Failed fillets

[SEC_MECH]

Hi, I often come across fillets that fail but I think that I have found one cause. Is there a less-than (<) statement when there should be a less-than_or_equal-to (<=) statement.

The attached file has 4 ribs.

Ribs 1 and 2 have no draft and fillet fine regardless of whether the fillet was done in one command (rib 1) or two (rib 2).

Ribs 3 and 4 have a 1 degree draft. 2mm fillets are successful if they are done in one command (rib 3). If the fillets are done in two steps (rib 4) then the second fillet of 2mm fails. It only succeeds if the fillet radius is reduced to 1.99mm.

Is it the physical geometry that is causing this fillet failure or is there a missing <= statement in the code.

[blandb]

Do you have all updates installed? I just opened your file in 2023, removed you fillets and applied all at once with no issues?

[SEC_MECH]

Hi, I'm running the latest 2023.1

I know that I can fillet all of the edges at once. In a real part that is not always possible. This demo shows how a fillet can fail but reducing the radius by the tiniest amount allows it to pass. I am frequently frustrated with failed fillets and thought that I had discovered a bug where a < sign, instead of a <= sign, was possibly used in the code.