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-   -   [snappyHexMesh] Unable to generate the desired mesh (https://www.cfd-online.com/Forums/openfoam-meshing/254712-unable-generate-desired-mesh.html)

MohdShaeq February 27, 2024 00:53

Unable to generate the desired mesh
 
4 Attachment(s)
Hello,

I have been trying very hard to generate a hexahedral mesh for a relatively simple geometry with snappyHexMesh. Even though I have now gained a fair bit of experience in working with the utility, however, I have not been able to generate the desired mesh as not all the features/surfaces are correctly recognised. I have tried several values of level under the features and refinementSurfaces sub-dictionaries, unfortunately to no avail.

Attached herewith are the images of the STL-surfaces and the generated mesh. The snappyHexMeshDict is as follows:-
Code:

/*--------------------------------*- C++ -*----------------------------------*\
| =========                |                                                |
| \\      /  F ield        | OpenFOAM: The Open Source CFD Toolbox          |
|  \\    /  O peration    | Version:  v1912                                |
|  \\  /    A nd          | Website:  www.openfoam.com                      |
|    \\/    M anipulation  |                                                |
\*---------------------------------------------------------------------------*/
FoamFile
{
    version    2.0;
    format      ascii;
    class      dictionary;
    object      snappyHexMeshDict;
}
// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //

// Which of the steps to run
castellatedMesh true;
snap            true;
addLayers      true;

// Geometry. Definition of all surfaces. All surfaces are of class
// searchableSurface.
// Surfaces are used
// - to specify refinement for any mesh cell intersecting it
// - to specify refinement for any mesh cell inside/outside/near
// - to 'snap' the mesh boundary to the surface
geometry
{
        Geometrie // STL filename
        {
                type triSurfaceMesh;
                file "Geometrie.stl";

                regions
                {
                        Brennkammer
                        {
                                name Brennkammer;
                        }

                        Einlass
                        {
                                name Einlass;
                        }

                        Kanal_aussen
                        {
                                name Kanal_aussen;
                        }

                        Kanal_innen
                        {
                                name Kanal_innen;
                        }
                }
        }

        Verfeinerungszylinder1
        {
                type      searchableCylinder;
                point1    (0 0 -0.03);
                point2    (0 0 0.07);
                radius    0.001652;
        }

        Verfeinerungszylinder2
        {
                type      searchableCylinder;
                point1    (0 0 0);
                point2    (0 0 -0.02);
                radius    0.043;
        }
};

// Settings for the castellatedMesh generation.       
castellatedMeshControls                //sub-dictionary of controls for castellated mesh.
{
        // Refinement parameters
            // ~~~~~~~~~~~~~~~~~~~~~

            // If local number of cells is >= maxLocalCells on any processor
            // switches from from refinement followed by balancing
            // (current method) to (weighted) balancing before refinement.
        maxLocalCells 300000; //100000;
       
        // Overall cell limit (approximately). Refinement will stop immediately
          // upon reaching this number so a refinement level might not complete.
            // Note that this is the number of cells before removing the part which
            // is not 'visible' from the keepPoint. The final number of cells might
            // actually be a lot less.
        maxGlobalCells 30000000; //1000000;
       
        // The surface refinement loop might spend lots of iterations refining just a
            // few cells. This setting will cause refinement to stop if <= minimumRefine
            // are selected for refinement. Note: it will at least do one iteration
            // (unless the number of cells to refine is 0)
        minRefinementCells 10; //10;
       
        // Allow a certain level of imbalance during refining
            // (since balancing is quite expensive)
            // Expressed as fraction of perfect balance (= overall number of cells /
            // nProcs). 0=balance always.
        maxLoadUnbalance 0.10;
       
        // Number of buffer layers between different levels.
          // 1 means normal 2:1 refinement restriction, larger means slower
          // refinement.
        nCellsBetweenLevels 1;


        // Explicit feature edge refinement
        // ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

        // Specifies a level for any cell intersected by its edges.
    // This is a featureEdgeMesh, read from constant/triSurface for now.
        features
        (
                {
                file "Geometrie.eMesh";
                level 5; //4; //5; //6
                }
        );

        // Surface based refinement
            // ~~~~~~~~~~~~~~~~~~~~~~~~

            // Specifies two levels for every surface. The first is the minimum level,
            // every cell intersecting a surface gets refined up to the minimum level.
            // The second level is the maximum level. Cells that 'see' multiple
            // intersections where the intersections make an
            // angle > resolveFeatureAngle get refined up to the maximum level.

