I am trying to make a cut out on a tube's outside surface with staying normal to the outside surface for the entire profile of the cut. The profile of the cut is a mix of circles, arcs and straight lines.
any suggestions of how to do this?
Please add file or pic so we can see exactly what your trying to do..
You could create the tube as a surface body wrap and trim then thicken to a solid body.
Can you attach your *.sldprt file here?
Take a look at the wrap feature. It will cut it normal to the cylinder as long as you click deboss and make the depth the thickness of the tube. Take a look at the example pic below.
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