Simulation Mesh Optimization

Posted by Keith Vittitoe on September 27, 2013 at 7:59 AM

Once the model is simplified to accommodate the best balance between mesh density and result
accuracy, the next step is to optimize the mesh. Recall from 1-minute calculus that we need to use
something we know to approximate something we dont. Thinking along those lines, the more regular
our tetrahedrons or triangles are, the more accurate the result will be. It's easy to calculate the area of
right triangles and isoceles triangles. "Regulah" as they say in the general vacinity of SolidWorks' HQ
is translated as mesh quality or "aspect ratio". Aspect ratio is calculated three ways by SolidWorks edge length, normals length, and inscribed/circumscribed circles check. For higher order calculations,
there is yet another mesh quality check - Jacobian, but we're not going there.

inscribed/circumscribed circles check

(can you tell which one is better?)
Of course, measuring the aspect ratio of millions of elements is a detailed process. Since we can't
affect that calculation, know that basically SolidWorks is making sure that most of the mesh elements
can be used in the calculation.
Let's pause for a moment to discuss "higher order" as I mentioned above regarding a Jacobian quality
check. By higher order, we are referencing the exponents of the equation describing the curve we
need to create a mesh element that approximates the shape of the model face (only 1 comma in that
whole sentence). An equation representing a straight line has no exponent (mx + b = y). As soon as
you step to x^2, the "line" curves. A "higher exponent" like x^3 or x^4 is synonymous with "higher
order". I don't want to get side-tracked with this, so I'll keep it simple - we've been discussing triangles
and tetrahedrons, but we could use mesh elements that are parabolic to approximate curved surfaces
- higher order elements. Now back to our mesh quality discussion.
So, why does SolidWorks calculate mesh error for us? I'll start by explaining what makes a "good"
mesh. Let's look at the thickness of a part, as an example. We want our elements size to match that
thickness - exactly one "triangle" high.

Or consider an inside or concave radius. That curve requires a curved element. If we are using a
relatively large element, then the elements will have to curve, so we either need a higher order

element or better yet, a smaller element so the discretization error is minimal. Otherwise, we get this
"jagged" result around the radius:

If we dont pay attention to these mesh considerations, Simulation will do its best to calculate what we
ask, but the result may be elements in the mesh with aspect ratios that negatively affect our results.
Remember, the more simple the shape, the more regular the shape, the more accuate the result
becomes (perfect vacuum and frictionless ice). Said another way, the approach to calculating the
volume of these two pyramidal shapes is fairly similar, but one result is going to be much more
accurate...

To avoid providing obviously wrong results, SolidWorks performs a mesh error check. We can help
ourselves, though. To address the need to minimize the mesh density, and optimize the element
aspect ratio, we can use mesh refinement techniques, the basis of which I've been attempting to
explain. Here's what SolidWorks offers in order of refinement:

Coarse to Fine adjustment of global mesh

Mesh parameters (adjust the global size and tolerance)

Automatic transitions (make sure the nodes from element to element match up)

Curvature-based mesh

Incompatible Mesh option (nodes don't match up)

Mesh Controls (adjust the mesh in specific areas of the model)

Mesh Methods (discussion coming soon in a blog post)

So, if you run a simulation in SolidWorks and get a mesh error that stops the calculation, that list is
where you start to correct the issue.
SOLIDWORKS Simulation

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