{"id":43209,"date":"2026-03-12T15:29:13","date_gmt":"2026-03-12T09:59:13","guid":{"rendered":"https:\/\/ckonnect.in\/solidworks\/?p=43209"},"modified":"2026-03-27T18:09:03","modified_gmt":"2026-03-27T12:39:03","slug":"mass-flow-is-out-of-fan-curves-rangewarning-in-solidworks-flow-simulation","status":"publish","type":"post","link":"https:\/\/ckonnect.in\/solidworks\/mass-flow-is-out-of-fan-curves-rangewarning-in-solidworks-flow-simulation\/","title":{"rendered":"\u201cMass Flow Is out of Fan Curve\u2019s Range\u201dWarning in SOLIDWORKS Flow Simulation"},"content":{"rendered":"\n<p>What This Warning Really Means?<\/p>\n\n\n\n<p><br>If you have ever run an internal flow in <a href=\"https:\/\/ckonnect.in\/solidworks\/flow-simulation\/\">SOLIDWORKS Flow Simulation<\/a> using fans, chances are you have seen this message pop up.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img fetchpriority=\"high\" decoding=\"async\" width=\"1005\" height=\"150\" src=\"https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image.png\" alt=\"Mass Flow is out of Fan curve's range\" class=\"wp-image-43210\" srcset=\"https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image.png 1005w, https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image-300x45.png 300w, https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image-768x115.png 768w\" sizes=\"(max-width: 1005px) 100vw, 1005px\" \/><\/figure>\n<\/div>\n\n\n<p>\u201cMass Flow is out of Fan Curve\u2019s Range\u201d<\/p>\n\n\n\n<p>The solver keeps running and the result is generated. But the warning just stays there\u2026 quietly making you question everything.<\/p>\n\n\n\n<p>I ran into this issue myself and initially did what most of us do-<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Double-checked the fan curve<\/li>\n\n\n\n<li>Checked the fan direction<\/li>\n\n\n\n<li>Rebuilt the study<\/li>\n\n\n\n<li>Simplified geometry<\/li>\n<\/ul>\n\n\n\n<p>Yet the warning refused to go away.<\/p>\n\n\n\n<p>Only after understanding how <a href=\"https:\/\/ckonnect.in\/solidworks\/flow-simulation\/\">SOLIDWORKS Flow Simulation<\/a> treats a fan did the problem finally make sense.<br>This blog shares that learning so you do not have to go through the same confusion.<\/p>\n\n\n\n<p>First Things First: This Is Not a \u201cFan Curve Error\u201d<\/p>\n\n\n\n<p>When you see this warning, the immediate reaction is-<\/p>\n\n\n\n<p>\u201cSomething is wrong with my fan curve.\u201d<\/p>\n\n\n\n<p>Most of the time, that is not true.<\/p>\n\n\n\n<p>The fan curve itself is usually fine.<br>The real problem lies in how the solver is calculating pressure around the Fan. To understand that we need to talk about fan operating points.<br>How a Fan Works Inside SOLIDWORKS Flow Simulation<\/p>\n\n\n\n<p>A fan curve is just a relationship between:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Pressure difference across the fan<\/li>\n\n\n\n<li>The Flow rate the fan can deliver<\/li>\n<\/ul>\n\n\n\n<p>In SOLIDWORKS Flow Simulation, that pressure difference is calculated as-<\/p>\n\n\n\n<p>&nbsp;                      <strong>\u0394<em>P<\/em>= <em>P<\/em> <sub>static, outlet<\/sub> \u2212 <em>P <\/em><sub>total, inlet<\/sub><\/strong>&nbsp; &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;where,<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>\u0394<em>P<\/em><\/strong> = Fan pressure rise<\/li>\n\n\n\n<li><strong><em>P<\/em><sub>static, outlet<\/sub><\/strong> = Static pressure at the fan outlet<\/li>\n\n\n\n<li><strong><em>P<\/em><\/strong><strong><sub>total, inlet<\/sub><\/strong> = Total pressure at the fan inlet<\/li>\n<\/ul>\n\n\n\n<p>Here\u2019s the important part-<\/p>\n\n\n\n<p>Flow Simulation does not force the Fan to operate at a fixed flow rate.<\/p>\n\n\n\n<p>Instead, it-<\/p>\n\n\n\n<ol start=\"1\" class=\"wp-block-list\">\n<li>Look at the pressure field around the Fan<\/li>\n\n\n\n<li>Calculates how much resistance the system is offering<\/li>\n\n\n\n<li>Finds a flow rate where the fan curve and the pressure field agree<\/li>\n<\/ol>\n\n\n\n<p>That intersection is called the fan operating point. If that operating point falls outside the defined fan curve, you get the warning.<br><br>So, Why Does the Fan Operating Point Go Out of Range?<\/p>\n\n\n\n<p>This is where things get interesting. Firstly, Mesh Quality<br>around the Fan In my case \u2014 and in most cases \u2014 the issue<br>came down to mesh density near the fan.