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<article data-uid="Technique-MeshResolution">
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<h1 id="mesh-resolution">Mesh Resolution</h1>
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<p><a class="xref" href="../../api/Hi.MachiningProcs.SessionShell.html#Hi_MachiningProcs_SessionShell_MachiningResolution_mm">MachiningResolution_mm</a> is the edge length of the cubes the
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workpiece is built from, and it is the single largest lever on how long a simulation takes. It is
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also the setting most often set once and forgotten, which is expensive in both directions: too
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fine and a run that should take minutes takes hours, too coarse and a feature the program is
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supposed to cut is not there to be cut.</p>
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<h2 id="choosing-a-value">Choosing a Value</h2>
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<p>Work coarse first. An early run answers questions — does the path collide, is the force roughly
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where it should be, does the optimizer have room — that do not need a fine mesh, and it answers
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them in a fraction of the time. Refine only for the final optimization pass, where the geometry
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that comes out is the deliverable.</p>
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<p>As a planning figure, a simulation run takes somewhere between <strong>2% and 150% of the actual
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machining time</strong>, spanning that whole range depending on the mesh and the step count. That is
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wide because it is genuinely a choice, not a property of the machine.</p>
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<p>Where the time actually goes, and which of the two costs is currently the bottleneck, is in
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<a href="cpu-usage.html">CPU Usage During Simulation</a>. The short version: at the fine resolutions real NC
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work needs, geometry removal dominates and a finer mesh is much slower; once the mesh is coarse
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enough that removal is cheap, the per-step costs dominate and coarsening further buys nothing.</p>
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<h2 id="what-value-you-actually-get">What Value You Actually Get</h2>
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<p>The number you type is a request, not the width. The workpiece is carved out of a cube grid that
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starts from one fixed root cube and is halved level by level, so every width the engine can
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actually build is a power of two in millimetres:</p>
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<pre><code>... 2 - 1 - 0.5 - 0.25 - 0.125 - 0.0625 - 0.03125 ...
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</code></pre>
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<p>A request that is not one of those is rounded <strong>to the next finer one</strong>, never to a coarser one,
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so the mesh you get is never worse than the mesh you asked for. The consequence worth knowing is
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that a value chosen off the ladder buys nothing:</p>
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<table>
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<thead>
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<tr>
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<th>Requested</th>
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<th>Actually built</th>
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</tr>
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</thead>
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<tbody>
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<tr>
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<td>0.5</td>
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<td>0.5</td>
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</tr>
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<tr>
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<td>0.4</td>
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<td>0.25</td>
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</tr>
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<tr>
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<td>0.3</td>
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<td>0.25</td>
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</tr>
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<tr>
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<td>0.25</td>
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<td>0.25</td>
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</tr>
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<tr>
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<td>0.2</td>
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<td>0.125</td>
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</tr>
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<tr>
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<td>0.125</td>
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<td>0.125</td>
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</tr>
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</tbody>
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</table>
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<p><strong>0.4 mm and 0.25 mm produce the same mesh, at the same cost.</strong> 0.4 is 0.25 wearing a misleading
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label: it reads as a coarse, cheap setting and runs as a fine, expensive one. If 0.25 mm is finer
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than the run needs, the next value that changes anything is 0.5 mm — and going the other way,
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0.125 mm is another eight times the voxels, not a small step.</p>
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<p>The ladder bottoms out at <strong>0.001953125 mm</strong>. A finer request is clamped to it, so the finest entry
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offered in the workpiece's Initial Resolution list builds the same mesh as the one above it.</p>
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<p>Pick from the ladder and the number shown in the mission row is the number the run used. That
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matters beyond tidiness: a recorded mesh is built at whatever resolution is in force when the
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record runs, so an off-ladder value is silently baked into the cache as its rounded neighbour.</p>
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<h2 id="what-the-mesh-does-not-change">What the Mesh Does Not Change</h2>
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<p>For a representative test case — downward circular slot milling with varying width and depth —
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the <strong>physical</strong> values move within about <strong>20%</strong> across the full range of mesh widths. The
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simulated forces, torques and temperatures from a coarse first pass are therefore already
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informative; they do not become a different answer when the mesh is refined.</p>
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<p>The visible geometry is a different matter, and it is what the three runs below show. Workpiece
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70 × 50 × 50 mm:</p>
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<p><img src="mesh-resolution-img/mesh-width-0125.png" alt="Mesh width 0.125 mm">
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Mesh width 0.125 mm</p>
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<p><img src="mesh-resolution-img/mesh-width-05.jpg" alt="Mesh width 0.5 mm">
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Mesh width 0.5 mm</p>
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<p><img src="mesh-resolution-img/mesh-width-1.png" alt="Mesh width 1 mm">
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Mesh width 1 mm</p>
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<h2 id="the-failure-mode-worth-knowing">The Failure Mode Worth Knowing</h2>
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<p><strong>A thin shell thinner than the mesh width can disappear entirely.</strong> The test case above has no
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thin shell, which is why its physical values are so insensitive; a part that does have one behaves
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differently, because the material the cutter should be meeting is not represented at all. Where
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the workpiece has a wall, web or floor thinner than the mesh width, the mesh must be finer than
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that feature before the run says anything about it.</p>
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<p>The related and much smaller effect is quantization ripple in the per-step ratios, which a finer
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mesh reduces — see <a class="xref" href="../milling-physics/machinability.html">Process Machinability</a>.</p>
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<h2 id="see-also">See Also</h2>
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<ul>
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<li><a href="cpu-usage.html">CPU Usage During Simulation</a> — which of the two cost drivers a given mesh width puts in the way</li>
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<li><a class="xref" href="../milling-physics/machinability.html">Process Machinability</a> — the mesh-quantization ripple in the availability ratios, and why it is an artifact rather than a signal</li>
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<li><a href="../../manual/setup/workpiece.html">Workpiece</a> — where the initial resolution is set, on the branch carrying the stock it applies to</li>
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</ul>
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