Standard Mesher setup at AutoSize level 4 is claiming 80,000,000 cells and counting

DaleKramer · January 18, 2024, 6:54am

I have this Standard Algorithm mesh that grew enormously, what have I done to make it so big?

The 2 refinements I used are the same as I used for my Hex Dominant Parametric meshes which stayed around 15 million cells.

I stopped it at over 80 million cells. Here is the log:

Model import took 20.958646361s.
Maximum precision of model and its entities: 0.001031866166658002 m.
Absolute small feature tolerance: 0.001 m.
Layer refinement was not applied on 8 faces because they were removed by small feature suppression, by the non-manifold boolean for conformal meshing or assigned as start/end faces in a sweep mesh refimenent.
Number of faces after 5m0.046066471s: 986977
Number of faces after 10m0.020021496s: 3740308
Number of faces after 15m0.009116597s: 4715356
Number of faces after 20m0.031016382s: 4715356
Number of faces after 25m0.000201957s: 4715356
Number of faces after 30m0.000317487s: 4715356
Number of faces after 35m0.004106731s: 1674168
Number of faces after 40m0.004760424s: 4232347
Number of faces after 45m0.099892596s: 4743954
Surface meshing took 49m41.95172042s.
Number of cells after 1h14m32.927909123s: 13525231
The mesh may be finer than desired. Please check the model and the mesh settings
Number of cells after 1h39m23.90492571s: 81189113

DaleKramer · January 18, 2024, 7:26pm

Its happening again right now here after I decided to just use a single surface refinement of all faces of my aircraft at a max size of 4 mm, which is an absolute requirement to keep the mesh smooth enough.

Should I cancel it or do the cells get reduced again before completion?

Here is the current meshing log:

Model import took 25.186151475s.

Maximum precision of model and its entities: 0.001031866166658002 m.

Absolute small feature tolerance: 0.001 m.

Layer refinement was not applied on 8 faces because they were removed by small feature suppression, by the non-manifold boolean for conformal meshing or assigned as start/end faces in a sweep mesh refimenent.

Number of faces after 5m0.045202503s: 856136

Number of faces after 10m0.012967398s: 2852486

Number of faces after 15m0.099823476s: 4620310

Number of faces after 20m0.048269625s: 4620310

Number of faces after 25m0.05978723s: 4620310

Number of faces after 30m0.059958988s: 4620310

Number of faces after 35m0.047142006s: 212726

Number of faces after 40m0.049616695s: 1973660

Number of faces after 45m0.056432756s: 4038548

Number of faces after 50m0.00628886s: 4649126

Number of faces after 55m0.020957842s: 4649126

Surface meshing took 58m29.980803959s.

Number of cells after 1h27m45.071278619s: 13532729

The mesh may be finer than desired. Please check the model and the mesh settings

Number of cells after 1h56m59.975564728s: 76996534

DaleKramer · January 18, 2024, 8:07pm

I had to stop it since there was no downward progression to about 15M cells:

Here is where I stopped it: