In the error message, it shows Fillet1=0, Fillet2=0, Fillet3=0, Fillet4=0. Is this correct?
Beyond that, you can set Parameters to Retain the Failed Design Point, then we can open that DP independently and see why the failure. https://ansyshelp.ansys.com/account/secured?returnurl=/Views/Secured/corp/v222/en/wb2_beta/retain_failed_design_points.html?q=failed%20design%20points
By default, Workbench does not retain design points after they are solved or if they fail.
To keep the calculated data and/or files for design points that fail:
In the Project Schematic, double-click the Parameter Set bar.
To save the failed design point files, in the Properties view, select the Keep Failed Design Points Files (Beta) check box.
To save the failed design point calculated data, in the Properties view, select the Retain Failed Design Points (Beta) check box.
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