I believe that the "for press fit, ignore interpenetrations larger than:" is only for geometry that is initial interference. If the geometry is not in interference/has a gap, then this feature ignored. I ran four test cases to confirm this:
- 1/4-symmetry pin and plate w/ hole with an initial interference of 0.05 in and "ignore interpenetrations larger than:" set to 0 in.
- 1/4-symmetry pin and plate w/ hole with an initial interference of 0.05 in and "ignore interpenetrations larger than:" set to 0.049 in.
- 1/4-symmetry pin and plate w/ hole with an initial interference of 0.05 in and "ignore interpenetrations larger than:" set to 0.05 in.
- 1/4-symmetry pin and plate w/ hole with an initial gap of 0.05 in and "ignore interpenetrations larger than:" set to 0 in. A thermal load was applied to the plate to shrink in onto the pin.
The results I got were:
- Interpenetration remained; no contact stresses developed.
- Interpenetration remained; no contact stresses developed.
- Interpenetration removed; contact stresses developed.
- Gap removed; contact stresses developed.
Were you having analyses fail if you didn't modify the interpenetration value or uncheck the box?