[aow]

Hello CFD Online,

I'm running into issues with simple test cases of the mergePatchPairs functionality of the blockMesh utility using identically-sized blocks that have different meshes and trying different ways of organizing 2 - 4 of these blocks.

For instance, shown below is an image of a successful example for 3 blocks that works when I use the mergePatchPairs function of the the blockMesh utility (see the blockMeshDict text below the image).



blockMeshDict

/*--------------------------------*- C++ -*----------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  1.7.1                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
FoamFile
{
    version         2.0;
    format          ascii;
    class           dictionary;
    object          blockMeshDict;
}

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

convertToMeters 1;

x1  0.0;
x2  10.0;
x3  20.0;
y1  0.0;
y2  10.0;
y3  20.0;
z1  0.0;
z2  10.0;

vertices
(
	//block1
    ($x1  $y1  $z1)
	($x2  $y1  $z1)
	($x2  $y2  $z1)
	($x1  $y2  $z1)
	($x1  $y1  $z2)
	($x2  $y1  $z2)
	($x2  $y2  $z2)
	($x1  $y2  $z2)
	//block 2
	($x2  $y1  $z1)
	($x3  $y1  $z1)
	($x3  $y2  $z1)
	($x2  $y2  $z1)
	($x2  $y1  $z2)
	($x3  $y1  $z2)
	($x3  $y2  $z2)
	($x2  $y2  $z2)
	//block3
	($x1  $y2  $z1)
	($x2  $y2  $z1)
	($x2  $y3  $z1)
	($x1  $y3  $z1)
	($x1  $y2  $z2)
	($x2  $y2  $z2)
	($x2  $y3  $z2)
	($x1  $y3  $z2)
);

blocks          
(
    hex (0 1 2 3 4 5 6 7)  (10 10 10)  simpleGrading (1 1 1)
	hex (8 9 10 11 12 13 14 15) (20 20 20) simpleGrading (1 1 1)
	hex (16 17 18 19 20 21 22 23) (20 20 20) simpleGrading (1 1 1)
);

edges           
(
);

boundary
(
    inlet
    {
        type wall;
        faces
        (
            (0 4 7 3)
			(16 20 23 19)
        );
    }
    outlet
    {
        type wall;
        faces
        (
            (9 13 14 10)
        );
    }
	top
    {
        type wall;
        faces
        (
            (4 5 6 7)
			(12 13 14 15)
			(20 21 22 23)
        );
    }
    bottom
    {
        type wall;
        faces
        (
            (0 1 2 3)
			(8 9 10 11)
			(16 17 18 19)
        );
    }
    right
    {
        type wall;
        faces
        (
			(0 1 5 4)
			(8 9 13 12)
        );
    }
    left
    {
        type wall;
        faces
        (
			(19 18 22 23)
			(17 21 22 18)
			(11 10 14 15)
        );
    }
	interface1
	{
		type wall;
		faces
		(
			(1 5 6 2)
		);
	}
	interface2
	{
		type wall;
		faces
		(
			(8 12 15 11)
		);
	}
	interface3
	{
		type wall;
		faces
		(
			(3 2 6 7)
		);
	}
	interface4
	{
		type wall;
		faces
		(
			(16 17 21 20)
		);
	}
);

mergePatchPairs
(
	(interface1 interface2)
	(interface3 interface4)
);
// ************************************************************************* //

However, when I edit the blockMeshDict to include a 4th block (see text below) in the empty corner of the 3 block configuration and try to use the mergePatchPairs function again, I get the following error report (after the modified blockMeshDict).

Modified blockMeshDict

/*--------------------------------*- C++ -*----------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  1.7.1                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
FoamFile
{
    version         2.0;
    format          ascii;
    class           dictionary;
    object          blockMeshDict;
}

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

convertToMeters 1;

x1 0.0;
x2 10.0;
x3 20.0;
y1 0.0;
y2 10.0;
y3 20.0;
z1 0.0;
z2 10.0;

vertices
(
	//block1
    ($x1 $y1 $z1)
	($x2 $y1 $z1)
	($x2 $y2 $z1)
	($x1 $y2 $z1)
	($x1 $y1 $z2)
	($x2 $y1 $z2)
	($x2 $y2 $z2)
	($x1 $y2 $z2)
	//block 2
	($x2 $y1 $z1)
	($x3 $y1 $z1)
	($x3 $y2 $z1)
	($x2 $y2 $z1)
	($x2 $y1 $z2)
	($x3 $y1 $z2)
	($x3 $y2 $z2)
	($x2 $y2 $z2)
	//block3
	($x1 $y2 $z1)
	($x2 $y2 $z1)
	($x2 $y3 $z1)
	($x1 $y3 $z1)
	($x1 $y2 $z2)
	($x2 $y2 $z2)
	($x2 $y3 $z2)
	($x1 $y3 $z2)
	//block4
	($x2 $y2 $z1)
	($x3 $y2 $z1)
	($x3 $y3 $z1)
	($x2 $y3 $z1)
	($x2 $y2 $z2)
	($x3 $y2 $z2)
	($x3 $y3 $z2)
	($x2 $y3 $z2)
);

