Thanks all for the postings - everyone comments are very helpful. Everyone of this forum - I am honor to get to know - I am glad to be a member of this forum.
To answer the Creo/Elements Pro simulation - The client I am working with is using this release. The original plan was to give back the data and pictures of results of the FEA. To get the job done (remember the phrase "Gittter-R-Done"). I do have active maintance and do have Creo v1 - v2 - v3. I will take the advise of those that suggested to use Creo 3 and tell them the limitations of CreoElements Pro. I will tell the client, I can give you result data - but you will have to realize that you can't open the new files. Hence I can only offer pictures for now. I'm sure they will respect the issues.
Some notes to comment on about small feaures.
The 3d data came from the client and the ProE user that created the Aluminum Extrusion created one HUGE AND COMPLEX sketch to make the feature. ( I plan to educate the User of better techniques of creating the same model - but use / create more features. These additional features will provide better and easier manipulations of the 3D). Back to the topic, I will edit the model and remove all small radii as many of you have suggested.
I will make constraints as many have pointed out or has suggested.
To comment on the computation time and complexity. To start, the goal is to show Manager's - which are all non-engineers the deformation of the polypropylene part. The last design there engineer created did not have the hour glass (pot belly) feature. The narrow hour glass (pot belly) feature was my suggested solution to them to fix the problem. I just hav to prove it via these simulations.
Sorry - back to the topic, The results are more understood via pictures, So the more the picture looks like the image they have of the part / assembly the better and easier my question and answer session. On a side note, my benefit is I get to bill for the time. Yahoo - more $$$ for the wife.
Again, thanks to all for everyone comments - I believe the my problem is closed.
Regards,
Dave Maloy