1. Find the problem location.
After the failure, an orange dot is drawn on the model at the coordinates listed in the error message. This is the location at which the meshing process stopped. The model is shown as transparent and the offending volume is selected to help you find the problem location:
- The orange dot may be difficult to see, so turn off the mesh seed points to improve visibility. (From the menus at the top of the User Interface, click Window, and uncheck Show Mesh Seeds.)
- Click the View as Outline icon to turn off all shading. This can really help you to see inside the model.
- Since the problematic volume is selected, note the ID for future reference. Adding it to a group (right click, and select Group > Create group) is a convenient way to quickly access the part later.
Surface and Edge Diagnostics are also very helpful for finding the problem:
- On the Meshing dialog, click the Diagnostics button.
- Move the slider to identify small entities that may be problematic.
2. Inspect and repair the geometry in the vicinity of the problem location.
Some things to look for include:
- Surfaces that overlap or are on top of one another
- Tiny gaps between surfaces or volumes
- Sliver surfaces
- Tiny volumes resulting from volumes that overlap
- Edges that are shared by more than two surfaces
The Geometry Tools (Edge Merging and Small Object Removal) can fix many of these problems. (Right click on the Geometry branch of the Design Study bar.) If these tools are unable to resolve the problem, return to CAD system to fix the geometry.
3. Refine the mesh locally
If the problem is on an edge or surface, try refining the mesh distribution locally. This is more efficient than refining an entire volume, and will prevent the mesh count from getting as big. Do this by:
- Open the Mesh Sizes dialog. (Right click off the model and click Edit…)
- Change the selection mode to either Surface or Edge. (Right click off the model, mouse over Selection type, and select the desired mode).
- Select the surfaces or edges in the model that will be refined.
- Move the Size adjustment slider toward Fine (between 0.75 and 0.9 is a good place to start)
- Click the Apply button in the Size adjustment group.
- Repeat as needed with other entities.
- Click Spread Changes when you are finished with your adjustments.
4. Refine the mesh on the volume.
The procedure is the same as in step 3, except set the selection mode to Volume.
5. Adjust Mesh Enhancement
The problem might be due to overlapping Mesh Enhancement layers. On the Meshing dialog, click the Enhancement button, and reduce the Layer Factor to 0.3.