        refinementSurfaces
        {
                Geometrie
                {
                        level (1 1); // default (min max) refinement for whole surface

                        regions
                        {
                                Brennkammer
                                {
                                        level (0 0);
                                        patchInfo
                                        {
                                                type wall; // Optional specification of patch type (default is wall). No constraint types (cyclic, symmetry) etc. are allowed.
                                        }
                                }

                                Einlass
                                {
                                        level (6 6);
                                        patchInfo
                                        {
                                                type patch; // Optional specification of patch type (default is wall). No constraint types (cyclic, symmetry) etc. are allowed.
                                        }
                                }

                                Kanal_aussen
                                {
                                        level (3 3);
                                        patchInfo
                                        {
                                                type wall; // Optional specification of patch type (default is wall). No constraint types (cyclic, symmetry) etc. are allowed.
                                        }
                                }

                                Kanal_innen
                                {
                                        level (3 3);
                                        patchInfo
                                        {
                                                type wall; // Optional specification of patch type (default is wall). No constraint types (cyclic, symmetry) etc. are allowed.
                                        }
                                }
                        }
                }
        }

        // Resolve sharp angles
        resolveFeatureAngle 30;
       
        // Region-wise refinement
            // ~~~~~~~~~~~~~~~~~~~~~~

            // Specifies refinement level for cells in relation to a surface. One of
            // three modes
            // - distance. 'levels' specifies per distance to the surface the
            //  wanted refinement level. The distances need to be specified in
            //  descending order.
            // - inside. 'levels' is only one entry and only the level is used. All
            //  cells inside the surface get refined up to the level. The surface
            //  needs to be closed for this to be possible.
            // - outside. Same but cells outside.

           
    refinementRegions
        {
                Geometrie
                {
                        mode distance;
                        levels ((0.005 3));
                }

                Verfeinerungszylinder1
                {
                        mode inside;
                        levels ((1E15 3));
                }

                Verfeinerungszylinder2
                {
                        mode distance;
                        levels ((0.02 2));
                }
        };
               
        // Mesh selection
        // ~~~~~~~~~~~~~~

            // After refinement patches get added for all refinementSurfaces and
            // all cells intersecting the surfaces get put into these patches. The
            // section reachable from the locationInMesh is kept.
            // NOTE: This point should never be on a face, always inside a cell, even
            // after refinement.

                locationInMesh (0 0 -0.02);

        // Whether any faceZones (as specified in the refinementSurfaces)
        // are only on the boundary of corresponding cellZones or also allow
        // free-standing zone faces. Not used if there are no faceZones.
            allowFreeStandingZoneFaces false;
}
 
 // Settings for the snapping.
 snapControls
 {
        //- Number of patch smoothing iterations before finding correspondence
    //  to surface
        nSmoothPatch 3;

        //- Relative distance for points to be attracted by surface feature point
    //  or edge. True distance is this factor times local
    //  maximum edge length.
        tolerance 2.0;

        //- Number of mesh displacement relaxation iterations.
        nSolveIter 30;

        //- Maximum number of snapping relaxation iterations. Should stop
    //  before upon reaching a correct mesh.
        nRelaxIter 5;

        // Feature snapping

                //- Number of feature edge snapping iterations.
        //  Leave out altogether to disable.
                nFeatureSnapIter 10;

                // - Detect ( geometric only ) features by sampling the surface
                // ( default = false ).
                implicitFeatureSnap false ;

                // - Use castellatedMeshControls :: features ( default = true )
                explicitFeatureSnap true ;

                // - Detect points on multiple surfaces ( only for explicitFeatureSnap )
                multiRegionFeatureSnap true ;
 }
 
 addLayersControls
{
    // Are the thickness parameters below relative to the undistorted
    // size of the refined cell outside layer (true) or absolute sizes (false).
    relativeSizes true;

    // Per final patch (so not geometry!) the layer information
    layers
    {
          Geometrie
      {
                  nSurfaceLayers 2;
          }
    }

    // Expansion factor for layer mesh
    expansionRatio 1.0;

    // Wanted thickness of final added cell layer. If multiple layers
    // is the thickness of the layer furthest away from the wall.
    // Relative to undistorted size of cell outside layer.
    // See relativeSizes parameter.
    finalLayerThickness 0.3;

