[bhushanp]

I was getting contact errors which were due to improper imprinting. On checking in Ansys spaceclaim, I found that even after setting a very low tolerance or a super high tolerance value, the contact is not detected. I double checked to ensure that in my cad the surfaces are in contact and not interfering. I don't understand why Ansys thinks there is nothing to imprint when clearly the surface has not been imprinted.
Attaching images of Ansys giving the error and how the surface is to get an idea how the imprint should look like:


Any idea related to why this could be happening would be greatly appreciated.

[bhushanp]

so I solved the imprint error by splitting all the bigger parts each into smaller parts which were able to imprint on the bigger surface. However, now while making auto connections Ansys randomly selects a nearby face along with the required face to make the contact. I tried adjusting the tolerance value and face overlap tolerance and that reduced the overlapping selections a bit but still they are about 55. When I select each overlapping one, it gives me only one overlapping region in terminal. Thus I can only troubleshoot one and if I can't figure it out, I don't know which other is overlapping. While trying to find overlapping region, sometimes it has perfectly good faces, one on each side which should be a proper contact. I don't know with which other face the double contact is being made (maybe some other pair). How do I find this other pair. And any better way to do this auto contact process in Ansys?