[blebon]

I get the following error when running adaptive meshing with heat transfer only when creating baffles:

/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  4.1                                   |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : 4.1
Exec   : buoyantPimpleRelativeDyMFoam
Date   : Aug 26 2017
Time   : 13:08:54
Host   : 
PID    : 71504
Case   : run/direct_chill_AMI_baffles
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Allowing user-supplied system call operations

// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
Create time

Create mesh for time = 0

Selecting dynamicFvMesh solidBodyMotionFvMesh
Selecting solid-body motion function rotatingMotion
Applying solid body motion to cellZone rotatingZone
Reading thermophysical properties

Selecting thermodynamics package
{
    type            heRhoThermo;
    mixture         pureMixture;
    transport       const;
    thermo          hConst;
    equationOfState rhoConst;
    specie          specie;
    energy          sensibleInternalEnergy;
}

AMI: Creating addressing and weights between 96728 source faces and 96728 target faces
AMI: Patch source sum(weights) min/max/average = 1, 1.0006151, 1.0000008
AMI: Patch target sum(weights) min/max/average = 1, 1.0006151, 1.0000008
Reading transportProperties

Reading casting velocity

Reading field U

Reading/calculating face flux field phi

Creating turbulence model

Selecting turbulence model type RAS
Selecting RAS turbulence model kOmegaSST
Selecting patchDistMethod meshWave
bounding k, min: 0 max: 0.1 average: 0.1
bounding omega, min: 0 max: 1 average: 1
kOmegaSSTCoeffs
{
    alphaK1         0.85;
    alphaK2         1;
    alphaOmega1     0.5;
    alphaOmega2     0.856;
    gamma1          0.55555556;
    gamma2          0.44;
    beta1           0.075;
    beta2           0.0828;
    betaStar        0.09;
    a1              0.31;
    b1              1;
    c1              10;
    F3              false;
}


Reading g

Reading hRef
Calculating field g.h

Reading field p_rgh

Creating field dpdt

Creating field kinetic energy K

No MRF models present

Radiation model not active: radiationProperties not found
Selecting radiationModel none
Creating finite volume options from "constant/fvOptions"

Selecting finite volume options model type mushyZoneSource
    Source: melt1
    - selecting all cells
    - selected 4187281 cell(s) with volume 0.00070747277

PIMPLE: Operating solver in PISO mode

Reading/calculating face velocity rhoUf

Courant Number mean: 8.9612124e-05 max: 0.00078561122

Starting time loop

Courant Number mean: 8.8724876e-05 max: 0.00077783289
deltaT = 1.1764706e-05
Time = 1.176470588e-05

AMI: Creating addressing and weights between 96728 source faces and 96728 target faces
AMI: Patch source sum(weights) min/max/average = 0.9999976, 1.0006151, 1.0000007
AMI: Patch target sum(weights) min/max/average = 0.9999976, 1.0006151, 1.0000007
DICPCG:  Solving for pcorr, Initial residual = 1, Final residual = 0.0079730276, No Iterations 10
time step continuity errors : sum local = 0.0013459109, global = -0.00080712699, cumulative = -0.00080                   712699
Execution time for mesh.update() = 19.84 s
diagonal:  Solving for rho, Initial residual = 0, Final residual = 0, No Iterations 0
PIMPLE: iteration 1
- selecting all cells
- selected 4187281 cell(s) with volume 0.00070747277
- selecting all cells
- selected 4187281 cell(s) with volume 0.00070747277
DILUPBiCG:  Solving for Ux, Initial residual = 0.25250652, Final residual = 7.8829779e-09, No Iteratio                   ns 50
DILUPBiCG:  Solving for Uy, Initial residual = 0.29979727, Final residual = 7.9730354e-09, No Iteratio                   ns 49
DILUPBiCG:  Solving for Uz, Initial residual = 0.0012666971, Final residual = 9.3209637e-09, No Iterations 30
- selecting all cells
- selected 4187281 cell(s) with volume 0.00070747277
DILUPBiCG:  Solving for e, Initial residual = 0.044821635, Final residual = 8.8728646e-09, No Iterations 35


