[H25E]

Hi, I'm trying to mesh a car (porsche 911) with sHM but while it is meshing appears this foam warnings:

/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  2.1.1                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : 2.1.1-221db2718bbb
Exec   : snappyHexMesh -overwrite
Date   : Oct 08 2014
Time   : 18:20:42
Host   : "pc"
PID    : 5083
Case   : /home/hector/Desktop/porsche
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Disallowing user-supplied system call operations

// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
Create time

Create mesh for time = 0

Read mesh in = 1.92 s

Overall mesh bounding box  : (-1.5 -4 -0.605885) (1.5 2.4 1.2)
Relative tolerance         : 1e-06
Absolute matching distance : 7.29529e-06

Reading refinement surfaces.
Read refinement surfaces in = 0.09 s

Reading refinement shells.
Refinement level 4 for all cells inside refinementBox
Read refinement shells in = 0 s

Setting refinement level of surface to be consistent with shells.
Checked shell refinement in = 0 s

Reading features.
Read features in = 0 s


Determining initial surface intersections
-----------------------------------------

Edge intersection testing:
    Number of edges             : 750976
    Number of edges to retest   : 750976
    Number of intersected edges : 25255
Calculated surface intersections in = 2.05 s

Initial mesh : cells:245760  faces:750976  points:259677
Cells per refinement level:
    0    245760

Adding patches for surface regions
----------------------------------

Patch    Type    Region
-----    ----    ------
PTri:

5    wall    PTri_patch0

Added patches in = 0.03 s

Selecting decompositionMethod hierarchical

Refinement phase
----------------

--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 237020, 4(81587 81648 89517 89456), produces a valid tet decomposition.
--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 237021, 4(81647 89516 89517 81648), produces a valid tet decomposition.
--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 237022, 4(89455 89456 89517 89516), produces a valid tet decomposition.
--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 214170, 4(81586 81587 81648 81647), produces a valid tet decomposition.
--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 236842, 4(81586 89455 89456 81587), produces a valid tet decomposition.
--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 237017, 4(81586 81647 89516 89455), produces a valid tet decomposition.
--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 0, 4(1 62 7931 7870), produces a valid tet decomposition.
--> FOAM Warning : 
    From function Foam::List<Foam::tetIndices> Foam::polyMeshTetDecomposition::faceTetIndices(const polyMesh&, label, label)
    in file meshes/polyMesh/polyMeshTetDecomposition/polyMeshTetDecomposition.C at line 565
    No base point for face 1, 4(61 7930 7931 62), produces a valid tet decomposition.

etc, etc, etc...

And then, few minutes later appears that crash message

Point is not inside the mesh or on a face or edge

I tried adding a lot of decimal numbers to the locationInMesh numbers, also i found a post that says that is necessary select the points with negative X in the blockmeshdict but this neither worked. I tried also make a coarser background mesh and modifying the mintetquality number (-1e30, 1e-30, 0 and 1) but I always get the same result.

Could someone give me some help? Thanks


PD: I give you here the block and snappyhexmesh dicts.

/*--------------------------------*- C++ -*----------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  2.1.1                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
FoamFile
{
    version     2.0;
    format      ascii;
    class       dictionary;
    object      blockMeshDict;
}

// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //

convertToMeters 1;

//Bounding Box : (-0.98043 -2.2003 -0.605885) (0.980019 2.26228 0.665978)

vertices
(
    (-1.5 2.4 -0.605885)
    (1.5 2.4 -0.605885)
    (1.5  -4 -0.605885)
    (-1.5 -4 -0.605885)
    (-1.5 2.4 1.2)
    (1.5 2.4 1.2)
    (1.5  -4 1.2)
    (-1.5 -4 1.2)
);

blocks
(
    hex (0 3 7 4 1 2 6 5) (60 128 32) simpleGrading (1 1 1)
);

edges
(
);

boundary
(
    frontAndBack
    {
        type patch;
        faces
        (
            (1 2 6 5)
            (0 4 7 3)
        );
    }
    inlet
    {
        type patch;
        faces
        (
        (2 3 7 6)
        );
    }
    outlet
    {
        type patch;
        faces
        (
            (0 1 5 4)
        );
    }
    lowerWall
    {
        type wall;
        faces
        (
            (0 1 2 3)

        );
    }
    upperWall
    {
        type patch;
        faces
        (
            (4 5 6 7)
        );
    }
);

// ************************************************************************* //

/*--------------------------------*- C++ -*----------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  2.1.1                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
FoamFile
{
    version     2.0;
    format      ascii;
    class       dictionary;
    object      snappyHexMeshDict;
}
// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //

// Which of the steps to run
castellatedMesh true;
snap            true;
addLayers       true;


// Geometry. Definition of all surfaces. All surfaces are of class
// searchableSurface.
// Surfaces are used
// - to specify refinement for any mesh cell intersecting it
// - to specify refinement for any mesh cell inside/outside/near
// - to 'snap' the mesh boundary to the surface
geometry
{
    PTri.stl
    {
        type triSurfaceMesh;
        name PTri;
    }

    refinementBox
    {
        type searchableBox;
        min (-1.2 -3 -0.505885);
        max (1.2 2.25 0.9);
    }
};



// Settings for the castellatedMesh generation.
castellatedMeshControls
{

    // Refinement parameters
    // ~~~~~~~~~~~~~~~~~~~~~

    // If local number of cells is >= maxLocalCells on any processor
    // switches from from refinement followed by balancing
    // (current method) to (weighted) balancing before refinement.
    maxLocalCells 1000000;

    // Overall cell limit (approximately). Refinement will stop immediately
    // upon reaching this number so a refinement level might not complete.
    // Note that this is the number of cells before removing the part which
    // is not 'visible' from the keepPoint. The final number of cells might
    // actually be a lot less.
    maxGlobalCells 20000000;

    // The surface refinement loop might spend lots of iterations refining just a
    // few cells. This setting will cause refinement to stop if <= minimumRefine
    // are selected for refinement. Note: it will at least do one iteration
    // (unless the number of cells to refine is 0)
    minRefinementCells 10;

    // Allow a certain level of imbalance during refining
    // (since balancing is quite expensive)
    // Expressed as fraction of perfect balance (= overall number of cells /
    // nProcs). 0=balance always.
    maxLoadUnbalance 0.10;


    // Number of buffer layers between different levels.
    // 1 means normal 2:1 refinement restriction, larger means slower
    // refinement.
    nCellsBetweenLevels 3;



    // Explicit feature edge refinement
    // ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

    // Specifies a level for any cell intersected by its edges.
    // This is a featureEdgeMesh, read from constant/triSurface for now.
    features
    (
        //{
        //    file "someLine.eMesh";
        //    level 2;
        //}
    );



    // Surface based refinement
    // ~~~~~~~~~~~~~~~~~~~~~~~~

    // Specifies two levels for every surface. The first is the minimum level,
    // every cell intersecting a surface gets refined up to the minimum level.
    // The second level is the maximum level. Cells that 'see' multiple
    // intersections where the intersections make an
    // angle > resolveFeatureAngle get refined up to the maximum level.

    refinementSurfaces
    {
        PTri
        {
            // Surface-wise min and max refinement level
            level (5 6);
        }
    }

    // Resolve sharp angles
    resolveFeatureAngle 30;


    // Region-wise refinement
    // ~~~~~~~~~~~~~~~~~~~~~~

    // Specifies refinement level for cells in relation to a surface. One of
    // three modes
    // - distance. 'levels' specifies per distance to the surface the
    //   wanted refinement level. The distances need to be specified in
    //   descending order.
    // - inside. 'levels' is only one entry and only the level is used. All
    //   cells inside the surface get refined up to the level. The surface
    //   needs to be closed for this to be possible.
    // - outside. Same but cells outside.

    refinementRegions
    {
        refinementBox
        {
            mode inside;
            levels ((1E15 4));
        }
    }


    // Mesh selection
    // ~~~~~~~~~~~~~~

    // After refinement patches get added for all refinementSurfaces and
    // all cells intersecting the surfaces get put into these patches. The
    // section reachable from the locationInMesh is kept.
    // NOTE: This point should never be on a face, always inside a cell, even
    // after refinement.
    locationInMesh (0.01000012312 0.910283903124 0.89749817401238);


    // Whether any faceZones (as specified in the refinementSurfaces)
    // are only on the boundary of corresponding cellZones or also allow
    // free-standing zone faces. Not used if there are no faceZones.
    allowFreeStandingZoneFaces true;
}



// Settings for the snapping.
snapControls
{
    //- Number of patch smoothing iterations before finding correspondence
    //  to surface
    nSmoothPatch 3;

    //- Relative distance for points to be attracted by surface feature point
    //  or edge. True distance is this factor times local
    //  maximum edge length.
    tolerance 4.0;

    //- Number of mesh displacement relaxation iterations.
    nSolveIter 0;

    //- Maximum number of snapping relaxation iterations. Should stop
    //  before upon reaching a correct mesh.
    nRelaxIter 5;