    // Minimum thickness of cell layer. If for any reason layer
    // cannot be above minThickness do not add layer.
    // Relative to undistorted size of cell outside layer.
    minThickness 0.1;

    // If points get not extruded do nGrow layers of connected faces that are
    // also not grown. This helps convergence of the layer addition process
    // close to features.
    // Note: changed(corrected) w.r.t 1.7.x! (didn't do anything in 1.7.x)
    nGrow 0;

    // Advanced settings

    // When not to extrude surface. 0 is flat surface, 90 is when two faces
    // are perpendicular
    featureAngle 60;

    // At non-patched sides allow mesh to slip if extrusion direction makes
    // angle larger than slipFeatureAngle.
    slipFeatureAngle 30;

    // Maximum number of snapping relaxation iterations. Should stop
    // before upon reaching a correct mesh.
    nRelaxIter 3;

    // Number of smoothing iterations of surface normals
    nSmoothSurfaceNormals 1;

    // Number of smoothing iterations of interior mesh movement direction
    nSmoothNormals 3;

    // Smooth layer thickness over surface patches
    nSmoothThickness 10;

    // Stop layer growth on highly warped cells
    maxFaceThicknessRatio 0.5;

    // Reduce layer growth where ratio thickness to medial
    // distance is large
    maxThicknessToMedialRatio 0.3;

    // Angle used to pick up medial axis points
    // Note: changed(corrected) w.r.t 1.7.x! 90 degrees corresponds to 130
    // in 1.7.x.
    minMedialAxisAngle 90;


    // Create buffer region for new layer terminations
    nBufferCellsNoExtrude 0;


    // Overall max number of layer addition iterations. The mesher will exit
    // if it reaches this number of iterations; possibly with an illegal
    // mesh.
    nLayerIter 50;
}



// Generic mesh quality settings. At any undoable phase these determine
// where to undo.

 meshQualityControls
{
    #include "meshQualityDict"

        maxNonOrtho 65;
    maxBoundarySkewness 20;
    maxInternalSkewness 4;
    maxConcave 80;
    minVol 1e-13;
    minTetQuality 1e-13;
    minArea -1;
    minTwist 0.05;
    minDeterminant 0.001;
    minFaceWeight 0.05;
    minVolRatio 0.01;
    minTriangleTwist -1;

        /*
        // Optional : some meshing phases allow usage of relaxed rules.
    // See e.g. addLayersControls::nRelaxedIter.
    relaxed
    {
        //- Maximum non-orthogonality allowed. Set to 180 to disable.
        maxNonOrtho 75;
    }

    // Advanced

    //- Number of error distribution iterations
    nSmoothScale 4;
    //- Amount to scale back displacement at error points
    errorReduction 0.75;
        */

    // Advanced
    nSmoothScale 4;
    errorReduction 0.75;

    relaxed
    {
        maxNonOrtho 55;
    }

    //- Number of error distribution iterations
    nSmoothScale 4;
    //- Amount to scale back displacement at error points
    errorReduction 0.75;
 
}


// Write flags
writeFlags
(
    scalarLevels        // write volScalarField with cellLevel for postprocessing
    layerSets                // write cellSets, faceSets of faces in layer
    layerFields    // write volScalarField for layer coverage
);


// Merge tolerance. Is fraction of overall bounding box of initial mesh.
// Note: the write tolerance needs to be higher than this.
mergeTolerance 1e-6;


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

I kindly entreat those reading this thread to provide me with suggestions and/or improvements. I would be highly thankful to you all.

Kind regards,
Mohd Shaeq

MohdShaeq March 4, 2024 03:18

Solved
 
4 Attachment(s)
I have been able to solve this problem. The trick lay in, as far as I can tell, employing inGroups under refinementSurfaces under the castellatedMeshControls sub-dictionary. The snappyHexMeshDict now reads as follows:-
Code:

/*--------------------------------*- C++ -*----------------------------------*\
| =========                |                                                |
| \\      /  F ield        | OpenFOAM: The Open Source CFD Toolbox          |
|  \\    /  O peration    | Version:  v2112                                |
|  \\  /    A nd          | Website:                                        |
|    \\/    M anipulation  |                                                |
\*---------------------------------------------------------------------------*/
FoamFile
{
    version    2.0;
    format      ascii;
    class      dictionary;
    object      snappyHexMeshDict;
}

