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Geometry and Mesh Troubleshooting

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2000 PTC

AutoGEM 2000i2
What is AutoGEM? Geometry & Mesh Troubleshooting Model inspection Diagnostics Examples Assemblies Example Fixing the Problem Summary

2000 PTC

What is AutoGEM?
Automatic Geometric Element Modeling (AutoGEM) The algorithm that automatically creates a p-type finite element mesh mapped to your models geometry. They are an idealization of the the real model Element types generated in Pro/MECHANICA: solids shells beams

2000 PTC

Geometry & Mesh Troubleshooting

Model Inspection... Two types of AutoGEM problems Geometry that causes a large number of elements
Remove geometry that is irrelevant to the simulation Suppress or delete unimportant features to optimize solution efficiency Modify dimensions or use tweak > replace to remove small surfaces

Geometry that is difficult to AutoGEM successfully

Redefine features Remodel sections Modify dimensions cover up bad geometry Seed the Mesh

2000 PTC

Geometry & Mesh Troubleshooting

Model Inspection... Examples of small surfaces created by rounds:

2000 PTC

Geometry & Mesh Troubleshooting

Model Inspection... Examples of small surfaces created by unaligned surfaces:

2000 PTC

Geometry & Mesh Troubleshooting

Model Inspection... A narrow surface created by exterior ribs on a round: Note that the rib on the left with the exterior rounds removed will AutoGEM with many fewer elements. Edges with zero angle:

Small surfaces and curves or zero angles typically do not cause a meshing failure, but do result in a less efficient analysis
TIP: Suppress rounds and chamfers that remove material and leave those that add material.
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Geometry & Mesh Troubleshooting

Model Inspection... Pro/ENGINEER tools:
#Info#Geometry Check... Highlights any questionable geometry #Analysis#Model Analysis#Short Edge... Identifies small edges View in No-Hidden-line Mode or Shaded Mode Inspect the model for sliver sections or bad surfaces
Possible troubled areas

Shaded Mode

No-Hidden-line Mode
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Geometry & Mesh Troubleshooting - Example 1

Eliminating small edges Pro/E can highlight all edges less than a specified length Suppress features, modify dimensions or use #Tweak #Replace to eliminate small edges/surfaces. Tweak > Replace allows you to replace a surface with another. This can be useful if you arent able to change the problem feature because of Parent-Child relationships.

Replace this surface with DTM2

2000 PTC

Example #1

Geometry & Mesh Troubleshooting

AutoGEM Diagnostics Understanding AutoGEM status messages is important for diagnosis To view status in Integrated mode
#Run#Summary... (*.rpt file) #Run#Log... (*.stt file)
Monitor the status of automeshing

#Run#Diagnose
NEW in 2000i, expanded in 2000i

2000 PTC

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Geometry & Mesh Troubleshooting - Example 2

AutoGEM Diagnostics View status in Integrated mode #Run#Diagnose Identifies several problems with the model. In this example the message complains about "intersecting or overlapping" volume Pro/Mechanica highlights the surfaces where AutoGEM could not finish

Note: Surfaces remain highlighted while you manipulate the model

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Geometry & Mesh Troubleshooting - Example 2

Fix the model in Pro/E The bad geometry is caused by a sweep that was not aligned properly. This results in a small gap between the flange and the rest of the part.

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Geometry & Mesh Troubleshooting - Example 2

Fix the model in Pro/E (Option #1 - quick fix)

Add a surface-to-surface round to to "cover up" the bad geometry. The model now meshes successfully.

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Geometry & Mesh Troubleshooting - Example 2

Fix the model in Pro/E (Option #2 - better fix) Redefine the sweep

The sweep section is aligned with the outside edge of the model. This produces a small gap between the flange and the rest of the model Align the swept section with the inside edge of the model.
2000 PTC

Example #2

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Geometry & Mesh Troubleshooting - Example 3

AutoGEM Diagnostics
Message #1 - Knife Edge Cause: A cut resulted in a knife edge Solution: Eliminate the knife edge by suppressing/deleting the feature

Message #2 - Overlapping geometry Cause: The shell feature created invalid geometry for MECHANICA Solution: modify dimensions of the shell or round Message #3 - Slope Discontinuity Cause: The edge of this sweep overlaps an edge of a round
2000 PTC

Solution: modify dimensions of the sweep or round

Example #3

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Geometry & Mesh Troubleshooting - Assemblies

Modify dimensions or assembly constraints to account for gaps, overlaps or unaligned surfaces
Gaps Will not typically cause auto-meshing failures. Mechanica will inform you if parts are not connected. Analysis may result in failure due to insufficient constraints. Run a modal analysis to determine which parts are disconnected Interference Can cause meshing problems if surfaces/edges overlap Identify by performing a global interference check. What about contact analysis? Unaligned geometry Will not typically cause auto-meshing failures. Increases number of elements.
2000 PTC

Note: Suppress unnecessary parts, use simplified reps or modify dimensions

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Geometry & Mesh Troubleshooting - Merge

Trouble-shooting assemblies
It is often desirable to let Pro/MECHANICA merge the geometry between assembled components Geometry will merge if any surfaces or curves overlap within a tolerance:
less than (1/12) (Largest Absolute Accuracy Value of All Assembly Components) [see TAN #22423] Largest absolute accuracy = relative accuracy largest part model size. Measure the model size of each part (Info / Model Size) Determine the relative accuracy (Setup / Accuracy)

Modify dimensions or assembly constraints to permit or prevent geometry from merging. Use rigid connections, end/perimeter/spot welds or beams to connect geometry

Example #4
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Geometry & Mesh Troubleshooting - Example 4

Trouble-shooting assemblies
For contact analysis, you may want parts to interfere. Interference is OK if no surfaces or edges overlap (i.e. occupy the same space). Otherwise Mechanica will merge the overlapping geometry, and AutoGEM will likely fail. Change the assembly constraints to align offset. Note: there is still interference, but the surfaces no longer overlap Add enforced displacements to move the part back to the correct position. We now have ...2 disjoint bodies..., so we know were OK.
Introduce align offset

Overlappi ng geometry at symmetry surfaces

2000 PTC

Example #5
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Fixing AutoGEM Problems

When models fail to mesh, you can also... Add seed points, curves or volume regions. Change the part or assembly accuracy or use absolute accuracy. (This may be nearly impossible for complicated models as they may fail to regenerate.) Perform a Pro/E neutral file roundtrip - (#File #Export #Model #Neutral). This may clean up the model, but you will lose the history data.

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Summary
AutoGEM failures typically result because of small surfaces within geometry often due to modeling errors.
Spot problems early! Consider how Mechanica will handle features before you get too deep into the part creation. Pass this information on to the designers, if applicable. Make sure unnecessary features can be suppressed, limit geometry checks, and limit poor surface intersections. Use the new diagnostics features to trap problems within Pro/E Try to avoid breaking associativity to the CAD model. Contact customer support If the model still wont auto-mesh. Search the Customer Support knowledge base for more information about AutoGEM, Geometry troubleshooting and other useful topics. Sign up to receive email notification when relevant Customer Support documents added or updated.
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