Ok so I've got 2 bores that are the same diameter:
If I boolean both holes with the same tool body and in the same manner I get two different results:
Yes 3 tenths difference is too much.
All geometry modeled in Fusion.
Combine Tool: Inconsistent behavior
Yes. That is because the cutting tool was farther away from the bore the first time. The tool sits inside the bore the same amount both times (.0175")
For demonstration purposes/double checking I first moved them so the start of the taper was flush with the top face (this value was different because it was arbitrary) then moved them both .0175" inward.
If I use the align tool first to align the cutter with the bore and then move it in a consistent amount, I get the same consistent result.
Relying on measured results is sketchy. At the very least I would enable all digits and then click on the measured value in the UI, which copies the value to the clipboard.
