What are some common meshing errors and how do you fix them for solid models?

1 Mesh size and resolution

One of the most common meshing errors is choosing an inappropriate mesh size and resolution for your solid model. Mesh size refers to the average length of the edges of the elements, while resolution refers to the number and distribution of the elements. If your mesh size is too large, you may miss important features or details of your model, or introduce errors in the curvature or shape of the surfaces. If your mesh size is too small, you may create unnecessary elements that increase the computational cost and time of your analysis, or introduce numerical instability or noise. To fix this error, you need to balance the trade-off between mesh size and resolution, and use adaptive or local refinement techniques to increase the mesh density where it is needed, such as at corners, edges, or regions of high stress or strain.

2 Mesh topology and quality

Another common meshing error is having a poor mesh topology and quality for your solid model. Mesh topology refers to the shape and connectivity of the elements, while quality refers to the geometric properties and criteria of the elements, such as aspect ratio, skewness, orthogonality, or distortion. If your mesh topology is not compatible with your model geometry, you may create gaps, overlaps, or misalignments between the elements and the surfaces. If your mesh quality is low, you may create elements that are too stretched, twisted, or distorted, which can affect the accuracy and convergence of your analysis, or cause numerical errors or instability. To fix this error, you need to use appropriate mesh types and algorithms for your model geometry, such as structured or unstructured, hexahedral or tetrahedral, or linear or quadratic. You also need to use mesh quality checks and improvement tools to identify and correct any problematic elements, such as smoothing, swapping, collapsing, or splitting.

3 Mesh compatibility and conformity

A third common meshing error is having an incompatible or non-conforming mesh for your solid model. Mesh compatibility refers to the consistency and continuity of the mesh across different parts or regions of your model, while conformity refers to the alignment and matching of the mesh nodes and edges at the interfaces or boundaries of your model. If your mesh is incompatible or non-conforming, you may create discontinuities or gaps in the mesh that can affect the transfer of loads, displacements, or stresses across your model, or introduce errors or artifacts in your analysis results. To fix this error, you need to use appropriate meshing techniques and tools to ensure that your mesh is compatible and conforming across your model, such as using shared topology, coincident nodes, or contact elements.

4 Mesh verification and validation

A final common meshing error is not verifying and validating your mesh for your solid model. Mesh verification refers to the process of checking and testing your mesh for errors, such as using mesh quality checks, element counts, or visual inspection. Mesh validation refers to the process of evaluating and comparing your mesh and analysis results with other sources, such as analytical solutions, experimental data, or previous studies. If you do not verify and validate your mesh, you may not detect or correct any meshing errors that can affect your analysis results, or you may not be able to assess the accuracy and reliability of your analysis results. To fix this error, you need to perform mesh verification and validation steps before and after your analysis, using various methods and tools, such as sensitivity analysis, convergence analysis, error estimation, or uncertainty quantification.