Optimization and Suppressed Features
When it optimizes a part with suppressed features, Creo Simulate may change the shape of the part such that the suppressed feature no longer fits the part or loses a dimensioning basis. Whether this phenomenon occurs depends on how you developed the part as well as how you planned your design variables.
One of the most common examples of a suppressed feature problem lies in the area of parent/child relations. If you build a suppressed feature as a child of a dimension that is eliminated during optimization, the suppressed feature is no longer valid when you unsuppress it. You then need to rebuild that feature using a different dimensioning scheme.
Before suppressing any feature, review its dependencies on unsuppressed features and other aspects of the design. This approach enables you to better calculate predictable results of your shape changes and, thus, define your design variable ranges more effectively. You can also determine in advance which suppressed features you may need to redesign after the optimization.