[tdog]

Hi
I'm new to the forum and relatively new to OpenFoam. I'm trying to create a mesh from an ANSYS mesh file. I have done the following.
I've made a structure using SolidWorks, saving it as .sldprt and then importing it to Workbench. I meshed the structure and then made named selections for all of the surfaces, I then changed the options for the .msh to use ASCII formating and then exported the mesh as .msh.

When I run the fluentMeshToFoam command in OpenFoam I get the following output. In the output it says that it "Found 12208 undefined faces in mesh; adding to default patch.
done." which I don't understand, I don't know how to do it any other way. In order to make sure the mesh was in fact bad, I also ran checkMesh, which is the second output - it gave two errors. From what I understand from the errors, it's a bad mesh, but in what way should I change it?
I've attached my .msh, .sldprt and Workbench project file as a zip in the following link.
I hope you guys can help :-)
https://www.dropbox.com/s/bykl259mvq...sign1.zip?dl=0

bash-4.1$ fluentMeshToFoam abc.msh
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v3.0+                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : v3.0+-e941ee6c15e9
Exec   : fluentMeshToFoam abc.msh
Date   : Mar 30 2016
Time   : 13:49:04
Host   : "a531e13bda1b"
PID    : 187
Case   : /Users/thomasagger/Dropbox/00001/square
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Allowing user-supplied system call operations

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

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Dimension of grid: 3
Number of points: 7826

number of faces: 58998
Number of cells: 26447
Reading points
Reading points
Reading uniform faces
Reading uniform faces
Reading uniform faces
Reading uniform faces
Reading uniform faces
Reading uniform faces
Reading uniform faces
Other readCellGroupData: 2 1 674f 1 2
Reading uniform cells
Read zone1:1 name:interior-design1 patchTypeID:interior
Reading zone data
Read zone1:2 name:design1 patchTypeID:fluid
Reading zone data
Read zone1:5 name:movingwall patchTypeID:wall
Reading zone data
Read zone1:6 name:fixedwall patchTypeID:wall
Reading zone data
Read zone1:7 name:inlet patchTypeID:velocity-inlet
Reading zone data
Read zone1:8 name:cyclic1 patchTypeID:wall
Reading zone data
Read zone1:9 name:cyclic2 patchTypeID:wall
Reading zone data
Read zone1:10 name:out patchTypeID:pressure-outlet
Reading zone data


FINISHED LEXING


dimension of grid: 3
Creating shapes for 3-D cells
Building patch-less mesh...--> FOAM Warning : 
    From function Foam::polyMesh::polyMesh(const Foam::IOobject&, const Foam::Xfer<Foam::Field<Foam::Vector<double> > >&, const cellShapeList&, const faceListList&, const wordList&, const wordList&, const Foam::word&, const Foam::word&, const wordList&, bool)
    in file meshes/polyMesh/polyMeshFromShapeMesh.C at line 596
    Found 12208 undefined faces in mesh; adding to default patch.
done.

Building boundary and internal patches.
Creating patch 0 for zone: 1 start: 1 end: 46790 type: interior name: interior-design1
Creating patch 1 for zone: 5 start: 46791 end: 50948 type: wall name: movingwall
Creating patch 2 for zone: 6 start: 50949 end: 57529 type: wall name: fixedwall
Creating patch 3 for zone: 7 start: 57530 end: 57573 type: velocity-inlet name: inlet
Creating patch 4 for zone: 8 start: 57574 end: 57887 type: wall name: cyclic1
Creating patch 5 for zone: 9 start: 57888 end: 57929 type: wall name: cyclic2
Creating patch 6 for zone: 10 start: 57930 end: 58998 type: pressure-outlet name: out
Patch interior-design1 is internal to the mesh  and is not being added to the boundary.
Adding new patch movingwall of type wall as patch 0
Adding new patch fixedwall of type wall as patch 1
Adding new patch inlet of type patch as patch 2
Adding new patch cyclic1 of type wall as patch 3
Adding new patch cyclic2 of type wall as patch 4
Adding new patch out of type patch as patch 5

Writing mesh... to "constant/polyMesh"  done.