<\/p>\n\n\n\n<p>When the mesh is coarse:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Pressure gradients are not captured properly<\/li>\n\n\n\n<li>Inlet or outlet pressures fluctuate<\/li>\n\n\n\n<li>The solver temporarily predicts unrealistic pressure values<\/li>\n<\/ul>\n\n\n\n<p>As a result, the Fan appears to be operating at a flow rate that<br>does not exist on the curve. This is not physical behaviour \u2014 it is<br>a numerical artifact more of an in-software value or virtual, not<br>real life.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full is-resized\"><img decoding=\"async\" width=\"385\" height=\"314\" src=\"https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image-1.png\" alt=\"Pressure Difference vs Volume Flow rate\" class=\"wp-image-43211\" style=\"width:281px;height:auto\" srcset=\"https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image-1.png 385w, https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image-1-300x245.png 300w\" sizes=\"(max-width: 385px) 100vw, 385px\" \/><\/figure>\n<\/div>\n\n\n<p>Second, Very Low Flow Resistance<\/p>\n\n\n\n<p>If the flow path is very open and unrestricted:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The Fan tries to push a lot of air<\/li>\n\n\n\n<li>The predicted flow rate can exceed the curve limits<\/li>\n<\/ul>\n\n\n\n<p>This happens often in:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Simplified internal models<\/li>\n\n\n\n<li>Early design concepts<\/li>\n<\/ul>\n\n\n\n<p>Enclosures with large openings<\/p>\n\n\n\n<p>Third, Outlet Pressure Drops Below Atmospheric<\/p>\n\n\n\n<p>During early solver iterations, the pressure on the outlet side of the Fan can temporarily drop below atmospheric pressure.<\/p>\n\n\n\n<p>When that happens:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The operating point shifts into the negative side of the curve<\/li>\n\n\n\n<li>The solver flags the warning<\/li>\n<\/ul>\n\n\n\n<p>Again, this is usually temporary and numerical.<br>And finally,<br>Fan Geometry That Looks Right\u2014but Isn\u2019t<br>For axial fans-<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A small protrusion for the hub<\/li>\n<\/ul>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A lip around the outer diameter<\/li>\n\n\n\n<li>Annular, planar faces for the fan definition are required.<\/li>\n<\/ul>\n\n\n\n<p>If the Fan is represented only using split lines on a flat face, the solver<br>struggles to compute pressure correctly.<\/p>\n\n\n\n<p>Visually, it looks fine \u2014 numerically, it is not.<br><br><\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full is-resized\"><img decoding=\"async\" width=\"291\" height=\"275\" src=\"https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/image-2.png\" alt=\"If the Fan is represented only using split lines on a flat face, the solver\nstruggles to compute pressure correctly.\n\nVisually, it looks fine \u2014 numerically, it is not.\" class=\"wp-image-43212\" style=\"width:223px;height:auto\"\/><\/figure>\n<\/div>\n\n\n<p>Why Only Some Fans Show the Warning<\/p>\n\n\n\n<p>Another confusing aspect is when:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Multiple fans use the same fan curve<\/li>\n\n\n\n<li>Only one or two fans show the warning<\/li>\n<\/ul>\n\n\n\n<p>This is completely normal.<\/p>\n\n\n\n<p>Each Fan sees:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Different local geometry<\/li>\n\n\n\n<li>Different nearby obstructions<\/li>\n\n\n\n<li>Different pressure fields<\/li>\n<\/ul>\n\n\n\n<p>Therefore, each fan finds its own operating point, even if the curve is identical.<\/p>\n\n\n\n<p>What Actually Fixed the Problem?<\/p>\n\n\n\n<p>After understanding the root cause, the solution became very simple-<\/p>\n\n\n\n<p>Step 1- Fix the Fan Geometry<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Added small protrusions for hub and outer diameter<\/li>\n\n\n\n<li>Avoided flat, split-line-only fan definitions<\/li>\n<\/ul>\n\n\n\n<p>This alone improved pressure stability.<\/p>\n\n\n\n<p>Step 2- Refine the Mesh Where It Actually Matters<\/p>\n\n\n\n<p>This was the key change.<\/p>\n\n\n\n<p>Refining the mesh-<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>At the fan inlet<\/li>\n\n\n\n<li>At the fan outlet<\/li>\n<\/ul>\n\n\n\n<p>You can do this by-<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Applying a local mesh to the fan faces, or<\/li>\n\n\n\n<li>Creating a local mesh region around the Fan<\/li>\n<\/ul>\n\n\n\n<p>Both methods work.