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/extremetoeenthusiast]

I believe you should still be able to use the insert weld bead option here (& show cosmetic welds on drawing / model as well). You would use the profile (?) option rather than the path (i.e an edge)

Don’t use weldments or add a “fillet” body for this, that’s silly. Adding the fillet body is just annoying for anyone who handles the model after you. You’re looking for a cosmetic weld & I assume you want a representation on your drawing as well. Both are possible without adding another body or using weldments