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

// Which of the steps to run
castellatedMesh true;
snap            true;
addLayers      true;


// Geometry. Definition of all surfaces. All surfaces are of class
// searchableSurface.
// Surfaces are used
// - to specify refinement for any mesh cell intersecting it
// - to specify refinement for any mesh cell inside/outside/near
// - to 'snap' the mesh boundary to the surface
geometry
{
    Geometrie
    {
        type triSurfaceMesh;
        file "Geometrie.stl";
        regions
        {
            Brennkammer    { name Brennkammer;}
            Einlass        { name Einlass;}
            Kanal_aussen  { name Kanal_aussen;}
            Kanal_innen    { name Kanal_innen;}
        }
    }

    Verfeinerungszylinder1
        {
                type      searchableCylinder;
                point1    (0 0 -0.03);
                point2    (0 0 0.07);
                radius    0.0025;
        }

        Verfeinerungszylinder2
        {
                type      searchableCylinder;
                point1    (0 0 0);
                point2    (0 0 -0.02);
                radius    0.043;
        }
};

// Settings for the castellatedMesh generation.
castellatedMeshControls                //sub-dictionary of controls for castellated mesh.
{
        // Refinement parameters
            // ~~~~~~~~~~~~~~~~~~~~~

            // If local number of cells is >= maxLocalCells on any processor
            // switches from from refinement followed by balancing
            // (current method) to (weighted) balancing before refinement.
        maxLocalCells 1000000;

        // Overall cell limit (approximately). Refinement will stop immediately
          // upon reaching this number so a refinement level might not complete.
            // Note that this is the number of cells before removing the part which
            // is not 'visible' from the keepPoint. The final number of cells might
            // actually be a lot less.
        maxGlobalCells 20000000;

        // The surface refinement loop might spend lots of iterations refining just a
            // few cells. This setting will cause refinement to stop if <= minimumRefine
            // are selected for refinement. Note: it will at least do one iteration
            // (unless the number of cells to refine is 0)
        minRefinementCells 10;

        // Allow a certain level of imbalance during refining
            // (since balancing is quite expensive)
            // Expressed as fraction of perfect balance (= overall number of cells /
            // nProcs). 0=balance always.
        maxLoadUnbalance 0.10;

        // Number of buffer layers between different levels.
          // 1 means normal 2:1 refinement restriction, larger means slower
          // refinement.
        nCellsBetweenLevels 1;

    // Explicit feature edge refinement
    // ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

    // Specifies a level for any cell intersected by its edges.
    // This is a featureEdgeMesh, read from constant/triSurface for now.
    features
    (
        {
            file "Geometrie.eMesh";
            level 4;
        }
    );



    // Surface based refinement
    // ~~~~~~~~~~~~~~~~~~~~~~~~

    // Specifies two levels for every surface. The first is the minimum level,
    // every cell intersecting a surface gets refined up to the minimum level.
    // The second level is the maximum level. Cells that 'see' multiple
    // intersections where the intersections make an
    // angle > resolveFeatureAngle get refined up to the maximum level.

    refinementSurfaces
    {
                Geometrie
        {
            level (3 3); // Surface - wise min and max refinement level
            patchInfo
            {
                type wall;
                inGroups (GeometrieGroup);
            }

            regions
                    {
                Einlass        { level (1 1); patchInfo { type patch;} }
                Kanal_aussen        { level (6 6); patchInfo { type wall;} }
                Kanal_innen                { level (6 6); patchInfo { type wall;} }
                    }
                }
    }

    // Resolve sharp angles
        resolveFeatureAngle 30;

        // Region-wise refinement
            // ~~~~~~~~~~~~~~~~~~~~~~

            // Specifies refinement level for cells in relation to a surface. One of
            // three modes
            // - distance. 'levels' specifies per distance to the surface the
            //  wanted refinement level. The distances need to be specified in
            //  descending order.
            // - inside. 'levels' is only one entry and only the level is used. All
            //  cells inside the surface get refined up to the level. The surface
            //  needs to be closed for this to be possible.
            // - outside. Same but cells outside.

    refinementRegions
    {
        Verfeinerungszylinder1
                {
                        mode inside;
                        levels ((1E15 1));
                }

                Verfeinerungszylinder2
                {
                        mode distance;
                        levels ((0.02 3));
                }
    }

