Module 05: Mesh Quality and

Advanced Topics
Introduction to ANSYS Meshing

Release 2019 R2

1 © 2019 ANSYS, Inc.

 Overview

In this lecture we will learn about:

• Impact of the Mesh Quality on the Solution
• Quality criteria
• Methods for checking the Mesh Quality
• Tools to improve Quality in Meshing
• Concept of Assembly Meshing
• Assembly Meshing Methods & Controls
• Mesh requirements for Explicit Applications
• Physics Based Settings
• Mesh Based Connections

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 Preprocessing Workflow

Preprocessing
Meshing
and Solution

Geometry
Import / Geometry
Creation Cleanup /
Modifications

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 Mesh Process & Course Plan
Global
Controls
Module 3

Meshing Core Local

Methods Skills Controls
Module 2 Module 1 Module 4

Mesh
Quality
Module 5
4 © 2019 ANSYS, Inc.
 Impact of the Mesh Quality
Good quality mesh means that…
• Mesh quality criteria are within correct range
- Orthogonal quality …
• Mesh is valid for studied physics
- Boundary layer …
• Solution is grid independent
• Important geometric details are well captured

Bad quality mesh can cause

• Convergence difficulties
• Bad physic description
• Diffuse solution

User must…
• Check quality criteria and improve grid if needed
• Think about model and solver settings before generating the grid
• Perform mesh parametric study, mesh adaption …

5 © 2019 ANSYS, Inc.

 Impact of the Mesh Quality on the Solution (1)

• Example showing
difference between a
mesh with cells failing
the quality criteria
and a good mesh
• Unphysical values in
vicinity of poor
quality cells

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 Impact of the Mesh Quality on the Solution (2)
(max,avg)CSKEW =(0.912,0.291)
• Diffusion example (max,avg)CAR=(62.731,7.402)

Mesh 1
VzMIN≈-90ft/min
VzMAX≈600ft/min

Large cell size

(max,avg)CSKEW =(0.801,0.287)
change (max,avg)CAR=(8.153,1.298)
Mesh 2

VzMIN≈-100ft/min
VzMAX≈400ft/min

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 Grid Dependency (1)

x8
DP 0 DP 3
• Solution run with
multiple meshes
• Note : For all runs the
computed Y+ is valid for
wall function (first cell
not in laminar zone)

2%

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 Grid Dependency (2)

• Hexa cells can be stretched in

stream direction to reduce
number of cells
• Bias defined on inlet and
outlet walls
• Bias defined on inlet edges
– 16 000 cells (~DP2)
– Delta P = 310 Pa (~DP3)

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 Hexahedral versus Tetrahedral
Hexa
• Hexa: Concentration in one direction
– Angles unchanged
• Tetra: Concentration in one direction Tetra
– Angles change
• Prism: Concentration in one direction Prism
– Angles unchanged
• Solution for boundary layer resolution
– Hybrid prism/tetra meshes
– Prism in near-wall region, tetra in volume Tetra (in volume)

– Automated
– Reduced CPU-time for good boundary layer Prisms (near wall)
resolution
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 Mesh Statistics & Mesh Metrics
• Displays mesh information for Nodes and Elements
• List of quality criteria for the Mesh Metric
– Different physics and different solvers have different requirements for mesh quality

Mesh metrics available in Workbench Meshing include:

– Element Quality
– Aspect Ratio
– Jacobian Ratio (MAPDL, Corner Nodes, or Gauss Points)
– Warping Factor
– Parallel Deviation
– Maximum Corner Angle
– Skewness
– Orthogonal Quality For Multi-Body Parts, go to corresponding body in Tree Outline
to get its separate mesh statistics per part/body
– Characteristic Length

11 © 2019 ANSYS, Inc.

