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I'm running Creo 10 with a Creo Ansys Simulation add-in / license. I have a fairly simple setup with two circular plates touching each other. I've intentionally omitted screens of the parts for proprietary purposes, but the feature tree is below. For some reason, when I try to generate a mesh using a Free contact, it fails. But if I change it to a Frictionless contact, then generate the mesh, then switch back to a Free contact, then re-generate the mesh, it works... I'm not sure if this is a glitch or if I'm just missing something...
Below shows the steps of how I'm able to turn on and off the issue:
1) Contact is Free initially, Generate mesh > Mesh Fails
2) Change contact to Frictionless, Re-generate mesh > Mesh Succeeds
3) Change contact back to Free, Re-generate mesh > Mesh Succeeds
4) Change mesh size to low
5) Steps 1 thru 3 occur again
6) Change mesh size to medium
7) Steps 1 thru 3 occur again