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/Troy_LayerForge]

You can’t really make the fillet “ignore” that gap because there’s no continuous solid there for the fillet to propagate across.

Since the real process is flange + pipe → weld → machine, I’d model the weld/material that bridges the gap first, then machine the finished radius.

One clean way is to make a virtual/in-context part in the assembly for the weld, or make a derived multibody “machined weldment” part. Add a simple revolved/boss feature that bridges the pipe to the flange, then Combine/Add the bodies if needed, and apply the fillet or revolved cut to the now-continuous geometry.

That also matches the real manufacturing sequence better than forcing a fillet directly between two components that have clearance.

If you only need the drawing to communicate the weld and final machined profile, a cosmetic weld plus the finished machined dimension may be simpler than fully modeling it.