I'm not familar in working with stl. I mostly work with step. The following has been working for very well, but for planar faces only !

in FreeCAD but possible in the CAD you prefere as well ...
- import the stl files --> convert the mesh into solids
- make a compound out ouf the solids
- export the compound to step

in GMSH
- open the compound step
- GMSH Tools --> Options --> Geometry --> General --> Cut and merge faces (-string "Geometry.OCCConnectFaces = 1;")
- Mesh 3D
- ...

Bernd


Zitat von Krzysztof Bzowski <[email protected]>:

Hi,
I have two parts, which need to be meshed. One part is located inside another. To simplify the problem, imagine two cubes: one inside another.

http://i.stack.imgur.com/h87gD.png

Geometries are stored in STL files. From CAD point of view, one file contains an internal cube, another contains cube with a hole for an internal cube. All dimensions fits (there are no intersections). My task is to create a conformal tetrahedral mesh suitable for mechanical FEM analysis - without duplicated nodes on shared faces. Each element should contain information to which part it belongs. File format does not matter but Abaqus is preferred.

I decided to use gmsh, but I cannot mesh both parts together.
I tried the following commands:

 1. File -> Open Internal cube
 2. Add volume to internal cube
 3. File -> Merge External cube
 4. Add volume to external cube

This produces mesh but elements in internal cube are duplicated. It looks like gmsh does not treat hole (in external cube) as a void. I also tried to use Coherence in gmsh but it failed with error:

Error : Self intersecting surface mesh, computing intersections (this could take a while)

Error   : Surface mesh is wrong, cannot do the 3D mesh

I assume, that my geometries are fine:

 - Internal cube: http://pastie.org/10673562
 - External cube: http://pastie.org/10673564

How to create such a mesh which satisfy my requirements?

Best regards,
Krzysztof

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