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Simulation - Meshing a family of parts

Question asked by Michael Mueller on May 8, 2013
Latest reply on May 9, 2013 by Jared Conway

I am trying to run simulations on a single SolidWorks model where the only variable is the height.  I need to determine the worst case size in order to narrow the number of designs that I need to do mechanical testing on.  This is a medical device and will be evaluated by the FDA.  The heights range from 24mm - 70mm in 2mm increments.  I am struggling with getting results that are even close to linear across the range of sizes.  The FDA dictates that you mechanically test the tallest device, but they also state that it needs to be the worst case.  Is it best to use a consistent mesh size for each configuration?  Or is it best to have the number of elements be close to equal for each configuration regardless of mesh size?  If I use the automesh, it seems to produce unexpected results (i.e. 24mm showing higher Von Mises stress than the 70mm).