Error: inconsistent edge-face relationships trying to cut a body from a sketch

[vogt.mr]

Having trouble making a cut from a sketch. I've tried defining the sketch 3 different ways and received 3 different errors. In all cases, the sketch was derived from projected lines that were "broken link"ed into sketch lines.

• When the sketch (sketch 10) is defined by the body face, extrude positive direction, I get the "inconsistent edge-face relationships" error.
• When the sketch (sketch 11) is defined by the x-y plane, extrude positive direction, I get the "system inconsistency processing surface tangency" error
• When the sketch (sketch 12) is defined by a construction plane offset parallel to the x-y plane, extrude negative direction, I get the "There was a problem combining geometry together. If attempting a Join/Cut/Intersect, try to ensure that the bodies have a clear overlap (problems can occur where faces and edges are nearly coincident).

The first method worked for sketch 9 in the areas above and below the trouble selection represented by extrude 7 & 8 in the design history. 

I'm planning to run this on a CNC router/mill.

Any advice? 

Thank you

[jeff_strater]

That error usually means that the profile you are cutting is very close to, but not exactly coincident with, other faces in the model.  Let me take a look at the design, and see what I can see.

[jeff_strater · Accepted solution]

@vogt.mr , my suspicion was correct for this model.  The sketch you were extruding from does not match up exactly with the geometry adjacent to what you are trying to remove.  There are a couple of ways to achieve this.  In the screencast below, I edited sketch 12, and used Project to get more accurate curves for the parts adjacent to the bit you are trying to remove.  This mostly works (leaves a couple of unnecessary edges in the model).  But, the really easy way to do it is to just select the face, and use Delete.  In Solid mode, Delete is a "delete with heal", and nicely repairs things exactly as I think you want it:

[vogt.mr]

The delete key was SO MUCH EASIER! I didn't realize the program was that intuitive.

Thank you, that worked, I'll also watch the video to learn more and hopefully be able to fix the causes of error in the future!