Learning Forum

[sumanthp25]

Hi,

I am trying to generate a surface mesh for my model in ANSYS Fluent Meshing 2024 R2.

During surface meshing, Fluent gives the following warning:

"During Surface mesh, 404 folded/self-intersecting faces were identified.
To improve the quality, insert the 'Improve Surface Mesh' task."

The mesh diagnostics also show:

- Self Intersections: 416 faces, found on 2 face zones
- Self Proximity: 191 faces, found on 2 face zones
- Point Contacts: 1
- Invalid Normals: 66
- Free Faces: 0
- Multi Faces: 20,877, found on 115 face zones

I checked my geometry in SpaceClaim for intersecting or overlapping objects, but I could not find any obvious intersecting objects.

Share Topology is successful for my geometry.

Fluent also gives the following error when I try to proceed:

"The surface mesh quality is 1 which would lead to a failed volume mesh. Either an unsuitable min size was used or the model contains very sharp trailing edges. In the latter case, it is recommended to add a small chamfer to these edges in the CAD."

My questions are:

1. How can I identify the exact locations of the 404 folded/self-intersecting faces in Fluent Meshing?
2. Is there a way to mark or highlight these faces so I can identify which part of the geometry is causing the problem?
3. How should I interpret the 416 self-intersections and 191 self-proximity faces?
4. Since I cannot find any intersecting geometry in SpaceClaim, what could be causing these problems?
5. Could these be caused by very small gaps, sharp edges, or surface meshing issues?
6. What is the recommended procedure to clear these errors before generating the volume mesh?

I have attached screenshots showing the Fluent warnings and mesh diagnostics.

Any guidance on how to locate and fix these specific faces would be greatly appreciated.

Thank you.

[skulkarn]

Hello,

Please try to repair any sharp corners if exist in geometry. In Fluent meshing, go to Outline view, right click on mesh objects > Diagnostics and select the relevant option for repair.

[rademacherdacostacabral.v]

Hi!

"Share Topology is successful for my geometry." I frequently observe that the share topology in SpaceClaim seems to be successful but individual faces or edges are not properly shared. This has lead to all sorts of errors in fluent meshing. I would suggest to recheck if the share topology actually shared all obejcts entirely. In SpaceClaim look for edges that should be blue or purple but appear yellow. Edges where three or more objects meet are especially difficult to share in my experience. 

Kind regards
Vincent