--> FOAM FATAL ERROR:
Maximum number of iterations exceeded

    From function Foam::scalar Foam::species::thermo<Thermo, Type>::T(Foam::scalar, Foam::scalar, Foam::scalar, Foam::scalar (Foam::species::thermo<Thermo, Type>::*)(Foam::scalar, Foam::scalar)const, Foam::scalar (Foam::species::thermo<Thermo, Type>::*)(Foam::scalar, Foam::scalar)const, Foam::scalar (Foam::species::thermo<Thermo, Type>::*)(Foam::scalar)const) const [with Thermo = Foam::hConstThermo<Foam::rhoConst<Foam::specie> >; Type = Foam::sensibleInternalEnergy; Foam::scalar = double; Foam::species::thermo<Thermo, Type> = Foam::species::thermo<Foam::hConstThermo<Foam::rhoConst<Foam::specie> >, Foam::sensibleInternalEnergy>]
    in file /user/mxam/mxstbbl/OpenFOAM/OpenFOAM-4.1/src/thermophysicalModels/specie/lnInclude/thermoI.H at line 66.

FOAM aborting

#0  Foam::error::printStack(Foam::Ostream&) at ??:?
#1  Foam::error::abort() at ??:?
#2  Foam::heRhoThermo<Foam::rhoThermo, Foam::pureMixture<Foam::constTransport<Foam::species::thermo<Foam::hConstThermo<Foam::rhoConst<Foam::specie> >, Foam::sensibleInternalEnergy> > > >::calculate() at ??:?
#3  Foam::heRhoThermo<Foam::rhoThermo, Foam::pureMixture<Foam::constTransport<Foam::species::thermo<Foam::hConstThermo<Foam::rhoConst<Foam::specie> >, Foam::sensibleInternalEnergy> > > >::correct() at ??:?
#4  ? at ??:?
#5  __libc_start_main in "/lib64/libc.so.6"
#6  ? at ??:?
Aborted

The mesh looks all right:

/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  4.1                                   |
|   \\  /    A nd           | Web:      www.OpenFOAM.org                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : 4.1
Exec   : moveDynamicMesh -checkAMI
Date   : Aug 26 2017
Time   : 13:16:26
Host   : 
PID    : 71534
Case   : run/direct_chill_AMI_baffles
nProcs : 1
sigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
fileModificationChecking : Monitoring run-time modified files using timeStampMaster
allowSystemOperations : Allowing user-supplied system call operations

// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
Create time

Create mesh for time = 0

Selecting dynamicFvMesh solidBodyMotionFvMesh
Selecting solid-body motion function rotatingMotion
Applying solid body motion to cellZone rotatingZone
Writing VTK files with weights of AMI patches.


PIMPLE: Operating solver in PISO mode

Time = 1e-05
PIMPLE: iteration 1
--> FOAM Warning :
    From function virtual bool Foam::solidBodyMotionFvMesh::update()
    in file solidBodyMotionFvMesh/solidBodyMotionFvMesh.C at line 228
    Did not find volVectorField U Not updating Uboundary conditions.
    Point usage OK.
    Upper triangular ordering OK.
    Topological cell zip-up check OK.
    Face vertices OK.
  <<Number of duplicate (not baffle) faces found: 4. This might indicate a problem.
  <<Number of faces with non-consecutive shared points: 4. This might indicate a problem.
    Mesh topology OK.
    Boundary openness (-3.6710028e-16 4.4562628e-16 6.7448791e-17) OK.
    Max cell openness = 5.9972489e-16 OK.
    Max aspect ratio = 25.272324 OK.
    Minimum face area = 2.7957022e-09. Maximum face area = 6.910027e-07.  Face area magnitudes OK.
    Min volume = 4.0550359e-13. Max volume = 3.4550135e-10.  Total volume = 0.00070747277.  Cell volumes OK.
    Mesh non-orthogonality Max: 68.822452 average: 7.674973
    Non-orthogonality check OK.
    Face pyramids OK.
    Max skewness = 3.3704271 OK.
    Mesh geometry OK.
Mesh OK.
Calculating AMI weights between owner patch: AMI1 and neighbour patch: AMI2
AMI: Creating addressing and weights between 96728 source faces and 96728 target faces
AMI: Patch source sum(weights) min/max/average = 0.99999763, 1.0006151, 1.0000007
AMI: Patch target sum(weights) min/max/average = 0.99999763, 1.0006151, 1.0000007
ExecutionTime = 51.69 s  ClockTime = 52 s