<br>What matters is that the pressure field near the Fan is resolved properly.<\/p>\n\n\n\n<p><br>Step 3- Check the Fan Operating Point<\/p>\n\n\n\n<p>Instead of guessing, I plotted the fan operating point.<\/p>\n\n\n\n<p>Once the mesh is refined:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The operating point moved inside the fan curve<\/li>\n\n\n\n<li>The warning disappeared<\/li>\n\n\n\n<li>Results stabilized<\/li>\n<\/ul>\n\n\n\n<p>This is the single best way to confirm that the fan is behaving correctly.<\/p>\n\n\n\n<p>So, the important question, Should You Ignore This Warning?<\/p>\n\n\n\n<p>\u201cNo\u201d Even if the solver completes-<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Airflow values may be unrealistic<\/li>\n\n\n\n<li>Cooling performance may be mis<ins>&#8211;<\/ins>predicted<\/li>\n\n\n\n<li>Temperature results may look \u201cokay\u201d, but may be wrong<\/li>\n<\/ul>\n\n\n\n<p>Once the warning is resolved-<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Pressure fields stabilize<\/li>\n\n\n\n<li>Fan behaviour becomes physically meaningful<\/li>\n\n\n\n<li>You can trust the results<\/li>\n<\/ul>\n\n\n\n<p><strong>Final Takeaway<\/strong><\/p>\n\n\n\n<p>\u201cMass Flow is out of Fan Curve\u2019s Range\u201d does not tell you your fan is wrong but rather it tells you the solver cannot accurately determine the fan\u2019s operating point.<\/p>\n\n\n\n<p>In most cases:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The fan curve is correct<\/li>\n\n\n\n<li>The physics is correct<\/li>\n\n\n\n<li>The mesh near the Fan is not<\/li>\n<\/ul>\n\n\n\n<p>Refine the mesh, model the Fan properly, and always verify the operating point. Once you do that, this warning goes from being mysterious to completely logical.<br><\/p>\n\n\n\n<div class=\"wp-block-media-text is-stacked-on-mobile\" style=\"grid-template-columns:32% auto\"><figure class=\"wp-block-media-text__media\"><img loading=\"lazy\" decoding=\"async\" width=\"700\" height=\"683\" src=\"https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/Samvrudh-final-3.jpg\" alt=\"\" class=\"wp-image-43218 size-full\" srcset=\"https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/Samvrudh-final-3.jpg 700w, https:\/\/ckonnect.in\/solidworks\/wp-content\/uploads\/2026\/03\/Samvrudh-final-3-300x293.jpg 300w\" sizes=\"(max-width: 700px) 100vw, 700px\" \/><\/figure><div class=\"wp-block-media-text__content\">\n<p><strong>Samvrudh N<\/strong><br>As an Application Engineer \u2013 Simulation for <strong>SOLIDWORKS Simulation<\/strong>, specializing in <strong>Structural, Flow, and Plastics analysis<\/strong>, he focuses on delivering the most suitable simulation solutions and providing technical support to customers. He assists engineering teams in applying simulation tools for analysis, setup, and result interpretation to solve real-world engineering challenges, improve product performance, reduce development time, and minimize physical prototyping through simulation-driven design.<\/p>\n<\/div><\/div>\n","protected":false},"excerpt":{"rendered":"<p>What This Warning Really Means? If you have ever run an internal flow in SOLIDWORKS Flow Simulation using fans, chances are you have seen this message pop up. \u201cMass Flow is out of Fan Curve\u2019s Range\u201d The solver keeps running and the result is generated. But the warning just stays there\u2026 quietly making you question &hellip; <\/p>\n<p class=\"link-more\"><a href=\"https:\/\/ckonnect.in\/solidworks\/mass-flow-is-out-of-fan-curves-rangewarning-in-solidworks-flow-simulation\/\" class=\"more-link\">Continue reading<span class=\"screen-reader-text\"> &#8220;\u201cMass Flow Is out of Fan Curve\u2019s Range\u201dWarning in SOLIDWORKS Flow Simulation&#8221;<\/span><\/a><\/p>\n","protected":false},"author":82,"featured_media":43215,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[200],"tags":[],"class_list":["post-43209","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-solidworks-simulation","entry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v22.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>&quot;Mass Flow Is out of Fan Curve\u2019s Range&quot; Warning in Flow Analysis<\/title>\n<meta name=\"description\" content=\"Facing \u201cMass Flow Is out of Fan Curve\u2019s Range\u201d in SOLIDWORKS Flow Simulation? 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