[Britt]

Hi,

I need help, please. I have been working with OpenFOAM for quite some time and never had any bigger problems.
Currently I have no idea what is going on. I am trying to calculate the pressure drop and flow profile in a geometry.

The original geometry converged without any problems. In order to optimise the flow profile, we added a pre-distributer otherwise everything else stayed the same. Now the case won't run and I don't really understand the problem. I created the stl files in Salome and the final mesh in snappyHexMesh. All the parameters stayed the same.

This is the error I get trying to run the simulation:

/*---------------------------------------------------------------------------*\
  =========                 |
  \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox
   \\    /   O peration     | Website:  https://openfoam.org
    \\  /    A nd           | Version:  6
     \\/     M anipulation  |
\*---------------------------------------------------------------------------*/
Build  : 6
Exec   : rhoSimpleFoam
Date   : Nov 29 2018
Time   : 11:08:01
Host   : "bmi"
PID    : 15731
I/O    : uncollated
Case   : /OpenFOAM/openfoam-6/run//rhoCaseGeo24Neu
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster (fileModificationSkew 10)
allowSystemOperations : Allowing user-supplied system call operations

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

Create mesh for time = 0


SIMPLE: Convergence criteria found
        p: tolerance 0.01
        U: tolerance 0.0001
        e: tolerance 0.001
        "(k|epsilon|omega)": tolerance 0.001

Reading thermophysical properties

Selecting thermodynamics package 
{
    type            hePsiThermo;
    mixture         pureMixture;
    transport       sutherland;
    thermo          hConst;
    equationOfState perfectGas;
    specie          specie;
    energy          sensibleInternalEnergy;
}

Reading field U

Reading/calculating face flux field phi

pressureControl
    pMax 301988
    pMin 80530

Creating turbulence model

Selecting turbulence model type RAS
Selecting RAS turbulence model kEpsilon
RAS
{
    RASModel        kEpsilon;
    turbulence      on;
    printCoeffs     on;
    Cmu             0.09;
    C1              1.44;
    C2              1.92;
    C3              0;
    sigmak          1;
    sigmaEps        1.3;
}

No MRF models present

No finite volume options present

Starting time loop

Time = 1

smoothSolver:  Solving for Ux, Initial residual = 1, Final residual = 0.0425999, No Iterations 2
smoothSolver:  Solving for Uy, Initial residual = 1, Final residual = 0.0394462, No Iterations 2
smoothSolver:  Solving for Uz, Initial residual = 1, Final residual = 0.0377472, No Iterations 2
#0  Foam::error::printStack(Foam::Ostream&) at ??:?
#1  Foam::sigFpe::sigHandler(int) at ??:?
#2  ? in "/lib/x86_64-linux-gnu/libc.so.6"
#3  Foam::symGaussSeidelSmoother::smooth(Foam::word const&, Foam::Field<double>&, Foam::lduMatrix const&, Foam::Field<double> const&, Foam::FieldField<Foam::Field, double> const&, Foam::UPtrList<Foam::lduInterfaceField const> const&, unsigned char, int) at ??:?
#4  Foam::symGaussSeidelSmoother::smooth(Foam::Field<double>&, Foam::Field<double> const&, unsigned char, int) const at ??:?
#5  Foam::smoothSolver::solve(Foam::Field<double>&, Foam::Field<double> const&, unsigned char) const at ??:?
#6  Foam::fvMatrix<double>::solveSegregated(Foam::dictionary const&) at ??:?
#7  Foam::fvMatrix<double>::solve(Foam::dictionary const&) in "/opt/OpenFOAM/OpenFOAM-6/platforms/linux64GccDPInt32Opt/bin/rhoSimpleFoam"
#8  Foam::fvMatrix<double>::solve() in "/opt/OpenFOAM/OpenFOAM-6/platforms/linux64GccDPInt32Opt/bin/rhoSimpleFoam"
#9  ? in "/opt/OpenFOAM/OpenFOAM-6/platforms/linux64GccDPInt32Opt/bin/rhoSimpleFoam"
#10  __libc_start_main in "/lib/x86_64-linux-gnu/libc.so.6"
#11  ? in "/opt/OpenFOAM/OpenFOAM-6/platforms/linux64GccDPInt32Opt/bin/rhoSimpleFoam"
Floating point exception (core dumped)

This is what checkMesh says. I know that there is an error due to a skewed face, but the original file had one as well, as you can see underneath:

