How to resolve erratic mesh protrusions in MFIX that shift when changing cell numbers?

When using MFIX’s mesher to generate grids, I inexplicably get some small protrusions, as shown in the image. However, when I adjust the number of cells in the x, y, or z directions (for example, from 42 to 40), these protrusions change position. Does anyone know how to resolve this issue?

Thank you in advance.

Here are a few things you can try in the Mesh>Mesher pane:

  1. Increase the snap tolerance, say 0.02 to 0.05 in all directions

  2. Set the facet angle tolerance to 0

  3. Decrease the dot product tolerance, say to 1e-4

  4. Decrease the intersection tolerance, say to 1E-8

Dear jeff,
Following your suggestion, I modified the parameters and set both the Small cell tolerance and Small area tolerance to 0.05. Now it runs, but during the process, many EpgErr files like the following were generated:

EPgErr_00.zip (50.8 KB)

EPgErr_0011.log
EPgErr_0020.log
EPgErr_0041.log
EPgErr_0050.log

I have attached some of them.

Well, it didn’t work :sob: .
After simulating for 0.2 seconds, the error “DT < DTmin” was reported.

Try to increase the normal distance tolerance to see if it helps.

Do you mean the small “arms” at the bottom left of your image? Are these the only errors?

Do you make the model entirely inside MFiX, or in a separate CAD program?

Yes, exactly those things.

And my geometry was entirely built within mfix.

Would you mind sharing you geometry?