"Bonded" contact set fails to implement

[CalculatorDave]

Howdy all,

I am running a SolidWorks Simulation static stress analysis on an assembly, and I'm having a ridiculous problem.

I must bond a simple cylindrical feature into a simple hole feature of exactly the same diameter. However, during the simulation, the two repeatedly fail to bond. The mesh nodes do not match up, but this shouldn't matter because I have established a surface bonding contact set - shouldn't this force the two surfaces to be bonded? I have also tried making the hole slightly smaller than the cylinder, and then using a shrink fit contact set - this also fails to bond the two surfaces.

Any suggestions on how I can brute-force these two surfaces into being bonded?

 

[Maxham1]

This may be too much brute force, but could you make them one part?

 

[PeteDB]

Try applying the same mesh control to the cylinder and hole surfaces when they are the same diameter. This should force the nodes to line up which would then merge the nodes on the two surfaces.
I do not know why the BONDED contact set did not work. I would expect it to work without needing mesh controls.