    //- Highly experimental and wip: number of feature edge snapping
    //  iterations. Leave out altogether to disable.
    //  Do not use here since mesh resolution too low and baffles present
    //nFeatureSnapIter 10;
}



// Settings for the layer addition.
addLayersControls
{
    // Are the thickness parameters below relative to the undistorted
    // size of the refined cell outside layer (true) or absolute sizes (false).
    relativeSizes true;

    // Per final patch (so not geometry!) the layer information
    layers
    {
        "(lowerWall|PTri).*"
        {
            nSurfaceLayers 1;
        }
    }

    // Expansion factor for layer mesh
    expansionRatio 1.0;

    //- Wanted thickness of final added cell layer. If multiple layers
    //  is the
    //  thickness of the layer furthest away from the wall.
    //  Relative to undistorted size of cell outside layer.
    //  is the thickness of the layer furthest away from the wall.
    //  See relativeSizes parameter.
    finalLayerThickness 0.3;

    //- Minimum thickness of cell layer. If for any reason layer
    //  cannot be above minThickness do not add layer.
    //  Relative to undistorted size of cell outside layer.
    minThickness 0.1;

    //- If points get not extruded do nGrow layers of connected faces that are
    //  also not grown. This helps convergence of the layer addition process
    //  close to features.
    // Note: changed(corrected) w.r.t 17x! (didn't do anything in 17x)
    nGrow 0;

    // Advanced settings

    //- When not to extrude surface. 0 is flat surface, 90 is when two faces
    //  make straight angle.
    featureAngle 30;

    //- Maximum number of snapping relaxation iterations. Should stop
    //  before upon reaching a correct mesh.
    nRelaxIter 3;

    // Number of smoothing iterations of surface normals
    nSmoothSurfaceNormals 1;

    // Number of smoothing iterations of interior mesh movement direction
    nSmoothNormals 3;

    // Smooth layer thickness over surface patches
    nSmoothThickness 10;

    // Stop layer growth on highly warped cells
    maxFaceThicknessRatio 0.5;

    // Reduce layer growth where ratio thickness to medial
    // distance is large
    maxThicknessToMedialRatio 0.3;

    // Angle used to pick up medial axis points
    // Note: changed(corrected) w.r.t 17x! 90 degrees corresponds to 130 in 17x.
    minMedianAxisAngle 90;


    // Create buffer region for new layer terminations
    nBufferCellsNoExtrude 0;


    // Overall max number of layer addition iterations. The mesher will exit
    // if it reaches this number of iterations; possibly with an illegal
    // mesh.
    nLayerIter 50;
}



// Generic mesh quality settings. At any undoable phase these determine
// where to undo.
meshQualityControls
{
    //- Maximum non-orthogonality allowed. Set to 180 to disable.
    maxNonOrtho 65;

    //- Max skewness allowed. Set to <0 to disable.
    maxBoundarySkewness 20;
    maxInternalSkewness 4;

    //- Max concaveness allowed. Is angle (in degrees) below which concavity
    //  is allowed. 0 is straight face, <0 would be convex face.
    //  Set to 180 to disable.
    maxConcave 80;

    //- Minimum pyramid volume. Is absolute volume of cell pyramid.
    //  Set to a sensible fraction of the smallest cell volume expected.
    //  Set to very negative number (e.g. -1E30) to disable.
    minVol 1e-13;

    //- Minimum quality of the tet formed by the face-centre
    //  and variable base point minimum decomposition triangles and
    //  the cell centre. This has to be a positive number for tracking
    //  to work. Set to very negative number (e.g. -1E30) to
    //  disable.
    //     <0 = inside out tet,
    //      0 = flat tet
    //      1 = regular tet
    minTetQuality 1e-30;

    //- Minimum face area. Set to <0 to disable.
    minArea -1;

    //- Minimum face twist. Set to <-1 to disable. dot product of face normal
    //- and face centre triangles normal
    minTwist 0.02;

    //- minimum normalised cell determinant
    //- 1 = hex, <= 0 = folded or flattened illegal cell
    minDeterminant 0.001;

    //- minFaceWeight (0 -> 0.5)
    minFaceWeight 0.02;

    //- minVolRatio (0 -> 1)
    minVolRatio 0.01;

    //must be >0 for Fluent compatibility
    minTriangleTwist -1;


    // Advanced

    //- Number of error distribution iterations
    nSmoothScale 4;
    //- amount to scale back displacement at error points
    errorReduction 0.75;
}


