Problem with extrusions when "working in meters” in complex geometries.
Let me start to explain the title of the post. I used the expression “working in meters” because, trivially, scaling all by 1.0e+03, the issue disappear. I said “complex geometries” because I was not able to reproduce the issue extruding a square with a circumferential hole in the middle.
The geometry attached (newCroocked.geo newCrooked.geo) was already posted few years ago by @thomas.toulorge and @mrasquin related to another issue.
As for the blade, the key parameter is sf (scale factor, line 4). If sf=1.0e-03, extrusion fails (figure 1). If sf>=0.01 everything goes well (figure 2). I also tried to set Geometry.Tolerance=1.0e-13 but it didn't help.
Originally I was working on a compressor blade mesh and there I also found that exists a threshold value of the extrusion depth for which the problem may arise or not.