Learning Forum

[audreygold]

Hello, I am having issues getting past the layered tetrahedrons meshing step of the simulation setup in the additive mnaufacturing module. I sometimes get the Silver Triangle Height being over 50% of the minimum and the Element Size being over 600% of the Defeature Size error messages, but every time I try to generate meshing, I get the same "the meshing engine failed due to running out of memory" and "a mesh could not be generated using the current meshing options and settings" error messages.

I have been trying every combination of meshing parameters that I can think of based on the recommended values from the Ansys Workbench Additive Manufacturing Analysis Guide. I have successfully ran the simulation twice before with different part files and settings, but now I am trying to model the simulation based on the actual laser parameters and printing settings I will be using on a LPBF printer to compare simulation results to printed results. Comparitively, this part and base plate is smaller and the base plate is more complex in geometry since that is the base plate that is specific to the printer. I read in the Analysis Guide that the part should be uploaded and the base plate should be built within the Construction Geometry section in Mechanical, but the part in this case is a very simple disc whereas the base plate is the more complex geometry in this case. Could this be contiributing to the meshing issues I am having?

I also uploaded the geometry of the base plate as a .stl file and then added the part on top of the base plate in SpaceClaim. Would this be causing any of these issues?

My main question is if there are any recommended combinations of meshing parameters that might produce a layered tetrahedron mesh for my part? I would like to keep the actual laser height between 40-100 microns when printing, which is my only main stipulation in the meshing section.

Is there something else I could be missing that would cause the memory error message? From what I have seen in threads, this error message only comes up with complex or intricate geometries and my base plate and part are definitely not complex or intricate.

I would really apprecite any help on this. Thanks in advance!

[Akshay Maniyar]

Hi,

I understand you're encountering difficulties with the meshing process in the additive manufacturing module, specifically with the Layered Tetrahedrons method. The issues you're facing with the Sliver Triangle Height and Element Size could be related to the settings you're using for the mesh generation.Please check the below Ansys help link for more details for meshing recommendation.

Layered Tetrahedrons Method Control (ansys.com)

Thanks,

Akshay Maniyar