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[Commercial meshers] FluentMesh3DtoFoam Powder Bed

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Old   October 14, 2019, 09:02
Default FluentMesh3DtoFoam Powder Bed
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Bill
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Hello,

I am trying to recreate the melting phenomenon in the video here:

I generated my powder bed geometry using spaceclaim, created an enclosure, exported this geometry to ANSYS Fluent Mesh, then generated the mesh, converted the mesh to OpenFOAM via Fluent3DMeshToFoam, however, it appears I'm only getting a shell for my solid spheres. (See attached images) and my internal mesh appears to be an entire volume that includes my powder bed spheres.

My question is: How can I get a solid mesh inside my spheres and not just the surface?

I checked my mesh in the Fluent mesh before exporting and there are definitely mesh cells inside the individual spheres.

I'm new to meshing so any help would be very much appreciated!

Thanks!
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File Type: jpg Mesh1.JPG (23.3 KB, 6 views)
File Type: jpg Mesh2.JPG (12.9 KB, 3 views)
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Old   October 15, 2019, 03:16
Default FluentMesh3DtoFoam Powder Bed
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Bill
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I just realized I should include more information about my problem...

Output of fluent3DMeshToFoam:

Dimension of grid: 3
Number of points: 31025
Number of faces: 306969
Number of cells: 147076
PointGroup: 6 start: 0 end: 18241. Reading points...done.
PointGroup: 7 start: 18242 end: 31024. Reading points...done.
FaceGroup: 1 start: 0 end: 3929. Reading uniform faces...done.
FaceGroup: 2 start: 3930 end: 132136. Reading uniform faces...done.
FaceGroup: 3 start: 132137 end: 285264. Reading uniform faces...done.
FaceGroup: 8 start: 285265 end: 296136. Reading uniform faces...done.
FaceGroup: 9 start: 296137 end: 306968. Reading uniform faces...done.
CellGroup: 4 start: 0 end: 67803 type: 1
CellGroup: 5 start: 67804 end: 147075 type: 1
Zone: 1 name: wall-enclosure_enclosure type: wall. Reading zone data...done.
Zone: 2 name: interior-enclosure_enclosure type: interior. Reading zone data...done.
Zone: 3 name: interior-spheresenclosure_solid type: interior. Reading zone data...done.
Zone: 4 name: enclosure_enclosure type: fluid. Reading zone data...done.
Zone: 5 name: spheresenclosure_solid type: solid. Reading zone data...done.
Zone: 8 name: contact_region-src type: interface. Reading zone data...done.
Zone: 9 name: contact_region-trg type: interface. Reading zone data...done.

FINISHED LEXING

Creating patch 0 for zone: 1 name: wall-enclosure_enclosure type: wall
Creating patch 1 for zone: 8 name: contact_region-src type: interface
Creating patch 2 for zone: 9 name: contact_region-trg type: interface
Creating cellZone 0 name: enclosure_enclosure type: fluid
Creating cellZone 1 name: spheresenclosure_solid type: solid
Creating faceZone 0 name: interior-enclosure_enclosure type: interior
Creating faceZone 1 name: interior-spheresenclosure_solid type: interior
faceZone from Fluent indices: 3930 to: 132136 type: interior
faceZone from Fluent indices: 132137 to: 285264 type: interior
patch 0 from Fluent indices: 0 to: 3929 type: wall
patch 1 from Fluent indices: 285265 to: 296136 type: interface
patch 2 from Fluent indices: 296137 to: 306968 type: interface

Output of checkMesh:

Mesh stats
points: 31025
internal points: 18242
faces: 306969
internal faces: 281335
cells: 147076
faces per cell: 4
boundary patches: 3
point zones: 0
face zones: 2
cell zones: 2

Overall number of cells of each type:
hexahedra: 0
prisms: 0
wedges: 0
pyramids: 0
tet wedges: 0
tetrahedra: 147076
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: 2
The mesh has multiple regions which are not connected by any face.
<<Writing region information to "0/cellToRegion"
<<Writing region 0 with 67804 cells to cellSet region0
<<Writing region 1 with 79272 cells to cellSet region1

Checking patch topology for multiply connected surfaces...
Patch Faces Points Surface topology
wall-enclosure_enclosure3930 1967 ok (closed singly connected)
contact_region-src 10872 5418 ok (closed singly connected)
contact_region-trg 10832 5398 ok (closed singly connected)

Checking faceZone topology for multiply connected surfaces...
FaceZone Faces Points Surface topology
interior-enclosure_enclosure128207 14991 multiply connected (shared edge)
interior-spheresenclosure_solid153128 16016 multiply connected (shared edge)
<<Writing 30796 conflicting points to set nonManifoldPoints

Checking basic cellZone addressing...
CellZone Cells Points Volume BoundingBox
enclosure_enclosure 67804 15009 5.45395e-10 (0.000302487 5.0085e-05 4.7487e-05) (0.00139752 0.00114956 0.00064385)
spheresenclosure_solid 79272 16016 1.72594e-10 (0.000312624 6.01485e-05 5.76708e-05) (0.00138664 0.00113826 0.000391691)

Checking geometry...
Overall domain bounding box (0.000302487 5.0085e-05 4.7487e-05) (0.00139752 0.00114956 0.00064385)
Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
Mesh has 3 solution (non-empty) directions (1 1 1)
Boundary openness (-6.68948e-17 7.92177e-17 5.13793e-17) OK.
Max cell openness = 2.2057e-16 OK.
Max aspect ratio = 7.529 OK.
Minimum face area = 1.15225e-11. Maximum face area = 5.95582e-09. Face area magnitudes OK.
Min volume = 3.48037e-17. Max volume = 1.45048e-13. Total volume = 7.17989e-10. Cell volumes OK.
Mesh non-orthogonality Max: 69.6067 average: 16.698
Non-orthogonality check OK.
Face pyramids OK.
Max skewness = 0.825862 OK.
Coupled point location match (average 0) OK.

Mesh OK.
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