Mesh stats
    points:           5672803
    faces:            14221444
    internal faces:   12633093
    cells:            4302341
    faces per cell:   6.24184
    boundary patches: 3
    point zones:      0
    face zones:       0
    cell zones:       0

Overall number of cells of each type:
    hexahedra:     3227829
    prisms:        498960
    wedges:        0
    pyramids:      0
    tet wedges:    3619
    tetrahedra:    2
    polyhedra:     571931
    Breakdown of polyhedra by number of faces:
        faces   number of cells
            4   9674
            5   24993
            6   161334
            7   9409
            8   1849
            9   218616
           10   167
           11   4394
           12   124622
           13   649
           14   1344
           15   14046
           16   3
           17   2
           18   829

Checking topology...
    Boundary definition OK.
    Cell to face addressing OK.
    Point usage OK.
    Upper triangular ordering OK.
    Face vertices OK.
   *Number of regions: 3
    The mesh has multiple regions which are not connected by any face.
  <<Writing region information to "0/cellToRegion"
  <<Writing region 0 with 4302339 cells to cellSet region0
  <<Writing region 1 with 1 cells to cellSet region1
  <<Writing region 2 with 1 cells to cellSet region2

Checking patch topology for multiply connected surfaces...
                   Patch    Faces   Points                  Surface topology
                   inlet     7110     7517  ok (non-closed singly connected)
                  outlet    12029    13476  ok (non-closed singly connected)
                    wall  1569212  1628516  ok (non-closed singly connected)

Checking geometry...
    Overall domain bounding box (-0.3269 0.0379803 -0.34785) (1.901 0.491 0.34785)
    Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
    Mesh has 3 solution (non-empty) directions (1 1 1)
    Boundary openness (-1.76143e-16 5.76543e-17 -5.98452e-18) OK.
    Max cell openness = 4.12917e-16 OK.
    Max aspect ratio = 9.40324 OK.
    Minimum face area = 1.80125e-09. Maximum face area = 3.40868e-05.  Face area magnitudes OK.
    Min volume = 6.49885e-13. Max volume = 1.9727e-07.  Total volume = 0.204486.  Cell volumes OK.
    Mesh non-orthogonality Max: 64.9715 average: 11.2926
    Non-orthogonality check OK.
    Face pyramids OK.
 ***Max skewness = 9.8635, 1 highly skew faces detected which may impair the quality of the results
  <<Writing 1 skew faces to set skewFaces
    Coupled point location match (average 0) OK.

Failed 1 mesh checks.

End

This is what checkMesh says about the original file that works without any problems:

Mesh stats
    points:           5791898
    faces:            14568536
    internal faces:   12950860
    cells:            4412891
    faces per cell:   6.23614
    boundary patches: 3
    point zones:      0
    face zones:       0
    cell zones:       0

Overall number of cells of each type:
    hexahedra:     3327354
    prisms:        518675
    wedges:        0
    pyramids:      0
    tet wedges:    3272
    tetrahedra:    0
    polyhedra:     563590
    Breakdown of polyhedra by number of faces:
        faces   number of cells
            4   8645
            5   22208
            6   156144
            7   8344
            8   1459
            9   217289
           10   150
           11   3950
           12   128346
           13   651
           14   1499
           15   14065
           16   1
           18   839

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
                   inlet    23327    23672  ok (non-closed singly connected)
                  outlet    12031    13480  ok (non-closed singly connected)
                    wall  1582318  1635315  ok (non-closed singly connected)

Checking geometry...
    Overall domain bounding box (-0.3269 0.038 -0.34785) (1.901 0.491001 0.34785)
    Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
    Mesh has 3 solution (non-empty) directions (1 1 1)
    Boundary openness (-5.28427e-17 -1.92478e-16 -2.64067e-16) OK.
    Max cell openness = 4.04381e-16 OK.
    Max aspect ratio = 9.07491 OK.
    Minimum face area = 9.40364e-09. Maximum face area = 3.36129e-05.  Face area magnitudes OK.
    Min volume = 1.41859e-10. Max volume = 1.65746e-07.  Total volume = 0.211583.  Cell volumes OK.
    Mesh non-orthogonality Max: 64.4231 average: 11.1884
    Non-orthogonality check OK.
    Face pyramids OK.
 ***Max skewness = 9.82298, 1 highly skew faces detected which may impair the quality of the results
  <<Writing 1 skew faces to set skewFaces
    Coupled point location match (average 0) OK.

Failed 1 mesh checks.

End

Since I have no idea what is going on, I would really appreciate your help.