End

bash-4.1$ checkMesh
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v3.0+                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : v3.0+-e941ee6c15e9
Exec   : checkMesh
Date   : Mar 30 2016
Time   : 13:53:28
Host   : "a531e13bda1b"
PID    : 188
Case   : /Users/thomasagger/Dropbox/00001/square
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Allowing user-supplied system call operations

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

Create polyMesh for time = 0

Time = 0

Mesh stats
    points:           7826
    internal points:  1720
    faces:            58998
    internal faces:   46790
    cells:            26447
    faces per cell:   4
    boundary patches: 6
    point zones:      0
    face zones:       0
    cell zones:       0

Overall number of cells of each type:
    hexahedra:     0
    prisms:        0
    wedges:        0
    pyramids:      0
    tet wedges:    0
    tetrahedra:    26447
    polyhedra:     0

Checking topology...
    Boundary definition OK.
    Cell to face addressing OK.
    Point usage OK.
    Upper triangular ordering OK.
    Face vertices OK.
    Number of regions: 1 (OK).

Checking patch topology for multiply connected surfaces...
    Patch               Faces    Points   Surface topology                  
    movingwall          4158     2429     ok (non-closed singly connected)  
    fixedwall           6581     3677     ok (non-closed singly connected)  
    inlet               44       44       ok (non-closed singly connected)  
    cyclic1             314      316      ok (non-closed singly connected)  
    cyclic2             42       44       ok (non-closed singly connected)  
    out                 1069     1073     ok (non-closed singly connected)  

Checking geometry...
    Overall domain bounding box (-0.05783 -2.02804e-16 -0.02) (0.06783 0.0187325 0.02)
    Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
    Mesh has 3 solution (non-empty) directions (1 1 1)
    Boundary openness (-1.36456e-19 -8.41151e-16 1.95199e-19) OK.
 ***High aspect ratio cells found, Max aspect ratio: 5789.09, number of cells 780
  <<Writing 780 cells with high aspect ratio to set highAspectRatioCells
    Minimum face area = 4.7198e-12. Maximum face area = 3.30474e-06.  Face area magnitudes OK.
    Min volume = 3.19826e-18. Max volume = 4.27022e-10.  Total volume = 3.26707e-07.  Cell volumes OK.
    Mesh non-orthogonality Max: 89.917 average: 53.0697
   *Number of severely non-orthogonal (> 70 degrees) faces: 17540.
    Non-orthogonality check OK.
  <<Writing 17540 non-orthogonal faces to set nonOrthoFaces
    Face pyramids OK.
 ***Max skewness = 5.87506, 3 highly skew faces detected which may impair the quality of the results
  <<Writing 3 skew faces to set skewFaces
    Coupled point location match (average 0) OK.

Failed 2 mesh checks.

End

[tdog]

I just read the sticky note and then tried the Fluent3DMeshToFoam which seems to give less problems as seen in the attached output. But when I run the checkMesh I get the same errors, see attached output

bash-4.1$ fluent3DMeshToFoam design1.msh
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v3.0+                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : v3.0+-e941ee6c15e9
Exec   : fluent3DMeshToFoam design1.msh
Date   : Mar 31 2016
Time   : 21:33:50
Host   : "a531e13bda1b"
PID    : 195
Case   : /Users/thomasagger/Dropbox/00001/square
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Allowing user-supplied system call operations

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

Dimension of grid: 3
Number of points: 7826
Number of faces: 58998
Number of cells: 26447
PointGroup: 3 start: 0 end: 1719.  Reading points...done.
PointGroup: 4 start: 1720 end: 7825.  Reading points...done.
FaceGroup: 1 start: 0 end: 46789.  Reading uniform faces...done.
FaceGroup: 5 start: 46790 end: 50947.  Reading uniform faces...done.
FaceGroup: 6 start: 50948 end: 57528.  Reading uniform faces...done.
FaceGroup: 7 start: 57529 end: 57572.  Reading uniform faces...done.
FaceGroup: 8 start: 57573 end: 57886.  Reading uniform faces...done.
FaceGroup: 9 start: 57887 end: 57928.  Reading uniform faces...done.
FaceGroup: 10 start: 57929 end: 58997.  Reading uniform faces...done.
CellGroup: 2 start: 0 end: 26446 type: 1
Zone: 1 name: interior-design1 type: interior.  Reading zone data...done.
Zone: 2 name: design1 type: fluid.  Reading zone data...done.
Zone: 5 name: movingwall type: wall.  Reading zone data...done.
Zone: 6 name: fixedwall type: wall.  Reading zone data...done.
Zone: 7 name: inlet type: velocity-inlet.  Reading zone data...done.
Zone: 8 name: cyclic1 type: wall.  Reading zone data...done.
Zone: 9 name: cyclic2 type: wall.  Reading zone data...done.
Zone: 10 name: out type: pressure-outlet.  Reading zone data...done.

