Circular pattern failing without any message

nicholas_betts

In this part studio for a worm gear the main gear fails to generate properly when the Z1 parameter is changed to 2. The problem occurs in the Circular pattern 2 feature. The pattern should replicate the grove 20 times, but every second one fails. While editing the feature it looks as shown in this image. The red outline suggests some error like non-manifold geometry, but there is no message about it and the feature is not showing as red. I have made a copy of my own and tried to correct the problem, but have not had any luck. I have two questions.

1. Why is no error displayed?
2. Is there some way to fix the problem and generate the gear properly.
   

https://cad.onshape.com/documents/8debf48a92e4eff2ad42217d/w/a8176d7619e9aff1cac8d3e6/e/759a81c91a3ea81b07e15c8f

P.S. First time posting. I hope this question is appropriate and makes sense!

NeilCooke

Your link is to the original feature. Regardless, is Reapply features enabled in the pattern?

nicholas_betts

The pattern is a Face pattern, so Reapply features is not present. I don't know much about Face patterns, but Reapply features is a good option and it solves most problems like this one, but unfortunately is not applicable.
I have made a copy of the document here. This is not my original copy because that is full of crazy experimentation to try and fix it (which I did not do properly with a branch).
https://cad.onshape.com/documents/658914e59bb2713d1e9de226/w/434e6075bee64f11dd317ef9/e/095b7c1abdc18908065ac478?configuration=B=0.0045000000000000005+meter;Module=5.0E-4+meter;Q=10.0;X=0.0;Z1=2.0;Z2=20.0&renderMode=0&uiState=6690eca4d7b1af22aba457d6

NeilCooke

Make it a part pattern and pattern the surface. Then Boolean subtract.