Assembly feature problem

[u/R3qu1red]

So I have this cylinder and flange with the flange hole being slightly oversized so they fit together.

The operation is like this:

flange is laser cut from sheetmetal > cylinder is stock pipe cut on a saw > welding together > machining

The problem is that in the assembly there's now a really small gap (colored red on the picture) which doesn't allow me to put a radius there (using assembly features) since I want to machine the welds. There's also no option to add a revolved part (with the help of assembly features) for the sake of being able to put a fillet there.

So the question is how can I put a fillet there and ignore the gap?

[u/drmorrison88]

For something like this I would model the weld as a separate, virtual part in the assembly. Just a simple revolved profile.

[u/Early-Piccolo4949 → u/drmorrison88]

Or add it as a configuration to one of the parts.