This problem occurs only if I create baffles (for sliding the rotatingZone). If I run the same solver for a few iterations, but without creating the baffles (i.e. no createBaffles and mergeOrSplitBaffles -split after snappyHexMesh), I get the following:

Starting time loop

Courant Number mean: 8.7933632e-05 max: 0.00077478393
deltaT = 1.1764706e-05
Time = 1.1764706e-05

DICPCG:  Solving for pcorr, Initial residual = 1, Final residual = 0.0090929751, No Iterations 13
time step continuity errors : sum local = 0.00051673172, global = -3.383239e-08, cumulative = -3.383239e-08
Execution time for mesh.update() = 1.35 s
diagonal:  Solving for rho, Initial residual = 0, Final residual = 0, No Iterations 0
PIMPLE: iteration 1
- selecting all cells
- selected 3470648 cell(s) with volume 0.00070742718
- selecting all cells
- selected 3470648 cell(s) with volume 0.00070742718
DILUPBiCG:  Solving for Ux, Initial residual = 0.2182415, Final residual = 6.5444622e-09, No Iterations 37
DILUPBiCG:  Solving for Uy, Initial residual = 0.26917409, Final residual = 8.6276434e-09, No Iterations 37
DILUPBiCG:  Solving for Uz, Initial residual = 0.034115545, Final residual = 8.0461001e-09, No Iterations 30
- selecting all cells
- selected 3470648 cell(s) with volume 0.00070742718
DILUPBiCG:  Solving for e, Initial residual = 0.046034907, Final residual = 7.1364143e-09, No Iterations 29
DICPCG:  Solving for p_rgh, Initial residual = 0.8427223, Final residual = 0.0082917735, No Iterations 119
- selecting all cells
- selected 3470648 cell(s) with volume 0.00070742718
diagonal:  Solving for rho, Initial residual = 0, Final residual = 0, No Iterations 0
time step continuity errors : sum local = 2.4750221e-09, global = -9.8323748e-11, cumulative = -3.3930714e-08
DICPCG:  Solving for p_rgh, Initial residual = 0.17367083, Final residual = 9.4662022e-09, No Iterations 443
- selecting all cells
- selected 3470648 cell(s) with volume 0.00070742718
diagonal:  Solving for rho, Initial residual = 0, Final residual = 0, No Iterations 0
time step continuity errors : sum local = 4.5486516e-15, global = 4.9450138e-18, cumulative = -3.3930714e-08
DILUPBiCG:  Solving for omega, Initial residual = 0.089374264, Final residual = 7.5486908e-09, No Iterations 23
DILUPBiCG:  Solving for k, Initial residual = 0.99999999, Final residual = 9.4425125e-09, No Iterations 41
ExecutionTime = 27.5 s  ClockTime = 28 s

What is going wrong here? My boundary conditions should be correct since the same solver works with the same mesh albeit without baffles.

Also, I am using rhoConst and hConst, so I did not expect the T calculation from e to diverge.

thermoType
{
    type            heRhoThermo;
    mixture         pureMixture;
    transport       const;
    thermo          hConst;
    equationOfState rhoConst;
    specie          specie;
    energy          sensibleInternalEnergy;
}

I can get the case running with same boundary and initial conditions with MRF also.

[blebon]

Weird resolution for this:

I managed to get rid of the error by removing the value key in the cyclicAMI boundary condition for T:

"AMI.*"
    {
        type            cyclicAMI;
    }

instead of

"AMI.*"
    {
        type            cyclicAMI;
        value           0;
    }