Meshing Density Effect in FEA

Mesh density is extremely important. If your mesh is too coarse, your results can contain serious errors. If your mesh is too fine, you will waste computer resources, experience excessively long run times, and your model may be too large to run on your computer system. To avoid such problems, always address the issue of mesh density before you begin your model generation.

Perform an initial analysis using what seems to you to be a "reasonable" mesh. Reanalyze the problem using twice as many elements in critical regions, and compare the two solutions. If the two meshes give nearly the same results, then the mesh is probably adequate. If the two meshes yield substantially different results, then further mesh refinement might be required. You should keep refining your mesh until you obtain nearly identical results for succeeding meshes.

In this case, increased mesh density will be provided at junction between nozzle and header box of Air Cooler Heat Exchanger.
First, normal mesh density with 30mm length was given at the whole model. The stress intensity was given at 237.157MPa







And for second analysis, mesh density increased by 2 times, and the result increased at 323.598MPa.








And after re-run the anysis with increasing the density, we obtain: