Is this a known problem? I've an assembly model that has a mix of solid and sheet metal parts. I've been successfully running the model without problems, and getting good results.
I changed the thickness of one sheet metal part to evaluate a high stress location. When I changed it back to the original thickness, my contacts, which had been "no penetration" stopped working, and became bonded. Nothing I could do would change this, including deleting all contacts and loads, and reapplying.
I started stripping the assembly back and rerunning, to try and figure out where the problem was.
I began getting an error: "Internal error. Number of element nodes is greater than maximum allowed. Element Number =" It didn't matter how far back I stripped the assembly, I still got that error. I finally stripped it back to a single part, and was able to run an analysis. Anything more than this, and I got the error.
I've noticed in the past that when you make analysis changes, that Simulation has a hard time "forgetting" what was there before. Is there a way to strip all of the Simulation information from an assembly, so I can start over without creating a brand new assembly? I had to do a new assembly already last week, and the new has worn off the situation.