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When working with a coworker the other day we came across a mesh failed error, which if you’ve been using COSMOS you will have probably seen this error once or twice.
So, what to do? Well maybe we can suppress some feature. No, we can’t, it’s a plastic part under pressure; we really needed all the fillets. Okay, what next, let’s try raising the mesh quality. No, we still couldn’t get the mesh to create. At this point we are both going #%(@!. I got a great idea! 2008’s alternate meshing is amazing, that should work. Crank for an hour….. boom! “MESH FAILED!!!!”
While looking at our options we saw the second line in the mesh quality dialog. “What’s this number doing for us?”
 “TO THE HELP FILE!!” COSMOS help says. 
Tolerance. Sets the tolerance value. The default tolerance is 5% of the global element size. If the distance between two nodes is smaller than this value, the nodes are merged unless otherwise specified by contact conditions.
Adjusting the tolerance can help resolve some meshing problems. For example, if meshing fails due to free edges, increasing the tolerance can solve the problem. The tolerance cannot exceed 30% of the element size.
Translated: This means the tolerance will either include small edges or sliver face or will polish the out. We raised the tolerance to 20 percent of the global element size and it meshed in 2 minutes!
YEAH! Thanks Help File!!!!
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