 Mesh Quality Metrics (1)
On cell On face
Orthogonal Quality (OQ) A1
A1
Derived directly from c1
c2
f1 e1
Fluent solver discretization e2
f2 e3
f3
• For a cell it is the minimum of: c3
A2 A2
Ai  f i Ai  ci A3
A3
| Ai || f i | | Ai || ci |
computed for each face i
Ai  ei
For the face it is computed as the minimum of | Ai || ei | computed for each edge I
Where Ai is the face normal vector and fi is a vector from the centroid of the
cell to the centroid of that face, and ci is a vector from the centroid of the cell to
the centroid of the adjacent cell, where ei is the vector from the centroid of the 0 1
face to the centroid of the edge Worst Perfect
At boundaries and internal walls ci is ignored in the computations of OQ
12 © 2019 ANSYS, Inc.
 Mesh Quality Metrics (2)
Skewness Optimal (equilateral) cell

Two methods for determining skewness:

1. Equilateral Volume deviation:
optimal cell size − cell size
Skewness = optimal cell size

Applies only for triangles and tetrahedrons Actual cell

2. Normalized Angle deviation:  max Circumsphere
 max − e e −  min 
Skewness = max 
 180 − e
,
e 
  min
Where  e is the equiangular face/cell (60 for tets
and tris, and 90 for quads and hexas) 0 1
– Applies to all cell and face shapes Perfect Worst
– Used for hexa, prisms and pyramids
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 Mesh Quality
Mesh quality recommendations
Low Orthogonal Quality or high skewness values are not recommended
Generally try to keep minimum orthogonal quality > 0.1, or maximum skewness < 0.95. However these values
may be different depending on the physics and the location of the cell
Fluent reports negative cell volumes if the mesh contains degenerate cells
Skewness mesh metrics spectrum

Orthogonal Quality mesh metrics spectrum

14 © 2019 ANSYS, Inc.

 Aspect Ratio

2-D:
• Length / height ratio: δx/δy
3-D δy
• Area ratio δx
• Radius ratio of circumscribed / inscribed circle

Limitation for some iterative solvers

• A < 10 … 100
• (CFX: < 1000)
Large aspect ratio are accepted where there is no
strong transverse gradient (boundary layer ...)

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 Jacobian Ratio (MAPDL)
Jacobian Ratio Mesh Metric Plot

• The way MAPDL computes Jacobian Ratio

makes it difficult to identify mesh quality
problems because worst quality elements
are located in same histogram bar as best
quality elements
• When improving mesh by quality it is
important to have continuous bands from
bad to good
Good (1) OK (30) Bad (100) Fail (-100)

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 Jacobian Ratio

There are 3 mesh metrics related to

Jacobian Ratio:
1. Jacobian Ratio (MAPDL)
2. Jacobian Ration (Corner Nodes): Inverse
of JR (MAPDL)
3. Jacobian Ratio (Gauss Points): Similar to
JR (Corner Nodes) but calculated at
integration points rather than actual
nodes. More similar to solver
calculation for tet mesh. Not very good
metric for shell mesh.

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 Characteristic Length

• Characteristic Length mesh metric added for explicit to help find time
step:

CFL Condition:

Shells are not yet supported

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 Smoothness

Checked in solver
• Volume Change in Fluent Recommendation:
– Available in Adapt/Volume Good: 1.0 < σ < 1.5
Fair: 1.5 < σ < 2.5
– 3D : σi = Vi / Vnb Poor: σ > 5 … 20

• Expansion Factor in CFX

– Checked during mesh import
– Ratio of largest to smallest element volumes
surrounding a node

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 Mesh Quality Check for CFX
• The CFX solver calculates 3 important measures of mesh quality at the start of a
run and updates them each time the mesh is deformed
• Mesh Orthogonality
• Aspect Ratio
• Expansion Factor

+--------------------------------------------------------------------+
| Mesh Statistics |
+--------------------------------------------------------------------+ Good
Domain Name: Air Duct (OK)
Minimum Orthogonality Angle [degrees] = 20.4 ok
Maximum Aspect Ratio = 13.5 OK
Maximum Mesh Expansion Factor = 700.4 !
Domain Name: Water Pipe Acceptable
Minimum Orthogonality Angle [degrees] = 32.8 ok
Maximum Aspect Ratio = 6.4 OK (ok)
Maximum Mesh Expansion Factor = 73.5 !
Global Mesh Quality Statistics :
Minimum Orthogonality Angle [degrees] = 20.4 ok Questionable
Maximum Aspect Ratio = 13.5 OK (!)
Maximum Mesh Expansion Factor = 700.4 !

