pretty cool model.
not sure what version of solidworks you're running but have you tried showing the beams (render beams) to see if they are the sizes you expect them to be?
overall, what you're describing, i have never seen. have you spoken with your reseller about this? i think what they will need (and if you want more help on this through the forum as well) is the assembly and simulation results in the "bad" state and also in the good state. more information about the workflow in between iterations would also be helpful. what specifically are you changing, is the area that isn't working being affected by those changes..etc.
Thanks for your reply Jared. To elaborate:
- I am running 2013.
- Rendering beams does not work for me (less than a 10th of them show up, but I will look into that.
- I believe any change involving a remesh (wether in the problematic area or not) will cause a problem. For example, just changing the value of a load is fine, but modifying a mesh control value is not.
- Right after posting this I found that switching back and forth between solvers (FFEPlus and Direct sparse) for each consecutive run makes it work. This is much less time consuming that creating a new analysis every time. I'm making progress...
- I am going to see what can be done through the reseller.
switching the solvers seems like a strange way to fix it. but like you said, much easier than your other method. keep us in the loop.