The hot-rolling process can be simulated via static analysis in two load steps. The first load step pushes the billet until it establishes contact with the rollers, and the second pulls the billet by rotating the rollers.

Before rezoning, back up results and restart files associated with the initial run in a separate directory. Rezoning updates results and restart files, so the original files are no longer available should you wish to try rezoning at another substep.

If rezoning is performed at a substep where the original mesh is too distorted (where shape-checking (SHPP or CHECK) indicates errors), then rezoning will not work. Rezoning should therefore be performed at an earlier substep.

A new mesh that is too fine as compared to the original mesh may cause mapping (MAPSOLVE) errors. The primary requirement for the new mesh is that it should properly capture the outer surface geometry of the deformed model.

Check the model after remeshing (REMESH,FINISH) to verify that all boundary conditions, contact pairs, and loadings have transferred correctly from the original mesh to the new mesh.

After rezoning, if the analysis diverges again after passing the initial run's diverged time, multiple rezonings may be necessary. If the analysis diverges again before passing the initial run’s diverged time, then either the new mesh is of insufficient quality, or other problems unrelated to mesh distortion (such as geometry and material instabilities) exist.