// Advanced

// Flags for optional output
// 0 : only write final meshes
// 1 : write intermediate meshes
// 2 : write volScalarField with cellLevel for postprocessing
// 4 : write current intersections as .obj files
debug 0;


// Merge tolerance. Is fraction of overall bounding box of initial mesh.
// Note: the write tolerance needs to be higher than this.
mergeTolerance 1e-6;


// ************************************************************************* //

[wyldckat]

Greetings H25E,

Run the following commands, after you've ran blockMesh:

checkMesh -allTopology -allGeometry -constant
surfaceCheck constant/triSurface/PTri.stl

The first one will diagnose if there is something particularly wrong with the base mesh that was created with blockMesh and the second one will check if the STL file is sane or not

Best regards,
Bruno

[H25E]

Thanks for your answer, I'm really stuck here. I generate a coarse mesh with blockMesh to accelerate the process (8000 cells) and then I executed sHM again but it returns the same error without writing any mesh.

I launched checkMesh and here we have the result:

hector@pc:~/Desktop/porsche$ checkMesh -allTopology -allGeometry -constant
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  2.1.1                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : 2.1.1-221db2718bbb
Exec   : checkMesh -allTopology -allGeometry -constant
Date   : Oct 11 2014
Time   : 21:23:53
Host   : "pc"
PID    : 2854
Case   : /home/hector/Desktop/porsche
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Disallowing user-supplied system call operations

// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
Create time

Create polyMesh for time = constant

Time = constant

Mesh stats
    points:           9471
    faces:            25400
    internal faces:   22600
    cells:            8000
    boundary patches: 5
    point zones:      0
    face zones:       0
    cell zones:       0

Overall number of cells of each type:
    hexahedra:     8000
    prisms:        0
    wedges:        0
    pyramids:      0
    tet wedges:    0
    tetrahedra:    0
    polyhedra:     0

Checking topology...
    Boundary definition OK.
    Cell to face addressing OK.
    Point usage OK.
    Upper triangular ordering OK.
    Face vertices OK.
    Topological cell zip-up check OK.
    Face-face connectivity OK.
    Number of regions: 1 (OK).

Checking patch topology for multiply connected surfaces ...
    Patch               Faces    Points   Surface topology                   Bounding box
    frontAndBack        1600     1722     ok (non-closed singly connected)   (-1.5 -4 -0.605885) (1.5 2.4 1.2)
    inlet               400      451      ok (non-closed singly connected)   (-1.5 -4 -0.605885) (1.5 -4 1.2)
    outlet              400      451      ok (non-closed singly connected)   (-1.5 2.4 -0.605885) (1.5 2.4 1.2)
    lowerWall           200      231      ok (non-closed singly connected)   (-1.5 -4 -0.605885) (1.5 2.4 -0.605885)
    upperWall           200      231      ok (non-closed singly connected)   (-1.5 -4 1.2) (1.5 2.4 1.2)

Checking geometry...
    Overall domain bounding box (-1.5 -4 -0.605885) (1.5 2.4 1.2)
    Mesh (non-empty, non-wedge) directions (1 1 1)
    Mesh (non-empty) directions (1 1 1)
    Boundary openness (-4.72339e-18 1.3379e-17 -2.9731e-17) OK.
 ***High aspect ratio cells found, Max aspect ratio: 2.60365e+198, number of cells 8000
  <<Writing 8000 cells with high aspect ratio to set highAspectRatioCells
    Minumum face area = 0.0135441. Maximum face area = 0.096.  Face area magnitudes OK.
    Min volume = 2e-300. Max volume = 2e-300.  Total volume = 1.6e-296.  Cell volumes OK.
    Mesh non-orthogonality Max: 180 average: 180
 ***Number of non-orthogonality errors: 22600.
  <<Writing 22600 non-orthogonal faces to set nonOrthoFaces
 ***Error in face pyramids: 48000 faces are incorrectly oriented.
  <<Writing 25400 faces with incorrect orientation to set wrongOrientedFaces
    Max skewness = 5.78066e-13 OK.
    Coupled point location match (average 0) OK.
 ***Error in face tets: 73400 faces with low quality or negative volume decomposition tets.
  <<Writing 25400 faces with low quality or negative volume decomposition tets to set lowQualityTetFaces
    Min/max edge length = 0.0451471 0.32 OK.
    All angles in faces OK.
    Face flatness (1 = flat, 0 = butterfly) : average = 1  min = 1
    All face flatness OK.
    Cell determinant (wellposedness) : minimum: 0.0255014 average: 0.491182
    Cell determinant check OK.
 ***Concave cells (using face planes) found, number of cells: 8000
  <<Writing 8000 concave cells to set concaveCells

Failed 5 mesh checks.

