mm, which is fine).

The tutorial for this design accelerator is basically non-existant, the errors provide no explanation.

"Modeling: Cannot create this iFeature!"

"Modeling: Not possible to create Hub Groove!"

Attempts to change the orientation always add an error related to generating an angle constraint, if the part is constrained in advance and orientation is left to the design accelerator, this particular error does not arise.

Please, in summary, provide a detailed true tutorial/explanation on what the spline generator is looking for and needs to complete any hub groove.  There must be some numbers from the calculation results that we can use to ensure successful generation each time.

The part files cannot be provided without approval from my supervisor, but again, we are looking for consistent function with this generator, not a specific part.

Thank you for your time,

Sean C. Fountain | Development Engineer | Efficient Drivetrains Inc. | efficientdrivetrains.com

[SeanFountain]

I still need an answer if someone can help, it would be greatly appreciated.