Hello Edward. Probably that is the main problem with the numerical simulation. When geometry is far away from regular shapes is always a challenge to get a quality mesh and some times the mesh itself. I really don't know what should be the procedure you need but in my short experience is almost a cut and trial process. Divide the geometry in several parts having regular shape is a good resource. Using diferent kind of elements is other. Mesh from axis to faces and then volumes has been a good strategy in some cases. Controlling the size of the elements and inflation is another resource. Finally the best results in my case has been reached using ICEM.

Hi Edward Jenks . as I understand from your question your geometry has large domain and small detail. In this kind of geometry meshing could be very challenging. In your study, Ansys Fluent meshing and poly-Hexa elements could be very useful . You can use local mesh sizing like Curvature and Proximity for capturing small details and use global size for large domain.

I think if possible you can make 2D gemotry first and can define it like axis symmetric in setting option of ANSYS Fluent . As you said you made axis symmetric sweep while drawing gemotry , So I think in your result you can show periodic in result contour instead. So simplifying your geometry in 2D you can easily do perfect mesh meeting required criteria and can reduce mesh numbers and calculation iterations time.. I have attached some pictures (subject to copyright of my professor and me in my M.SC thesis in KUET,Bangladesh) for better understanding of my proposal.

Thank you very much.

Dear Edward Jenks ,

Have you tried using Tessellation? Approach by triangles?

Complex geometries, such as biological surfaces, use this triangle technique.

It is the same process used to fragment a 3D dem file to be able to print in 3D. The same that the film industry uses to make animations with extreme complexity.

I think it will work!

Good luck.

Regards,

Prof. Wiltgen

Links:

https://www.researchgate.net/search.Search.html?type=publication&query=tessellation

Conference Paper Ray Tracing Complex Models Containing Surface Tesselations

https://ieeexplore.ieee.org/abstract/document/5650292

Article A two phase technique for optimal tessellation of complex ge...

I think your problem is with sharp edge please create small edge avoid zero