I'm trying to run an optimisation study on a gear with a thin web and holes drilled through the web.
I've set up some relations to keep the web in the middle of the gear facewidth, and I've used the web thickness and the hole diameter as design variables in the study.
The .rpt file keeps giving the error:
** Warning: Changing the parameters has produced invalid
model or geometry for the following parameter
values:
Parameters:
d18 10.14 (this is the web thickness, which started at 10)
d28 20 (hole diameter, unchanged in this iteration)
Recovering from invalid parameter values by cutting
step size.
but if I go back to the model and enter the values it shows (which are only a small change from the start point) it regenerates fine.
What gives?
(Initially I used the number of holes as a variable, leaving the diameter fixed, but it recognised the unit as "mm" and then started trying to use non-integer values!)
Edit: I've tried it with both "Repeat P-Loop Convergence" and "Remesh after each shape update" selected, and now with neither selected. Same result either way.
Edit 2: It seems to be running, but for every iteration it has to go through about four 'invalid geometry' cycles, which is making it really slow...