End

"***Error in face tets: 73400 faces with low quality or negative volume decomposition tets.", what is tet decomposition? It's the same error that sHM gives to me.

[H25E]

And with surfaceCheck:

/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  2.1.1                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : 2.1.1-221db2718bbb
Exec   : surfaceCheck constant/triSurface/PTri.obj
Date   : Oct 11 2014
Time   : 21:35:15
Host   : "pc"
PID    : 2868
Case   : /home/hector/Desktop/porsche
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Disallowing user-supplied system call operations

// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
Reading surface from "constant/triSurface/PTri.obj" ...

Statistics:
Triangles    : 21855
Vertices     : 13022
Bounding Box : (-0.98043 -0.605885 -2.26228) (0.980019 0.665978 2.2003)

Region    Size
------    ----
part    21855


Surface has no illegal triangles.

Triangle quality (equilateral=1, collapsed=0):
    0 .. 0.05  : 0.0946237
    0.05 .. 0.1  : 0.101304
    0.1 .. 0.15  : 0.0812171
    0.15 .. 0.2  : 0.0583391
    0.2 .. 0.25  : 0.0551361
    0.25 .. 0.3  : 0.0472203
    0.3 .. 0.35  : 0.0565088
    0.35 .. 0.4  : 0.0479524
    0.4 .. 0.45  : 0.0419584
    0.45 .. 0.5  : 0.0580645
    0.5 .. 0.55  : 0.0582933
    0.55 .. 0.6  : 0.0677191
    0.6 .. 0.65  : 0.0447952
    0.65 .. 0.7  : 0.0424159
    0.7 .. 0.75  : 0.0244795
    0.75 .. 0.8  : 0.0344086
    0.8 .. 0.85  : 0.0275452
    0.85 .. 0.9  : 0.0186685
    0.9 .. 0.95  : 0.0209105
    0.95 .. 1  : 0.0184397

    min 3.02579e-07 for triangle 798
    max 0.999996 for triangle 21569

Edges:
    min 0.00125755 for edge 1576 points (-0.699321 0.281457 1.68512)(-0.699931 0.282372 1.68573)
    max 1.57158 for edge 20330 points (0.137944 -0.460121 0.746644)(-0.000632 -0.454017 -0.818798)

Checking for points less than 1E-6 of bounding box ((1.96045 1.27186 4.46258) meter) apart.
    close unconnected points 4182 (0.673681 -0.310279 0.171876) and 11936 (0.67368 -0.310279 0.171876) distance:1e-06
    close unconnected points 3844 (-0.584833 0.536278 -0.170445) and 1223 (-0.584833 0.536278 -0.170444) distance:1e-06
    close unconnected points 3867 (-0.755935 -0.307533 -0.042439) and 4634 (-0.755934 -0.307533 -0.042439) distance:1e-06
    close unconnected points 3842 (-0.640512 0.425194 -0.342825) and 1228 (-0.640512 0.425194 -0.342824) distance:1e-06
    close unconnected points 3703 (0.733105 -0.008766 0.447708) and 12072 (0.733105 -0.008766 0.447707) distance:1e-06
    close unconnected points 1535 (-0.702406 0.244835 0.494323) and 9526 (-0.702406 0.244835 0.494322) distance:1e-06
    close unconnected points 9711 (-0.643773 0.387963 0.54402) and 1534 (-0.643773 0.387963 0.544019) distance:1e-06
    close unconnected points 4185 (0.67794 -0.304786 -0.610599) and 11930 (0.67794 -0.304786 -0.610598) distance:1e-06
    close unconnected points 2819 (-0.736875 0.214623 -0.633886) and 7972 (-0.736874 0.214623 -0.633885) distance:1.41421e-06
    close unconnected points 3172 (-0.718001 0.222558 -0.693105) and 8323 (-0.718001 0.222558 -0.693104) distance:1e-06
    close unconnected points 3726 (-0.784802 -0.348732 -0.652158) and 4620 (-0.784801 -0.348732 -0.652158) distance:1e-06
    close unconnected points 2904 (-0.847406 -0.025855 -0.70643) and 4638 (-0.847406 -0.025855 -0.706429) distance:1e-06
    close unconnected points 2478 (0.84632 -0.025855 -0.707779) and 3766 (0.84632 -0.025855 -0.707778) distance:1e-06
    close unconnected points 2905 (-0.846187 -0.086891 -0.708262) and 4639 (-0.846187 -0.086891 -0.708261) distance:1e-06
    close unconnected points 2476 (0.845097 -0.086891 -0.709609) and 3764 (0.845097 -0.086891 -0.709608) distance:1e-06
    close unconnected points 2471 (0.828628 -0.295021 -0.697084) and 3763 (0.828628 -0.295021 -0.697083) distance:1e-06
    close unconnected points 3806 (-0.433543 0.543297 0.881377) and 1488 (-0.433543 0.543297 0.881376) distance:1e-06
    close unconnected points 28 (-0.821758 -0.359107 -0.690581) and 3729 (-0.821758 -0.359107 -0.69058) distance:1e-06
    close unconnected points 1517 (0.663591 0.272301 0.914988) and 3828 (0.663591 0.272301 0.914987) distance:1e-06
    close unconnected points 2469 (0.829195 -0.359413 -0.751406) and 184 (0.829195 -0.359413 -0.751405) distance:1e-06
    close unconnected points 3821 (0.602429 0.352257 1.13751) and 1507 (0.602428 0.352257 1.13751) distance:1e-06
    close unconnected points 4170 (0.001613 0.324792 1.61589) and 1497 (0.001612 0.324792 1.61589) distance:1e-06
    close unconnected points 2757 (-0.550327 0.123986 -1.6759) and 9331 (-0.550326 0.123986 -1.6759) distance:1e-06
    close unconnected points 2652 (0.70244 0.127038 -1.65279) and 1415 (0.702439 0.127038 -1.65279) distance:1e-06
    close unconnected points 2697 (0.542037 -0.029823 -1.88552) and 5711 (0.542036 -0.029823 -1.88552) distance:1e-06
    close unconnected points 3257 (-0.677451 -0.062171 -1.89034) and 7399 (-0.67745 -0.062171 -1.89034) distance:1e-06
    close unconnected points 3258 (-0.648165 -0.066749 -1.9041) and 7401 (-0.648164 -0.066749 -1.9041) distance:1e-06
Found 27 nearby points.

