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Some regions of a bonded-always pair might not be recognized as being in initial closed contact. Increasing the pinball depth may help overcome that behavior. Also, if you have slight initial penetrations or gaps, setting keyopt(9)=1 (exclude both initial geometrical penetration or gap and offset) will prevent artificial initial contact stresses from developing within the bonded pair. Symmetric contact pairs can be more susceptible to chatter - use asymmetric instead. Lastly, using MPC formulation may help the contact pair to behave in a linear fashion.
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