I assume that you're speaking only of the 'Thread' feature and NOT Threaded Holes, correct?
OK, the 'Thread' feature, when applied, was designed to adjust the size of the cylindrical face, be it a hole or a shaft/boss, so as to represent the initial size before threading. Note that this was based on a rule-of-thumb taken from the thread design section of the
'Machinery's Handbook'. The problem is that the 'Thread' feature is an older and in reality, partially-obsolete, feature. One of the issues, which you've already noticed, is that there's a problem with the feature's attempt to adjust the size of the hole/shaft/boss, but ONLY if the face was the result of a feature created using the Sketcher. If you had defined say a hole by creating a Cylinder feature subtracted from a body then there'd have been no warning and the size of the 'hole' would have been adjusted. The same if the Shaft was created using a Cylinder feature. Of course, if you're using a Boss feature everything works just fine.
The reason for this is that the 'Thread' feature was originally implemented before there was extensive use of the sketcher. In those days 'holes' were usually created using either subtracted Cylinders or Cylindrical 'Pockets', and Shafts/Studs started life as Cylinders or Bosses. The issue is that the code was attempting to modify the feature's Diameter parameter but it doesn't recognize Sketch parameters (I know, this should have been fixed, but it's not trivial). Of course with the advent of a true 'Threaded Hole' feature with NX 5.0 this was no longer an issue with respect to Hole since they were created together with the Thread feature. However, many people still create Shafts/Studs using Cylinders and Bosses so that's why I stated the the old 'Thread' feature is only 'partially obsolete'. So the rule now is, make ALL threaded holes using 'Threaded Hole' features. Threaded shafts and studs should still start out as Cylinders and Bosses as you do not YET have a new 'Threaded Male' feature.
As for the chamfer issue, that's really just so that the symbolic representation of the thread, the extra dashed circles, look like their in the correct location. If you're not concerned about how they look (this has no effect on how they will appear when you create your Drawings) then just add your hole/shaft relief (chamfers) in whatever order you wish.
Anyway, I hope that helps explain what you're seeing and how to avoid the warnings.
John R. Baker, P.E.
Product 'Evangelist'
Product Engineering Software
Siemens PLM Software Inc.
Industry Sector
Cypress, CA
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