I have been struggling with interference of my part file and am in search of help. I have tried many different things with contact points with and without penetration, bonded contacts, shrink fit, incompatible mesh etc. I cannot seem to find a breadth of information/guidance on this. I will say that while I have tried using these, I may not have tried everything or selected the right things to make them work for the simulation. The fixed geometry is the bottom plate. The force is 15 lbf on the tail "seat". The material doesn't much matter at this point, I just want to get this working.
There are a few things I have tried that have bypassed the meshing errors, but then the simulation fails to complete. I have included the SW file and a picture of the error. The only difference between the file in the picture and the most updated one (which is attached, 6) is I tried changing some of the geometry where the interference for the first pair of bodies was.
Ah, now it seems you have stumbled on one of those pesky 'undocumented features' in SW. I've seen the same thing where parts which are mated do not bond using Global Bonding for some unknown reason. The only way I've found to work around this, short of making an entirely new model, is to use the Contact Sets feature to find and bond surfaces of selected parts with the rest of the assembly. Select the part, choose the option to 'find with the assembly' and search automatically. Then you need to select the ones you want to create from the window in the bottom.