Occasionally, the Cool (FEM) analysis results will not converge. Generally, when this is the case, the cause is poor matching between the mold elements and the part elements. This can be confirmed and the areas of poor matching can be studied using the Improper part-mold contact result.
The Improper part-mold contact result shows how well the tetrahedral elements of the mold match those of the part. If the elements do not match well, the analysis will fail.
Obtaining this result
This result does not appear in the Study Tasks pane by default. Instead you can create it as a New Plot after the analysis has run by clicking 
( ), then clicking 
New Plot and selecting Plots from the drop-down menu. Improper part-mold contact is listed in the Available results.
Using this result
During the analysis, the solver checks the internal section of the mold to ensure that the mold mesh matches the part mesh. Where there is perfect mesh matching, the Improper part-mold contact result appears blue with a value zero (0). Where there is no contact the Improper part-mold contact result appears red, with a value one (1). For the Cool (FEM) analysis to run successfully, there should be no red areas of no contact.
If your Improper part-mold contact results shows red areas, remesh the mold and fix these areas.
Things to look for
- Check that there are no areas of red, indicating no contact.