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Trimming a frame by multiple faces with curved profiles

Hi Everyone,
I have the following frame setup:
And I'm trying to cut the grey frame so that it can rest on top of the blue ones. I'm trying to do these cuts such that these pieces can be cut on a miter saw.
If for the grey frame I use the "limit frame ends to parts" option, I get a cut that's "too accurate", in that it accounts for the rounded corner of the frame and results in a profile that's not done as a flat cut (and thus not achievable with a saw):
If I change the profile of the blue frame to not have rounded corners, then the cut is done as I'd like, but I'd prefer to include the rounded corners in the model.
If I limit the frame end to a face, or instead of limiting the frame ends I do a trim and trim to the face of the blue frame, I almost get what I want, except the trim goes too far:
This seems like the perfect use for the "trim to face boundaries" option, but Onshape says it's unable to trim some segments:
I thought this was because the face I selected is narrower than the frame I'm trying to trim, but making a custom wider rectangle on that face results in a similar error:
Does anyone have any suggestions for how I might achieve what I'm trying to do?
Thanks!
Comments
I don't have a lot of experience with frames.
Can you do version one and replace face the rounded edges that make the sawing difficult?
else a more hacky solution:
make the blue frames double. one with rounded corners (to keep) and one just to enable the cut to the grey part and delete these parts afterwards…
This is an issue with the trim command in frames. It is very powerful, but sometimes, you need to do some workarounds to get simple results. You can do this in various ways, but I would probably use a couple of splits and booleans. Split your grey part twice and boolean together the pieces you want to keep.
I got the shape you're looking for but the cut list won't accept it. I used a replace face and move face for other frames in the past but not this one. This seems to limit use of the cut list for this application.
https://cad.onshape.com/documents/1e201407c3a9e0781abcaff2/w/a0a6031ff7904b413a3900ec/e/6f61ff7366c79b7e944f2423
just using replace face on the fillet faces seems to work. Here's an example (piggybacking on glen's model) https://cad.onshape.com/documents/72e66e52499f52723cd229df/w/e2a85f83ffd954052371bbd5/e/116eec4d083764ab6416fe00
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Nice catch Evan.
Wow, thank you all for your insightful comments. I appreciate it!