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I wasn't able to extract your file, the *.rar came over corrupt.
That said, I bet it's an accuracy problem. Remember, the default accuracy is relative. That value (.0012 default) is the allowed ratio between the longest and shortest edge. From the screen shots it seems that your part is pretty long with some fine detail. That usually creates weird problems like this where a simple cut won't work.
These sort of parts benefit from absolute accuracy which is the actual value of the shortest edge allowed. I usually start at .0001 for inch parts, .0024 for millimeter.
Frankly, we never use relative accuracy because of issues like this. We do a lot of injection molded parts which end up having a lot of small edges. It's maddening to get 200+ features into an organic molded plastic part and find you cannot create a rib due to an accuracy problem. That far into it, changing the accuracy is sometimes impossible as other earlier features fail with the new accuracy value. Had this happen just last week using a client start part with relative accuracy. Had to jump through several hoops to finsh the part.
Sorry to be so long winded ... |