I am attempting to mesh a complicated design (~80,000 faces) for a microchannel heat sink, as pictured, and I would appreciate some advice. I have tried a range of different mesh controls (especially face sizing and body sizing), mesh settings and element sizes, and all have failed to produce a working mesh. The most common errors are shown in the linked picture, in particular the one regarding "The following surfaces cannot be meshed with acceptable quality. Try using a different element size or virtual topology." However, I have already reduced the element size to 2x10^-6 m, which takes two days to resolve before failure.
Unfortunately I cannot alter the geometry significantly, as it is imported from generation in SolidWORKS as either a STEP or an x.t file. As such, any advice for how I can successfully mesh the geometry for CFD analysis in FLUENT would be greatly appreciated.
I can provide more details or the geometry file itself if required.
Thanks in advance.
Thank you for your suggestions. In the end I solved the issue by importing the original mesh generated by COMSOL into SpaceClaim, then employing both the "Smooth" and "Reduce Faces" tools in tandem to simplify the geometry, before finally using SolidWORKS to turn the smoothed mesh into a solid body. This body retained many of the same features as the original, but was much less complex, having two orders of magnitude fewer faces. In turn, this permitted both meshing and heat transfer analysis in FLUENT.
