April, I have a couple questions for you. Are you (1) using the Shrink Fit option, and (2) are you trying to find stresses relating to the knurl or is it an option to suppress it alltogether and use a plain cylinder?
I personally have never had great luck with the distance deformation option, it never seems to hit the mark!
1) No, I have not used the Shrink Fit option.
2) We are trying to find the force it would take to push the pin with the knurling into the hole. Both the knurl and the block would deform a bit so using it as a plain cylinder would not work. After it deforms, I also want to see how much I can torque the pin before spinning loose. Deformation would be a factor in torquing.
Do you know if there is a way to measure the inner diameter instead of just using the sketch option and drawing a circle along the the model?
This is a fairly complex problem for FEA. However, you may be able to find a formula to give you an approximate value. There are a few calculators available on the interweb.