20 © 2019 ANSYS, Inc.

 Mesh Quality Check for Fluent
Grid check tools available
• Check : Perform various mesh consistency checks
• Report Quality : lists worse values of orthogonal
quality and aspect ratio
• TUI command mesh/check-verbosity sets the
level of details in the report

21 © 2019 ANSYS, Inc.

 Factors Affecting Quality
Geometry problems
Geometry cleanup in ANSYS SpaceClaim
• Small edge
or
• Gaps
Virtual topology & pinch in Meshing
• Sharp angle
Meshing parameters
• Sizing Function On / Off
• Min size too large
• Mesh setting change
• Inflation parameters
• Local defeaturing can help a lot…
– Total height
– Maximum angle
• Hard sizing
Meshing methods Mesh setting change
• Hex meshing is often more constrained than tet meshing
• Hex dominant meshing can result in pyramids, so while it might look nice on the surface
the volume mesh could be low quality
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 Complex Geometries Hex Meshing

• For complex geometries hex Meshing, you can use SpaceClaim Meshing

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 Mesh requirements for Explicit Applications
• Uniform Element Size (in finest zoned regions)
- Smallest element size controls the time step used to advance the solution in time
- Explicit analyses compute dynamic stress waves that propagate throughout the entire
mesh
• Element size controlled by the user throughout the mesh
- Not automatically dependent on geometry
➢ Implicit analyses usually have static region of stress concentration where mesh is refined (strongly dependent on geometry)
➢ In explicit analyses, the location of regions of high stress constantly change as stress waves propagate through the mesh
- Mesh refinement is usually used to improve efficiency
➢ Mesh transitions should be smooth for maximum accuracy
• Meshes consisting mostly of hex elements are preferred
- More efficient
- Sometimes more accurate for slower transients

SpaceClaim Meshing may be a good option for explicit applications. Please refer to the SpaceClaim Meshing training course
24 © 2019 ANSYS, Inc.
 Physics Based Settings (1)
• Different types of analyses have different meshing requirements
– Structural: coarser mesh with higher order elements
– CFD: finer, smoothly varying mesh, boundary layer resolution
➢ Different CFD solvers have different requirements as well
– Explicit Dynamics: uniformly size mesh desired
• Possible to set common defaults by setting the Physics Preference
Default Global Controls
Physics Solid Element Midside Relevance Smoothing Transition
Preference Midside Nodes Nodes Center
Option
Mechanical Kept Curved Coarse Low Fast
CFD Dropped Curved Fine Medium Slow
Electromagnetic Kept Straight Medium Medium Fast
Explicit Dropped Curved Coarse High Slow

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 Beams and Shells Mesh Connections

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 How to activate new connection option

Ensure that solids are not part of the active assembly.

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 Best Practices : Recommended Input

• Set the facet quality to 7 before importing model in to Mechanical

‐ SC -> SC Options -> Rendering quality
‐ DM -> Tools -> Options ->Graphics -> Facet Quality
• Perform Extend operation in SC, DM or in any other upstream CAD package
‐ Connection gap to be resolved should be of the order of mesh size.
• Remove overhangs in upstream CAD. Overhangs are small penetrations
between two surfaces which when unresolved can lead to mesh failure or
mesh quality issues.
• Avoid imprinting edges at CAD level or performing share topology
‐ If CAD has imprinted edges, then use Virtual Topology to remove them.
• If model has faces with missing facets, it should be fixed in upstream CAD

28 © 2019 ANSYS, Inc.

 Best Practices : General Connection Strategy

This strategy is useful when model is clean and doesn’t have much difference
between the smallest and largest gap to be connected across.

• Find the smallest and largest gap between the entities to be connected.
‐ Define a list of connection tolerance
➢ smallest gap < smallest connection tolerance and largest gap < largest connection tolerance

• Check for unconnected edges

‐ Create named selections on faces attached to unconnected edges.
• Activate mesh worksheet
‐ Add a step in worksheet based on named selection created before.
‐ Add a step for “AllBodies” with connection tolerance(s) used previously as global tolerance(s)

29 © 2019 ANSYS, Inc.