Surface is not closed since not all edges connected to two faces:
    connected to one face : 4550
    connected to >2 faces : 381
Conflicting face labels:5841
Dumping conflicting face labels to "problemFaces"
Paste this into the input for surfaceSubset

Number of unconnected parts : 295
Splitting surface into parts ...

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There is someway to avoid surfaceCheck generates these annoying .obj files?

Thanks for your time

PD: double post due to max length post limitation.

[wyldckat]

Hi H25E,

Oh my! I wasn't expecting the base mesh to have so many errors!! I gave it a quick try myself and apparently you didn't notice these warning messages that blockMesh gives you:

Creating block mesh topology
--> FOAM Warning : 
    From function cellModel::mag(const labelList&, const pointField&)
    in file meshes/meshShapes/cellModel/cellModel.C at line 128
    zero or negative pyramid volume: -5.77883 for face 0
--> FOAM Warning : 
    From function cellModel::mag(const labelList&, const pointField&)
    in file meshes/meshShapes/cellModel/cellModel.C at line 128
    zero or negative pyramid volume: -5.77883 for face 1
--> FOAM Warning : 
    From function cellModel::mag(const labelList&, const pointField&)
    in file meshes/meshShapes/cellModel/cellModel.C at line 128
    zero or negative pyramid volume: -5.77883 for face 2
--> FOAM Warning : 
    From function cellModel::mag(const labelList&, const pointField&)
    in file meshes/meshShapes/cellModel/cellModel.C at line 128
    zero or negative pyramid volume: -5.77883 for face 3
--> FOAM Warning : 
    From function cellModel::mag(const labelList&, const pointField&)
    in file meshes/meshShapes/cellModel/cellModel.C at line 128
    zero or negative pyramid volume: -5.77883 for face 4
--> FOAM Warning : 
    From function cellModel::mag(const labelList&, const pointField&)
    in file meshes/meshShapes/cellModel/cellModel.C at line 128
    zero or negative pyramid volume: -5.77883 for face 5
--> FOAM Warning : 
    From function blockMesh::createTopology(IOdictionary&)
    in file blockMesh/blockMeshTopology.C at line 255
    negative volume block : 0, probably defined inside-out
--> FOAM Warning : 
    From function polyMesh::polyMesh(... construct from shapes...)
    in file meshes/polyMesh/polyMeshFromShapeMesh.C at line 888

Let's see, on this wiki page: http://openfoamwiki.net/index.php/BlockMesh - you can find a lot of information. Specially the section on how to visually diagnose the "blockMeshDict" file is essential.
From what I checked, the order of the vertices for the block are incorrect. This works properly:

    hex (1 2 6 5 0 3 7 4) (60 128 32) simpleGrading (1 1 1)

As for the STL file, ouch... that's one bad surface mesh
There is no option for surfaceCheck to not give you all of those obj files. It's clearly trying to tell you that the surface mesh is reaaaaaaally bad and it's pointing out every single piece it was able to find, so that you can inspect yourself as to why that's different from all other pieces .

