[MMarczak]

Hi all!

I have an issue with using mergeMeshes utility. I am working on quite simple geometry (rectangular domain done by cfMesh and rotating zone done in Salome).

Photos:
https://ibb.co/vwqgRNy
https://ibb.co/w78fPnn

Both meshes pass checkMesh without any errors, but when I merge them using mergeMesh utility something goes wrong and checkMesh returns such errors:

Checking geometry...
    Overall domain bounding box (-400 -600 0) (1400 600 10.2)
    Mesh has 2 geometric (non-empty/wedge) directions (1 1 0)
    Mesh has 2 solution (non-empty) directions (1 1 0)
    All edges aligned with or perpendicular to non-empty directions.
    Boundary openness (5.33072e-19 -1.27998e-19 -2.60724e-14) OK.
 ***High aspect ratio cells found, Max aspect ratio: 2.152e+148, number of cells 336
  <<Writing 336 cells with high aspect ratio to set highAspectRatioCells
 ***Zero or negative face area detected.  Minimum area: 0
  <<Writing 827 zero area faces to set zeroAreaFaces
 ***Zero or negative cell volume detected.  Minimum negative volume: -1.20141e-17, Number of negative volume cells: 260
  <<Writing 260 zero volume cells to set zeroVolumeCells
    Mesh non-orthogonality Max: 90 average: 6.83007
   *Number of severely non-orthogonal (> 70 degrees) faces: 8951.
 ***Number of non-orthogonality errors: 198.
  <<Writing 9149 non-orthogonal faces to set nonOrthoFaces
 ***Error in face pyramids: 13 faces are incorrectly oriented.
  <<Writing 13 faces with incorrect orientation to set wrongOrientedFaces
 ***Max skewness = 5e+150, 710 highly skew faces detected which may impair the quality of the results
  <<Writing 710 skew faces to set skewFaces
    Coupled point location match (average 0) OK.

Failed 6 mesh checks

I visualize all bad elements in paraview and all of them are located in Z direction that has only one cell (2d simulation) and are in one region.

I tried two different meshes done for this simulation and results are the same.

I even try to omit these errors and go further with starting the simulation, but it doesn't want to run properly (thats why I am asking for an advice here). After typing solver command, code stops without any error on that point:

/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v1912                                 |
|   \\  /    A nd           | Website:  www.openfoam.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : _f3950763fe-20191219 OPENFOAM=1912
Arch   : "LSB;label=32;scalar=64"
Exec   : pimpleFoam
Date   : Jul 21 2021
Time   : 19:40:58
Host   : DESKTOP-HBV9367
PID    : 750
I/O    : uncollated
Case   : /home/mmarczak/myDocuments/Project/cfMeshSingleRotor/case/cfMeshSingleRotor_21_07
nProcs : 1
trapFpe: Floating point exception trapping enabled (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

Selecting dynamicFvMesh dynamicMotionSolverFvMesh
Selecting motion solver: solidBody
Applying solid body motion to cellZone rotatingZone
Selecting solid-body motion function rotatingMotion
Applying solid body motion to cellZone rotatingZone

PIMPLE: no residual control data found. Calculations will employ 3 corrector loops

Reading field p

Reading field U

Reading/calculating face flux field phi

Is that error connected with bad quality mesh? How I can solve both, mesh problem and simulation start issue?

Thanks in advance for all hints

[lucascy]

Any updates on this thread?