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EmanuelProfile picture@user9d3335974902·2d
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A first FEA study fails for boring reasons. Fix these five before you refine the mesh.

Most first simulation studies are not “too coarse.” They are ill-posed.


Before you add another million elements, check this order:


  1. Units. Mixed mm/N/MPa vs m/N/Pa will give you a beautiful, meaningless stress plot.

  2. Fixtures that match the real world. A fully fixed face is rarely how the part is held. If the physical part can rotate a fraction of a degree, your model should too.

  3. Loads as they are applied, not as they are imagined. A bolt preload is not a force on a hole edge. Bearing contact is not a uniform pressure unless you have proven it is.

  4. Material model. Linear isotropic steel is fine for a bracket. It is a lie for elastomers, composites, and anything past yield if you are making a go/no-go call.

  5. Mesh only where the gradient lives. Fillets, contact, and load introductions. The rest of the part can stay coarse.


If the reaction forces do not balance the applied loads, do not interpret von Mises. The study is not solved.


This is the kind of unblocking we do inside Engy Lab — CAD, simulation, automation, and the AI tools around them. Bring the model, the BC screenshot, and the question that is actually stalling you.