As for repairing the STL file, there is already a lot of information here: http://openfoamwiki.net/index.php/Sn...xing_STL_files

Best regards,
Bruno

[H25E]

Well, this is being a bit demotivating...

About the first part, I thought my blocmeshdict was correct. You took my last 4 points and put them at the beginning, what's the difference? Anyway I achieve to install PyFoam but when I launched it there was an error that googling I found that i had to install VTK python. I had some problems to install it and I belive that is not correctly installed. I followed this steps:

http://kazenotaiyo.blogspot.com.es/2010/06/installing-vtk-in-ubuntu-and-making.html

I problems in the cmake step. Anyway when i launch now pyFoamDisplayBlockMesh.py appears that message:

Using system-VTK
 PyFoam WARNING on line 282 of file /usr/local/lib/python2.7/dist-packages/PyFoam/Applications/DisplayBlockMeshQt.py : While reading Desktop/porsche/constant/polyMesh/blockMeshDict this happened: 'patches' 
Traceback (most recent call last):
  File "/usr/local/bin/pyFoamDisplayBlockMesh.py", line 11, in <module>
    DisplayBlockMesh()
  File "/usr/local/lib/python2.7/dist-packages/PyFoam/Applications/DisplayBlockMeshQt.py", line 744, in __init__
    nr=1)
  File "/usr/local/lib/python2.7/dist-packages/PyFoam/Applications/PyFoamApplicationQt4.py", line 37, in __init__
    exactNr=exactNr)
  File "/usr/local/lib/python2.7/dist-packages/PyFoam/Applications/PyFoamApplication.py", line 155, in __init__
    result=self.run()
  File "/usr/local/lib/python2.7/dist-packages/PyFoam/Applications/PyFoamApplicationQt4.py", line 59, in run
    self.setupGUI()
  File "/usr/local/lib/python2.7/dist-packages/PyFoam/Applications/DisplayBlockMeshQt.py", line 751, in setupGUI
    self.dialog=DisplayBlockMeshDialog(bmFile)
  File "/usr/local/lib/python2.7/dist-packages/PyFoam/Applications/DisplayBlockMeshQt.py", line 283, in __init__
    raise e
KeyError: 'patches'

But the worst part I supose that is the part of the stl files. I have some 3D models of different cars and all the models had got this kind of errors, and without models I can't make my project. It's a little difficult find free 3D models of cars in the internet, and the most of them are in .3ds format .max format or something like that, so I have to export them to stl or obj format and I suppose that's the reason for the low quality.

I believe that i have 4 problems. The first the nearby points, that i found the solution. The second is the edges connected only to one point, here I found one solution using admesh but it changes the original gemotry generating for example massif rims. There are two more problems, edges connected to >2 faces and the unnconected parts, that I hadn't found the solution. I have to solve all this 4 problems to achieve sHM the models?

Again, thanks for your time. It's my first time with linux and openFoam and it's being harder than I expected.

[wyldckat]

Originally Posted by H25E

Well, this is being a bit demotivating...

Whoever told you OpenFOAM is easy to use, lied Well, perhaps didn't lie, but omitted that OpenFOAM is reaaaaaaally very picky about every single detail, no matter how small. We could say it's relentlessly unforgiving, because it's trying to simulate the real life physics, which are also unforgiving
Remember, unless in certain special conditions, gravity will always work and is also unforgiving

Originally Posted by H25E

About the first part, I thought my blocmeshdict was correct. You took my last 4 points and put them at the beginning, what's the difference?

You were telling blockMesh to build your block with negative volume. It's as if you were trying to build a house starting by the roof and then making a hole through the roof to dump the cement directly inside and through the roof, in order to create the floor.

Originally Posted by H25E

Using system-VTK
 PyFoam WARNING on line 282 of file /usr/local/lib/python2.7/dist-packages/PyFoam/Applications/DisplayBlockMeshQt.py : While reading Desktop/porsche/constant/polyMesh/blockMeshDict this happened: 'patches' 
[...]
KeyError: 'patches'

Depends on the version of PyFoam you're using and OpenFOAM version. The keyword "patches" is the old way of defining the "boundary" block: http://www.openfoam.org/version2.0.0/meshing.php - search for the section "Changes to blockMesh".
I honestly don't use much PyFoam, so I'm not familiar with its limitations.