FINISHED LEXING

Creating patch 0 for zone: 5 name: movingwall type: wall
Creating patch 1 for zone: 6 name: fixedwall type: wall
Creating patch 2 for zone: 7 name: inlet type: velocity-inlet
Creating patch 3 for zone: 8 name: cyclic1 type: wall
Creating patch 4 for zone: 9 name: cyclic2 type: wall
Creating patch 5 for zone: 10 name: out type: pressure-outlet
Creating cellZone 0 name: design1 type: fluid
Creating faceZone 0 name: interior-design1 type: interior
faceZone from Fluent indices: 0 to: 46789 type: interior
patch 0 from Fluent indices: 46790 to: 50947 type: wall
patch 1 from Fluent indices: 50948 to: 57528 type: wall
patch 2 from Fluent indices: 57529 to: 57572 type: velocity-inlet
patch 3 from Fluent indices: 57573 to: 57886 type: wall
patch 4 from Fluent indices: 57887 to: 57928 type: wall
patch 5 from Fluent indices: 57929 to: 58997 type: pressure-outlet

Writing mesh to "/Users/thomasagger/Dropbox/00001/square/constant/region0"

End

bash-4.1$ checkMesh
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v3.0+                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : v3.0+-e941ee6c15e9
Exec   : checkMesh
Date   : Mar 31 2016
Time   : 21:34:16
Host   : "a531e13bda1b"
PID    : 196
Case   : /Users/thomasagger/Dropbox/00001/square
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Allowing user-supplied system call operations

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

Create polyMesh for time = 0

Time = 0

Mesh stats
    points:           7826
    internal points:  1720
    faces:            58998
    internal faces:   46790
    cells:            26447
    faces per cell:   4
    boundary patches: 6
    point zones:      0
    face zones:       1
    cell zones:       1

Overall number of cells of each type:
    hexahedra:     0
    prisms:        0
    wedges:        0
    pyramids:      0
    tet wedges:    0
    tetrahedra:    26447
    polyhedra:     0

Checking topology...
    Boundary definition OK.
    Cell to face addressing OK.
    Point usage OK.
    Upper triangular ordering OK.
    Face vertices OK.
    Number of regions: 1 (OK).

Checking patch topology for multiply connected surfaces...
    Patch               Faces    Points   Surface topology                  
    movingwall          4158     2429     ok (non-closed singly connected)  
    fixedwall           6581     3677     ok (non-closed singly connected)  
    inlet               44       44       ok (non-closed singly connected)  
    cyclic1             314      316      ok (non-closed singly connected)  
    cyclic2             42       44       ok (non-closed singly connected)  
    out                 1069     1073     ok (non-closed singly connected)  

Checking geometry...
    Overall domain bounding box (-0.05783 -2.02804e-16 -0.02) (0.06783 0.0187325 0.02)
    Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
    Mesh has 3 solution (non-empty) directions (1 1 1)
    Boundary openness (1.65459e-18 -3.97844e-15 4.77899e-18) OK.
 ***High aspect ratio cells found, Max aspect ratio: 5789.09, number of cells 780
  <<Writing 780 cells with high aspect ratio to set highAspectRatioCells
    Minimum face area = 4.7198e-12. Maximum face area = 3.30474e-06.  Face area magnitudes OK.
    Min volume = 3.19826e-18. Max volume = 4.27022e-10.  Total volume = 3.26707e-07.  Cell volumes OK.
    Mesh non-orthogonality Max: 89.917 average: 53.0697
   *Number of severely non-orthogonal (> 70 degrees) faces: 17540.
    Non-orthogonality check OK.
  <<Writing 17540 non-orthogonal faces to set nonOrthoFaces
    Face pyramids OK.
 ***Max skewness = 5.87506, 3 highly skew faces detected which may impair the quality of the results
  <<Writing 3 skew faces to set skewFaces
    Coupled point location match (average 0) OK.

Failed 2 mesh checks.

End