 Things to Remember
• Gap size cannot be larger than the element size / connection size
‐ If your biggest gap size to be resolved is 1 mm then the element size has to be greater than 1 mm.
• Faces (width), edges (length) which are below the connection tolerance(s) will
be defeatured
• In case quad meshing fails, triangle mesh is generated a warning message will
be given in UI
‐ RMB click -> problematic topology will show the bodies on which triangle mesh was generated.
‐ If triangle mesher fails as well, then mesh failure is reported to UI and CAD facets are displayed.

Faces successfully meshed

Face failed in mesh generation

30 © 2019 ANSYS, Inc.

 Connection Size Explained
Connection size serves two purposes. They are:
• Discretization of edges before connections are performed • Target mesh size is 10 mm
• Merging of CAD edges at mesh level • If default connection size (i.e 10 mm) is used the connection
won’t be realized.
• Three short edges will get combined into a single edge at
mesh level.
• Mesher will create a single division on the combined edge
as shown in the image below. Thus, putting this mesh edge
outside of defined connection tolerance.

3 short edges with combined

length of ~9.7 mm

Continued on next slide

Minimum tolerance required to connect is 0.6 mm
31 © 2019 ANSYS, Inc.
 Connection Size Explained

A. Reducing the connection B. Further reducing the

size to 4 mm while keeping connection size to 1 mm while
the same tolerance keeping the same tolerance

Two edges got merged

Connected region

Connected region
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 Worksheet Explained

• Connect operation is performed in the

order of steps defined in worksheet.
• Mesh gets generated after all the
connections are performed.
• AllBodies is a default named selection
available for usability purposes. As the
name suggests, its scoped to all active
bodies in the model.
• Named selections scoped to faces or bodies
are allowed to be scoped.
Order
Indicates Named Connection option which Connection tolerance(s)
whether a selection determines which edges used to determine which
step is active used to within the tolerance are entities are within specified
or not define scope considered for connections tolerance

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 Worksheet Explained

Front view
CAD

1
Dimensions are in mm
Side view
Model requires a minimum
tolerance of 1 mm to be
properly connected. Expected mesh after
connections

2 2 Continued on next slide

1
34 © 2019 ANSYS, Inc.
 Worksheet Explained A
Tolerance = 1.2 mm
Step 1 Connect option: All to All
Named selection with 3 faces
Using 1 mm tolerance globally without controlling shown in image A.
the connection order will not yield a good mesh B
Step 2
Tolerance = 0.2 mm
All bodies. This step will establish Connect option: All to All
Middle two plates connection between the horizontal
will get collapsed face and edges highlighted in
on to each other as green in image B. C
distance between
them is ~ 1mm Step 3
Tolerance = 1.2 mm
Named selection on 2 faces as Connect option: Free to Free
shown in image C.
Step 4 D
Named selection on 2 faces as
Tolerance = 1.2 mm
shown in image D.
Connect option: Free to Free

CAD Step 5
Named selection on 2 faces as
shown in image E.
E Tolerance = 1.2 mm
Connect option: Free to Free
35 © 2019 ANSYS, Inc.
 Why Extensions should be performed?
Performing extend operations in upstream cad have following advantages:
• Requires fewer and smaller tolerances to get the model connected. Thus increasing the overall robustness.
• Reduces chances of mesh getting distorted after connection.

Connected mesh when

Original CAD without extension Connected mesh
extensions are performed

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 Why overhangs should be performed?
Removing overhangs in upstream cad have following advantages:
If the tolerance is not big enough to
• Fewer mesh failures. Thus increasing the overall robustness.
entirely collapse the overhang then it
• Improved mesh quality.
can cause elements with short edges

Overhang area of the blue face

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 Why overhangs should be performed?

