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Projection vs Intersection

Hello all,

Looking for some guidance, I have an assembly with a tapered hole reamed through all three parts/flanges, making one consistent/concentric cone, or so is the intent!
The theory is that each flange is made from a different material, and therefore cuts differently, to test this theory I am projecting/intersecting the cones from each flange to the upper surface.
When using intersection I notice the vectors all become perfect, and the resultant circle diameters are all within a micron.
Using projection the vectors are minusculely out, but the circle diameters are circa 0,1mm different, proving the theory that the softer material cuts bigger.
Problem is we have never measured this before, we don’t know if 0,1mm is a true reflection, and reading the help section I can’t figure out the difference in how projection/intersection works?
Any help would be much appreciated!
Thanks I’m advanced!
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