blocks          
(
    hex (0 1 2 3 4 5 6 7)  (10 10 10)  simpleGrading (1 1 1)
	hex (8 9 10 11 12 13 14 15) (20 20 20) simpleGrading (1 1 1)
	hex (16 17 18 19 20 21 22 23) (20 20 20) simpleGrading (1 1 1)
	hex (24 25 26 27 28 29 30 31) (10 10 10) simpleGrading (1 1 1)
);

edges           
(
);

boundary
(
    inlet
    {
        type wall;
        faces
        (
            (0 4 7 3)
			(16 20 23 19)
        );
    }
    outlet
    {
        type wall;
        faces
        (
            (9 13 14 10)
			(25 29 30 26)
        );
    }
	top
    {
        type wall;
        faces
        (
            (4 5 6 7)
			(12 13 14 15)
			(20 21 22 23)
			(28 29 30 31)
        );
    }
    bottom
    {
        type wall;
        faces
        (
            (0 1 2 3)
			(8 9 10 11)
			(16 17 18 19)
			(24 25 26 27)
        );
    }
    right
    {
        type wall;
        faces
        (
			(0 1 5 4)
			(8 9 13 12)
        );
    }
    left
    {
        type wall;
        faces
        (
			(19 18 22 23)
			(27 26 30 31)
        );
    }
	master1
	{
        type wall;
        faces
        (
			(1 5 6 2)
        );
    }
	master2
	{
        type wall;
        faces
        (
			(3 2 6 7)
        );
    }
	master3
	{
        type wall;
        faces
        (
			(24 28 31 27)
        );
    }
	master4
	{
        type wall;
        faces
        (
			(24 25 29 28)
        );
    }
	slave1
	{
        type wall;
        faces
        (
			(8 12 15 11)
        );
    }
	slave2
	{
        type wall;
        faces
        (
			(16 17 21 20)
        );
    }
	slave3
	{
        type wall;
        faces
        (
			(17 21 22 18)
        );
    }
	slave4
	{
        type wall;
        faces
        (
			(11 10 14 15)
        );
    }
);

mergePatchPairs
(
	(master1 slave1)
	(master2 slave2)
	(master3 slave3)
	(master4 slave4)
);
// ************************************************************************* //

Error Report

/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  5.0                                   |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : 5.0
Exec   : blockMesh
Date   : May 31 2018
Time   : 17:45:08
Host   : "n0536"
PID    : 6021
I/O    : uncollated
Case   : /civil/shared/motley/andrew25/OpenFOAM/5.0/buildings/olaDyMFoam/May29/B0-S0-Unbroken/test2
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

Creating block mesh from
    "/civil/shared/motley/andrew25/OpenFOAM/5.0/buildings/olaDyMFoam/May29/B0-S0-Unbroken/test2/system/blockMeshDict"
Creating block edges
No non-planar block faces defined
Creating topology blocks
Creating topology patches

Creating block mesh topology

Check topology

        Basic statistics
                Number of internal faces : 0
                Number of boundary faces : 24
                Number of defined boundary faces : 24
                Number of undefined boundary faces : 0
        Checking patch -> block consistency

Creating block offsets
Creating merge list .

Creating polyMesh from blockMesh
Creating patches
Creating cells
Creating points with scale 1
    Block 0 cell size :
        i : 0.5 .. 0.5
        j : 0.5 .. 0.5
        k : 0.5 .. 0.5

    Block 1 cell size :
        i : 0.25 .. 0.25
        j : 0.25 .. 0.25
        k : 0.25 .. 0.25

    Block 2 cell size :
        i : 0.25 .. 0.25
        j : 0.25 .. 0.25
        k : 0.25 .. 0.25

    Block 3 cell size :
        i : 0.5 .. 0.5
        j : 0.5 .. 0.5
        k : 0.5 .. 0.5

Creating merge patch pairs

Adding point and face zones
Creating attachPolyTopoChanger


--> FOAM FATAL ERROR:
Face 56180 reduced to less than 3 points.  Topological/cutting error B.
Old face: 2(10612 11053) new face: 2(19853 21825)

    From function void Foam::slidingInterface::coupleInterface(Foam::polyTopoChange&) const
    in file slidingInterface/coupleSlidingInterface.C at line 1768.

FOAM aborting

#0  Foam::error::printStack(Foam::Ostream&) in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/lib/libOpenFOAM.so"
#1  Foam::error::abort() in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/lib/libOpenFOAM.so"
#2  Foam::slidingInterface::coupleInterface(Foam::polyTopoChange&) const in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/lib/libdynamicMesh.so"
#3  Foam::polyTopoChanger::topoChangeRequest() const in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/lib/libdynamicMesh.so"
#4  Foam::polyTopoChanger::changeMesh(bool, bool, bool, bool) in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/lib/libdynamicMesh.so"
#5  Foam::attachPolyTopoChanger::attach(bool) in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/lib/libdynamicMesh.so"
#6  ? in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/bin/blockMesh"
#7  __libc_start_main in "/lib64/libc.so.6"
#8  ? in "/gscratch/motley/shared/OpenFOAM500/OpenFOAM-5.0/platforms/linux64GccDPInt32Opt/bin/blockMesh"
Aborted

I believe it is caused by one of two things. First, I am suspicious of the master and slave patches being specified incorrectly. Second, I may be violating some rule for face merging since the error message I get states that a face has been reduced to less than 3 points (i.e. it becomes a line?), which probably comes from some incorrectly specified points for a face definition.

If anyone has any idea as to what happened, I would appreciate your assistance and insight very much!