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The message you are seeing is more a warning than an error.

It stipulates that the ratio of turbulent


viscosity over the laminar viscosity is large than 1e5. While this is not an error per-say, it is usually
non-physical to have such a high ratio (note that this ratio limit is defined in Solve-> Controls ->
Limits). This ratio becomes very high in region of high turbulence, where the grid is (in most cases)
too coarse. In many case, this message occurs at the beginning of a simulation and will disappear
as the simulation converges.
Generally speaking, the turbulent viscosity ratio warning could occur because of four primary
reasons
1. If the scale of your mesh is non-physical. Sometimes you create your model in mm and you forget
to set the right units in FLUENT when you read the mesh. Make sure the scale of the model is
correct.
2. If the inlet boundary condition values for turbulence parameters are high. Make sure you set
reasonable values of the turbulence parameters. It is recommended to use the Intensity and
(turbulent viscosity ratio or length scale or hydraulic diameter) instead of k and epsilon while
specifying turbulence parameters.
3. If the initial condition values of k and epsilon are non-physically high. Make sure that these values
too are relatively low
4. If you start the simulation with second order schemes for k and epsilon. Make sure you start with
first order and move to second order. If the warning still continues, you can use first order for epsilon
as the epsilon equation is more sensitive and difficult to converge (and is mostly the culprit behind
the viscosity limitation warnings)
If these four things are set correctly then the viscosity limitation warning can come because of mesh
issues. If the skewness of the mesh is too high (above 0.9-0.95). Make sure that the skewness is
under 0.9.
Also note that for certain types of flows, for instance atmospheric boundary layer flows, the turbulent
viscosity ratio can be as high as 1e+08 or 1e+09. In such cases, the limit can be increased. Go to
Solution Controls, click the Limits tab (located below the under-relaxation factors) and enter a higher
value.

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