Originally Posted by H25E

But the worst part I supose that is the part of the stl files. I have some 3D models of different cars and all the models had got this kind of errors, and without models I can't make my project. It's a little difficult find free 3D models of cars in the internet, and the most of them are in .3ds format .max format or something like that, so I have to export them to stl or obj format and I suppose that's the reason for the low quality.

That's what happens when you don't monitor the Forums and social networks for ideas. I've seen a few models over the past several months... there was one "driveAr" or something like that... here you go, it's the "DrivAer": http://www.cfd-online.com/Wiki/DrivAer_Model - it's not in STL, but IGES/STEP to STL... see this page: http://openfoamwiki.net/index.php/OS_Meshing

Originally Posted by H25E

It's my first time with linux and openFoam and it's being harder than I expected.

"Real life is hard. Properly simulating real life is harder."

[H25E]

Well, to create a positive volume I have to indicate to blockMesh to start in positive coordinates and go to negative ones? That way it worked and sHM could mesh but... It meshed the internal part of the car!! and nothing in the outside, how can modify this to mesh the car for external flow? Maybe I have to modify the stl and make it chunky?

And, the low quality of my 3D models will interference the simulation results?

EDIT: I answer myself to the first question, putting the locationmesh point in the external part of the car, that way sHM meshed the external part but also the internal one, which is not the best solution...

[wyldckat]

Hi H25E,

Originally Posted by H25E

Maybe I have to modify the stl and make it chunky?
And, the low quality of my 3D models will interference the simulation results?

All depends on the level of details you're looking for in the results. I have a few links in my Twitter for reminding me some good links on topics about meshing... here you go:

• http://www.symscape.com/blog/cfd-tip...ctive-new-year
• http://www.cd-adapco.com/blog/dr-mes...rt-finish-race

Originally Posted by H25E

EDIT: I answer myself to the first question, putting the locationmesh point in the external part of the car, that way sHM meshed the external part but also the internal one, which is not the best solution...

Use surfaceCheck to diagnose your STL file... again
It very likely has a hole in the chassis or tires somewhere, which lead the mesh to leak into the car model

I strongly suggest that you start working with the simplest possible model first, so that you can gradually increase the level of complexity of your problem, without ending up in a situation where there are too many possible variables... for example, as the blog posts above indicate

By the way, this blog post of mine and the links therein might also come in handy: OpenFOAM: Interesting cases of bad meshes and bad initial conditions - You should notice the protocol on how problems can be isolated on each issue .

Best regards,
Bruno

[H25E]

Well, I have already assigned the engineering final project so now I have to continue althought the problems as I can.

The gaps that could be between faces due to the bad quality mesh also allows to sHM leak into the interior of the car? Or it's only a problem about the 3D model has a hole intentionally created by the author somewhere?

Thanks for your time

[wyldckat]

Hi H25E,

Originally Posted by H25E

Well, I have already assigned the engineering final project so now I have to continue althought the problems as I can.

If your assignment was that you had to lift 500kg over your head solely with your own strength, under Earth's standard gravity, without the assistance of other people, machines nor objects, what would you do?
In theory, you would start training your body to be able to handle gradually 50, 70, 80, 90, 100kg and so on, all the way up to where your body could develop to lift those 500 kg. Lifting strategies would also come in handy.

The same is applicable to this situation you're in... conceptually, that is . If you do not have enough training/experience to solve this issue directly, you will need to change your starting point and then gradually increase the difficulty/complexity of the problem until you reach your final objective. This is essentially what I wrote in the previous post.

Originally Posted by H25E

The gaps that could be between faces due to the bad quality mesh also allows to sHM leak into the interior of the car? Or it's only a problem about the 3D model has a hole intentionally created by the author somewhere?

It could be both.

I've remembered about a project I saw some years ago... one with a Vespa... on their website, they detailed some of the issues and solutions they went through. This post in particular should come in handy to you: http://www.vespalabs.org/Projects/Ve...Vespa_3D_Model

Best regards,
Bruno

[H25E]

Well, I was trainning all this time with blender and meshlab to close this gaps and well it worked, sometimes xD. The main problem is that designers build the cars in different layers and then when someone tries to package all in the same product, the vertexs that must concur don't concur. Thanks for the help, you can close the threat.