Why the gear can not be cut by a predefined surface?

Coreform Cubit Version: 2023.4.0
Platform: win10

menu

the model is a gear and some predefined surface(not plannar surface),
when i use any of the surface to webcut the gear, it fails to to work.

Cubit gives the following error messages:

Performing webcut operation…

Preserving undo information…done

ERROR: Error in webcutting volume with sheet.

ERROR: ACIS API error number 21034

ACIS API message = inconsistent face-body relationships

No volumes were webcut.

how to resolve this problem ? thanks.

if i use the “stitch” function to combine any two neighbouring sufaces into a new body, and then use it to do the webcut, it works;

webcut

another test:
if i combine another two surfaces into a new body by using the “stitch”, and then use it to do the webcut, it fails again and produce the same error message as the first test.

My guesses are that either minor geometric differences, or numerical tolerances, are causing issues when cutting with those bounded sheets. For example I mocked up a similar example to yours:

Note that the sheet doesn’t quite extend through the tooth:

image

Your example doesn’t seem to have the same level of gap that I have, but you can see the kind of challenge this poses.

I would recommend using the Sheet Extended From Surface, which will ensure you don’t encounter those kinds of issues:

Here’s my CUB5 file if you want to explore:

helical_gear.cub5 (4.2 MB)