Unexpected interference -- am I missing something or is it a bug?

[michaelpos]

I'm getting unexpected interferences between faces in my design.  I've probed around a lot with the measuring tool, and as far as I can tell all of the supposedly interfering faces are on the same plane.  In terms of the design itself it doesn't really matter, but I'd like to get to the bottom of it so I don't keep doing this in the future on a design where I might want to enter simulation.

Public link is available here: http://a360.co/2q6udib

Thank you!

[innovatenate]

If I use the interference tool in the Measure menu, I see the following results.

If I measure, there is a tiny offset, 3.081 E-4 mm.

Looking at the parameters, some are in inches and some are in mm. 

It seems like there may be a rounding issue here as a wild guess. I'm wondering if staying with one unit type might resolve the issue?

Are you having any difficulties in a simulation? The small interferences may not make a difference after the model is meshed. 

I look forward to your reply. 

Thanks,

[michaelpos]

Thanks, I see that offset now.

I don't think that different units should be an issue, as both the dado cut and the extrusion for the vertical brace used the same parameter (bracing_stock).  I've also done similar things before with mixed units and I've never seen this problem.  Is there an angle that is slightly off from 90 degrees somewhere?  That's the only thing I can think of, but I can't seem to find any.

[michaelpos]

I tried changing the units to mm and it didn't make any difference.

Another thing I tried is to measure the offset of the face of the vertical braces with the face of the dado cuts, copy that number into the clipboard, and then move all of the vertical braces in the +X direction (away from the interference).  Now the interferences have moved to the right side of the face, as seen below.  

But also notice that not all of the original interferences are reproduced on the right face.  This makes me think there either must be a non-uniform thickness, or things must be at a slight angle.  This makes no sense to me, as I cut the dados first and then drew the braces onto the plane of the dado cuts, which should ensure that they're on the same plane and the same angle, and I extruded using a single parameter (bracing_stock) to ensure a uniform thickness.

So I'm really at a loss here...

[innovatenate]

I went through the timeline and noticed some funny things like combine cut was being used and some really odd choice about using the faces of other parts as sketch planes. So, I reworked the design as a sanity check to see if I could get it assembled with joints, and using techniques I know should not produce any interferences. The results are in the below link for your perusal. You can play the timeline to see what I did step by step.

http://a360.co/2pqImry

I suspect there were a few things that just weren't lined up 100% as you were going through the timeline which is why the inspection tool is reporting interferences. Changing few things around the compute all feature is a bit faster too (seemingly). 

I hope this helps. If you have any questions about my approach, please let me know. I am happy to help.

Thanks,