It seems that your model has re-entrant conners orstress concentration area somewhere. How about convergence? have you checked it yet? Try it out...InFEA,usometimes facesimilar problems andcost utime and time to get over...
Basic knowledge of FEA (and also pro/mechanica) is nodoubtedly helpful in your trouble. You shouldrefer to some mechanica books for better understandings and methods dealing with such situations. (mechanica structure tutorial of Roger Toogood may be the best choice)
7 or 9 p-loop pass? I thought that it'snot important. you shouldbetterchange theAutoGemdefault option andthen re-create the mesh. (remember to select the option "delete mesh points when deleting elements" in the autoGEM setting dialog box.
When you get fringe contour results covered with all blue, that means you are missing something in your analysis. Check your all B.C. and rerun the analysis. Since it has more than one part, you may also need to check if you have created the contact right.