Reply To: Design Modeler for Fluid Simulaton

[Rob]

Hard to tell from the image, but my guess is it's a hex block mesh, so possibly ICEM Hexa and an excessively large amount of time doing decomposition. There's a reason CFD solvers moved from i j k block meshes to the fully unstructured codes of today. 

Re the gap - I'd remove the chamfer as Nick suggests or look into pinch control (Ansys Meshing).