High aspect ratio triangles left behind by

mesher in the overhang region

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 Tips & Tricks:
How to remove overhangs

Overhang width is ~0.7 mm

• Activate multiple connection steps
• Define a small tolerance as first value and then
define a larger tolerance value
Other option would be to use worksheet

Continued on next slide

39 © 2019 ANSYS, Inc.
 Tips & Tricks:
How to remove overhangs

• Since there are only 3 parts, it not efficient to use scoped named selection to use
in worksheet. Thus, “AllBodies” was used instead.
• If there are large number of bodies/parts, then it is recommended to use scoped
named selection in worksheet.

Continued on next slide

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 Tips & Tricks:
How to remove overhangs

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 Tips & Tricks:
How to use model walk
Model walk helps you to visualize one entity at a time by navigating to it in UI.
Right mouse button click on warning message will allow you
to highlight entities related to that warning message in the UI.

Model walk menu under selections tab

Steps:
1. Show the problematic geometry from warning / error message The bottom info bar will show which
2. Click on Start in the walk menu entity you are on in the collection
3. Use Previous, Next, First, Last buttons

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 Semi-Submersible

Number of parts 2751

Number of elements 73,499

Minimum element quality 0.205

Connected and meshed in 33 seconds

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 Spar
Number of parts 836
Number of elements 419,218

Minimum element quality 0.39

Connected and meshed in 1.5 minutes

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 Performance

Manual effort Connections and mesh time No. of

No. of parts Model type
(time) (seconds) elements

~ 800 Only sheets ~1 hour 19 ~ 70k

~ 900 Sheets + beams < 30 mins 120 ~ 171k
~ 8100 Only sheets < 30 mins 160 ~ 280k
~ 15600 Sheets + beams < 30 mins 370 ~ 971k

Average quad meshing speed is ~0.25 to ~0.3 million elements per minute

45 © 2019 ANSYS, Inc.

 Summary

What have we learnt in this session:

• What is the impact of the Mesh Quality on the solution?

• What do Mesh Criteria mean?
• How can we check and improve the Mesh Quality?
• Can we create Polyhedral meshes in WB meshing ?
• What are the pre-requisite and controls of Polyhedral Meshing?
• What are the Mesh requirements for Explicit Applications?
• What are the different Physics Based Settings?
• How can we use mesh connection with beams and shells?

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 Appendix A: Advanced Controls
to improve the mesh quality
Introduction to ANSYS Meshing

Release 2019 R2

47 © 2019 ANSYS, Inc.

 Virtual Topology (1)
Without VT With VT

When to use?
• To merge together a number of small (connected)
faces/edges
• To simplify small features in the model
• To simplify load abstraction for mechanical analysis
• To create edge splits for better control of the surface
mesh control
Virtual cells modify topology
• Original CAD model remains unchanged
• New faceted geometry is created with virtual topology
Restrictions
• Limited to “developable” surfaces
• Virtual Faces cannot form a closed region

48 © 2019 ANSYS, Inc.

 Virtual Topology (2)
In some instances it may be desirable to modify
topology to allow application of some desired effect
(e.g., mesh control, load, support, …):
• Split face at vertices

• Split Edge

• Add a hard vertex

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 Automatic Virtual Topology
Automatically creating Virtual Faces
• Left Click Virtual Topology in Model Tree
• Set Behaviour in Details
- Controls aggressiveness of automatic VT algorithm
- Low: merges only the worst faces (and edges)
- Medium & High: try to merge more faces
- Custom: User Defined values for custom cleanup
- Repair: Just does some limited cleanup for small faces and edges
• Select if Face Edges shall be merged
• Right Click Virtual Topology and click Generate Virtual Cells
Manually creating a Virtual Face
• RMB on Model tree and select Insert Virtual Topology
• Select Virtual Topology from the Tree Outline
• Pick faces or edges, RMB and Insert Virtual Cell
All VT entities created can be seen in different colors if Virtual Topology is selected
in Tree Outline

50 © 2019 ANSYS, Inc.