    // Mesh selection
    // ~~~~~~~~~~~~~~

    // After refinement patches get added for all refinementSurfaces and
    // all cells intersecting the surfaces get put into these patches. The
    // section reachable from the locationInMesh is kept.
    // NOTE: This point should never be on a face, always inside a cell, even
    // after refinement.
    // This is an outside point locationInMesh (-0.033 -0.033 0.0033);

    locationInMesh (0 0 -0.02);

    /*locationsInMesh
(
    (( 0 0 -0.02) Brennkammer)
    (( 0  0.00199  0.0068) Kanal_aussen)
);*/

    // Whether any faceZones (as specified in the refinementSurfaces)
    // are only on the boundary of corresponding cellZones or also allow
    // free-standing zone faces. Not used if there are no faceZones.
    allowFreeStandingZoneFaces true;
}



// Settings for the snapping.
 snapControls
 {
        nSmoothPatch 3;
        tolerance 2.0;
        nSolveIter 30;
        nRelaxIter 5;
        // Feature snapping
                nFeatureSnapIter 10;
                // - Detect ( geometric only ) features by sampling the surface
                // ( default = false ).
                implicitFeatureSnap false ;
                // - Use castellatedMeshControls :: features ( default = true )
                explicitFeatureSnap true ;
                // - Detect points on multiple surfaces ( only for explicitFeatureSnap )
                        multiRegionFeatureSnap true ;
 }

addLayersControls
{
    // Are the thickness parameters below relative to the undistorted
    // size of the refined cell outside layer (true) or absolute sizes (false).
    relativeSizes true;

    // Per final patch (so not geometry!) the layer information
    layers
    {
        Geometrie
        {
            nSurfaceLayers 3;
        }
    }

    // Expansion factor for layer mesh
    expansionRatio 1.0;

    // Wanted thickness of final added cell layer. If multiple layers
    // is the thickness of the layer furthest away from the wall.
    // Relative to undistorted size of cell outside layer.
    // See relativeSizes parameter.
    finalLayerThickness 0.3;

    // Minimum thickness of cell layer. If for any reason layer
    // cannot be above minThickness do not add layer.
    // Relative to undistorted size of cell outside layer.
    minThickness 0.1;

    // If points get not extruded do nGrow layers of connected faces that are
    // also not grown. This helps convergence of the layer addition process
    // close to features.
    // Note: changed(corrected) w.r.t 1.7.x! (didn't do anything in 1.7.x)
    nGrow 0;

    // Advanced settings

    // When not to extrude surface. 0 is flat surface, 90 is when two faces
    // are perpendicular
    featureAngle 60;

    // At non-patched sides allow mesh to slip if extrusion direction makes
    // angle larger than slipFeatureAngle.
    slipFeatureAngle 30;

    // Maximum number of snapping relaxation iterations. Should stop
    // before upon reaching a correct mesh.
    nRelaxIter 3;

    // Number of smoothing iterations of surface normals
    nSmoothSurfaceNormals 1;

    // Number of smoothing iterations of interior mesh movement direction
    nSmoothNormals 3;

    // Smooth layer thickness over surface patches
    nSmoothThickness 10;

    // Stop layer growth on highly warped cells
    maxFaceThicknessRatio 0.5;

    // Reduce layer growth where ratio thickness to medial
    // distance is large
    maxThicknessToMedialRatio 0.3;

    // Angle used to pick up medial axis points
    // Note: changed(corrected) w.r.t 1.7.x! 90 degrees corresponds to 130
    // in 1.7.x.
    minMedialAxisAngle 90;


    // Create buffer region for new layer terminations
    nBufferCellsNoExtrude 0;


    // Overall max number of layer addition iterations. The mesher will exit
    // if it reaches this number of iterations; possibly with an illegal
    // mesh.
    nLayerIter 50;
}

// Generic mesh quality settings. At any undoable phase these determine
// where to undo.

 meshQualityControls
{
    #include "meshQualityDict"


    // Advanced

    //- Number of error distribution iterations
    nSmoothScale 4;
    //- Amount to scale back displacement at error points
    errorReduction 0.75;

}

// Write flags
writeFlags
(
    scalarLevels
    layerSets
    layerFields    // write volScalarField for layer coverage
);


// Merge tolerance. Is fraction of overall bounding box of initial mesh.
// Note: the write tolerance needs to be higher than this.
mergeTolerance 1e-6;

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

I hope that this thread maybe of help to someone in the future.

Kind regards,
Mohd Shaeq


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