[rmmrgttn]

Hello,

I have a problem with my final mesh when I use mergeMeshes. I work on a vertical axis wind turbine and I want to compute the aerodynamic forces on it. I created two meshes with ANSYS Meshing : the first one is a cylinder around the wind turbine (rotating part) and the second one is the fluid domain (static part). I converted the mesh in the correct format (with fluent3DMeshToFoam) and after, the checkMesh in OpenFOAM with these two meshes is OK.

I use mergeMeshes stator rotor to assembly these two meshes. I have this error with checkMesh

Checking geometry...
    Overall domain bounding box (-100 -100 -25) (100 300 175)
    Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
    Mesh has 3 solution (non-empty) directions (1 1 1)
    Boundary openness (-1.21064e-16 5.45597e-17 -2.88435e-16) OK.
 ***Open cells found, max cell openness: 1, number of open cells 140
  <<Writing 140 non closed cells to set nonClosedCells
  <<Writing 259901 cells with high aspect ratio to set highAspectRatioCells
 ***Zero or negative face area detected.  Minimum area: 0
  <<Writing 153433 zero area faces to set zeroAreaFaces
 ***Zero or negative cell volume detected.  Minimum negative volume: -1.2717e-06, Number of negative volume cells: 109846
  <<Writing 109846 zero volume cells to set zeroVolumeCells
    Mesh non-orthogonality Max: 180 average: 35.956
   *Number of severely non-orthogonal (> 70 degrees) faces: 3767400.
 ***Number of non-orthogonality errors: 361034.
  <<Writing 4128434 non-orthogonal faces to set nonOrthoFaces
 ***Error in face pyramids: 90190 faces are incorrectly oriented.
  <<Writing 85101 faces with incorrect orientation to set wrongOrientedFaces
 ***Max skewness = 3.55271e+135, 41541 highly skew faces detected which may impair the quality of the results
  <<Writing 41541 skew faces to set skewFaces
    Coupled point location match (average 0) OK.

Failed 6 mesh checks.

These errors appear only with a refined mesh. Maybe because of the high number of cells (14 millions of cells for the refined mesh and 7 millions for the non-refined mesh) ?

The refined mesh is made with "Inflation" in ANSYS Meshing.

checkMesh for the non-refined mesh :

Checking geometry...
    Overall domain bounding box (-100 -100 -25) (100 300 175)
    Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
    Mesh has 3 solution (non-empty) directions (1 1 1)
    Boundary openness (-1.0156e-16 6.08894e-17 -2.87194e-16) OK.
    Max cell openness = 2.74847e-16 OK.
    Max aspect ratio = 23.0191 OK.
    Minimum face area = 0.000372473. Maximum face area = 158.928.  Face area magnitudes OK.
    Min volume = 3.42439e-06. Max volume = 643.763.  Total volume = 1.59985e+07.  Cell volumes OK.
    Mesh non-orthogonality Max: 82.8572 average: 16.2069
   *Number of severely non-orthogonal (> 70 degrees) faces: 97.
    Non-orthogonality check OK.
  <<Writing 97 non-orthogonal faces to set nonOrthoFaces
    Face pyramids OK.
    Max skewness = 1.82115 OK.
    Coupled point location match (average 0) OK.

Mesh OK.

I don't understand why it's working with a non-refined mesh and not working with a refined mesh.

Thank you for your answers !

[lucascy]

Any updates on this thread?