 Automatic Virtual Topology Methods
Custom Auto-VT & VT Repair operations provide automated ways of simplifying geometry:

Custom VT Repair
Advantages: Advantages:
• More control over curvature. Creating • Targeted ways of removing small
VTs w/too much curvature can some edges, faces and slivers
times make meshing less successful • Can be used with other Auto-VT
methods or in place of them
Note: Mesh Based Defeaturing is the recommended approach for detailed models cleanup. It is much more robust, as it
cleans at mesh level. Virtual Topology is recommended for only those cases/bodies where Mesh Based Defeaturing is not
effective. VT can also be used for any selective local cleanup which was not handled by mesh based defeaturing
51 © 2019 ANSYS, Inc.
 Pinch
• Pinch control removes small features automatically or manually at the mesh level
➢ Slivers
➢ Short Edges
➢ Sharp Angles
• The Pinch feature works on vertices and edges only
• The Pinch feature is supported for the following mesh methods:
– Patch Conforming Tetrahedrons
– Thin Solid Sweeps
– Hex Dominant meshing
– Quad Dominant Surface meshing
before after before after
– Triangles Surface meshing
• Not supported for
– CutCell
– Patch Independent
– Multizone & General Sweep

Vertex-Vertex Edge-Edge

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 Polyhedral Meshing - For CFD/Fluent users only
Tetrahedrons
Behavior
• Meshes an entire model using Polyhedral mesh
– Polyhedral/HexCore meshing is not available
in WB meshing, only in Fluent meshing

Polyhedral
Access
• Fluent Meshing volume meshing technology is
accessible from a WB meshing setup only
through the WBPolyMeshingForFluent ACT
• To use, download the ACT (free) from the ANSYS HexCore
App Store
• Both Polyhedral and HexCore meshes can be
produced with high quality inflation

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 WB Meshing – Polyhedral meshes

Polyhedral mesh Characteristics

• Meshing method designed for the ANSYS FLUENT solver
• Generates a Polyhedral mesh
- Starting from a triangular surface mesh in WB meshing
- A prism-tet mesh is created and is natively converted to a high quality polyhedral mesh in Fluent
Meshing
• Supports Inflation
- Pre-inflation (Fluent Meshing algorithm)
• Comparison with Fluent Solver
poly conversion
- Natively created Polyhedral meshes are of
much better quality than Solver converted
polyhedral meshes

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 Polyhedral meshing

Pre-requisites
• Single or Multi-body part meshing only
- The ACT does not support multiple parts
- Share topology must be successful
• Mesh Controls
- Only program controlled inflation (defined inside the ACT panel)
- All bodies must be assigned a patch conforming Method (tetrahedrons)
- Only Advanced Size Function
• Surface meshing
- A triangular surface mesh needs to be created in WB meshing
- Skew =1 is acceptable

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 Polyhedral Meshing – Controls (1)

Meshing Parameters - ACT

• Symmetry/Periodics/inlet/outlet Boundary conditions
- Optionally indicate Named Selections if they do not follow the
standard Fluent Zone type naming conventions
• Internal Boundaries
- Allows the inflation mesh to go continuously across internal
fluid-fluid boundaries
- Optionally rename internal Solid/Fluid boundaries to include
the Fluid/Solid names
• Inflation Settings
- This is for Program Controlled inflation only

Note: Please consult the documentation for other important limitations

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 Polyhedral Meshing – Controls (2)
Meshing Parameters - ACT
• Volume meshing settings
- Use Size field for Volume meshing is BOI is present
- Volume Fill Options: Poly, Tet or HexCore
- Quality Method
➢ Orthogonal quality, Skewness and ICEM CFD quality are available
➢ The volume mesh is being improved if the initial mesh does not
meet the quality criteria., with successively more aggressive
options
• Debug Mode
- If run in Debug mode, the script is run in Fluent Meshing
standalone and the UI is available at the end of the volume
meshing, allowing for :
➢ Display of individual cell zone meshes
➢ Cell count, timing and quality information for each cell zone

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 Workshops for CFD users
Do any 2 OR 3 workshops from Workshops number 5a CFD, 5b CFD, 5c CFD, 5d CFD and 5e CFD

5.1 CFD 5.2 CFD 5.3 CFD 5.4 CFD 5.5 CFD

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 Workshops for FEA users

5.1 FEA 5.2 FEA

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 Workshop for Explicit users

5.1 Explicit

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