Sorry, tried to open your file at home, but I currently have SW 2003 on my home system. I will have to wait until I load 2004. I uninstalled the beta version. Spent all day today (Saturday!!) uninstalling, re-loading and patching Oracle, SmartTeam and SolidWorks 2004 on our work systems. 5 of us going at it including the SmarTeam server...... I'm about brain dead....... We have 29 systems and growing.
I strongly suspect that if your goemetry works manually and with certain values in the DT but fails with others, it is what I suggested - the smaller arc is getting bigger that the larger one before the larger one increases in size. So it "inverts" itself. If you change the order of the features in the tree and pay careful attention to this, you might fix it. On the other hand maybe not. You might have to do the DT value inputs it in steps so it never flips. You could put some Excel Bololeans in the DT cells to prevent the arc radii from over (or under) taking eachother, and force the use to enter the second value again after one arc has been updated. A bit cumbersome, but it might work.
Example: Imagine 2 concentric circles. Diameters are 0.5 and 1.0. If I increase the samll one to 0.75, it is still INSIDE the large one and I can increase the large one to anything I like of reduce it to a smig over 0.75. But if I increase the small one to, say 1.25 BEFORE I increase the large one to say 1.75, then it will not be INSIDE for some time during the update. Because it will be 0.25 larger than the large one for a short period of time. (same happens if I reduce the large one to less then 0.5 first.) Now in your case, you probably have some other sketch geometry which tied to your arcs and that's why it blows up with certain values, because it flips over and can't get back, because it finds a logicaL solution, but not the one you want.
Hope that made some kind of sense. It is hard to describe without your actual example to base it on.
I just though of something else. It definitely depends on what configuration you have active when you switch to the new one, so.....
If you have a dummy configuration in your DT which has the small arc VERY small and the large arc VERY large, then ALWAYS switch to that one BEFORE switching to a another one, it might solve your probelm becuase they could never flip.
Heck, I 'm just guessing in the dark here. But I have seen this sort of thing happen.
John Richards Sr. Mech. Engr.
Rockwell Collins Flight Dynamics
A hobbit's lifestyle sounds rather pleasant...... it's the hairy feet that turn me off.