[Bisht]

Hello Guys,

I am facing a lot of problems during the pore scale meshing of the attached geometry. It consist of a porous media in the center of a hollow tube. I want to generated the mesh on pore scale to calculate the properties of the porous media.

Procedure I followed so far:

1) Imported the geometry in .stl format. Build topology with tolerance of 0.00001. It generated the curves and few free edges (yellow) which I deleted.

2) I created a cylindrical body enclosing the tube. This cylindrical body represents the fluid volume of the hollow tube. I didn't define any material point due to complexity of the porous media (it consists of many elements and it is not possible to define the material point for every element). I let ICEM mesher to define its own material point during flood fill process

3) Defined the Max. element size as 4, min- 0.5, edge criterion- 0.05 and compute it with Octree tetra.

I got the mesh in the pores and around it as I want (see attached image). It also genrated lots of material point for different parts.

Mesh check shows some multiple edges and unattached vertices which I fixed. After smoothing, the quality of the mesh remained very poor, the lowest value is 0.1.

When I am trying to export it to fluent, it showing many uncovered faces which were not highlighted during mesh checking. A second mesh check shows a lots of new problems with uncovered face, orientation, missing internal faces and so on.
It seems like with smoothing all of these problems keep increasing.

These uncovered faces are at different location so I can't attached it to a single element while fixing. To solve this problem, I merge all the material point of the solid bodies together after mesh generation and then attached uncovred faces to it but the problem still exist and I am not able to export this mesh to fluent.

I am new to ICEM CFD and don't know any other method to generate meshes on the pore scale.

I spent a lot of time on this problem but couldn't find any solution.
Can anyone have some idea on how to do it and reduced the problem arising in the meshin?