I have a contact interface defined so there is no separation diameter. Fastener head surface region is smaller diameter than the counter bore surface diameter.
The message states that it cannot automatically detect the contacting surfaces even though there is one defined, the surfaces are normal to the fastener axis, hole axes exactly co-incident and there are only 2 components/1 interface. Is it looking in the wrong direction some how?
I am still suspicious that it has something to do with the non-native geometry. I believe that if I were to re-model as native geometry, the problem would just go away. There isn't anything special about the geometry.
When the model is run (no external loads) after dismissing the message, the contact region is ignored and all the fastener measures are all exactly zero. The software only does one pass. All very odd.
I don't think this will be resolved but should anyone remember this thread in the future after having come across and fixed the issue, please resolve this thread.
The old fashioned method works well as usual; albeit time consuming prep when there are many fasteners. In this case faster than remodelling.
Thanks