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Residuals and forces spiraling out of control before failing

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Old   September 6, 2018, 19:34
Default Residuals and forces spiraling out of control before failing
  #1
Member
 
Ed O'Malley
Join Date: Nov 2017
Posts: 30
Rep Power: 5
edomalley1 is on a distinguished road
Hi -

I'm running an external aerodynamics simulation of a leg in a cycling shoe. Previous models worked fine but my new geometry fails when running simpleFoam with this error:

mpirun detected that one or more processes exited with non-zero status, thus causing
the job to be terminated. The first process to do so was:

Process name: [[1404,1],1]
Exit code: 145

In the Log.simpleFoam file for the new geometry (and in the forces.dat file) the forces and moments quickly start to spiral way way out of bounds in just a couple time steps (by E^22) and residuals go up.

Below is the new simpleFoam log. Total force in the x direction in previous models stayed between 0.2 and 1.5 through every time step.

Any idea where I should look for the error?

Code:
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v1706                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : v1706-17752679325a
Arch   : "LSB;label=32;scalar=64"
Exec   : simpleFoam -decomposeParDict system/decomposeParDict.6 -parallel
Date   : Sep 06 2018
Time   : 15:48:54
Host   : "DESKTOP-1A6ON5E"
PID    : 1016
Case   : /mnt/c/Users/edoma/CFD/ShoeCFD/ShoeCases/LuckBlankCase
nProcs : 6
Slaves : 
5
(
"DESKTOP-1A6ON5E.1017"
"DESKTOP-1A6ON5E.1018"
"DESKTOP-1A6ON5E.1019"
"DESKTOP-1A6ON5E.1020"
"DESKTOP-1A6ON5E.1021"
)

Pstream initialized with:
    floatTransfer      : 0
    nProcsSimpleSum    : 0
    commsType          : nonBlocking
    polling iterations : 0
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

Create mesh for time = 0


SIMPLE: no convergence criteria found. Calculations will run for 160 steps.

Reading field p

Reading field U

Reading/calculating face flux field phi

Selecting incompressible transport model Newtonian
Selecting turbulence model type RAS
Selecting RAS turbulence model kOmegaSST
Selecting patchDistMethod meshWave
RAS
{
    RASModel        kOmegaSST;
    turbulence      on;
    printCoeffs     on;
    alphaK1         0.85;
    alphaK2         1;
    alphaOmega1     0.5;
    alphaOmega2     0.856;
    gamma1          0.555556;
    gamma2          0.44;
    beta1           0.075;
    beta2           0.0828;
    betaStar        0.09;
    a1              0.31;
    b1              1;
    c1              10;
    F3              false;
}

No MRF models present

No finite volume options present


Starting time loop

streamLine streamLines:
    Employing velocity field U
    automatic track length specified through number of sub cycles : 5

nearWallFields near: Sampling 1 fields
wallBoundedStreamLine wallBoundedStreamLines:
    Employing velocity field UNear
wallBoundedStreamLine wallBoundedStreamLines:
Reading surface description:
    yNormal

forces forces:
    Not including porosity effects

forces forceCoeffs1:
    Not including porosity effects

forceCoeffs forceCoeffs1:
    Not including porosity effects

Time = 1

smoothSolver:  Solving for Ux, Initial residual = 0.135244, Final residual = 0.0131051, No Iterations 7
smoothSolver:  Solving for Uy, Initial residual = 0.221967, Final residual = 0.021706, No Iterations 7
smoothSolver:  Solving for Uz, Initial residual = 0.102955, Final residual = 0.00947569, No Iterations 6
GAMG:  Solving for p, Initial residual = 1, Final residual = 0.0083848, No Iterations 6
time step continuity errors : sum local = 0.00339492, global = 0.000131918, cumulative = 0.000131918
smoothSolver:  Solving for omega, Initial residual = 0.00850392, Final residual = 0.000734336, No Iterations 2
bounding omega, min: -11305.7 max: 206538 average: 1191.11
smoothSolver:  Solving for k, Initial residual = 1, Final residual = 0.0528535, No Iterations 4
ExecutionTime = 24.31 s  ClockTime = 42 s

forces forces write:
    Sum of forces
        Total    : (1.28156 -0.0580492 0.0871446)
        Pressure : (1.11856 -0.0592977 0.0782166)
        Viscous  : (0.162997 0.00124855 0.00892796)
    Sum of moments
        Total    : (0.00961546 0.275512 -0.0834014)
        Pressure : (0.00900869 0.246646 -0.0737632)
        Viscous  : (0.000606767 0.0288652 -0.00963815)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.24239	(pressure: 1.11222	viscous: 0.130164)
        Cd       : 1.38697	(pressure: 1.21057	viscous: 0.176403)
        Cl       : 0.0943123	(pressure: 0.08465	viscous: 0.00966229)
        Cl(f)    : 1.28954
        Cl(r)    : -1.19523

Time = 2

smoothSolver:  Solving for Ux, Initial residual = 0.88129, Final residual = 0.0111583, No Iterations 2
smoothSolver:  Solving for Uy, Initial residual = 0.256073, Final residual = 0.00154053, No Iterations 2
smoothSolver:  Solving for Uz, Initial residual = 0.527083, Final residual = 0.00880131, No Iterations 2
GAMG:  Solving for p, Initial residual = 0.0732592, Final residual = 0.000555328, No Iterations 5
time step continuity errors : sum local = 0.00184624, global = 2.23016e-05, cumulative = 0.00015422
smoothSolver:  Solving for omega, Initial residual = 0.0372897, Final residual = 0.00204077, No Iterations 4
bounding omega, min: -7.48187 max: 3.4135e+17 average: 1.37094e+12
smoothSolver:  Solving for k, Initial residual = 0.0729652, Final residual = 0.00606091, No Iterations 1
ExecutionTime = 29.08 s  ClockTime = 49 s

forces forces write:
    Sum of forces
        Total    : (1.08122 -0.0393872 0.0579338)
        Pressure : (0.938682 -0.0404867 0.0508137)
        Viscous  : (0.142542 0.00109949 0.00712015)
    Sum of moments
        Total    : (0.00535194 0.238972 -0.067452)
        Pressure : (0.00482941 0.211936 -0.05898)
        Viscous  : (0.000522525 0.027036 -0.00847204)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.07761	(pressure: 0.955698	viscous: 0.121916)
        Cd       : 1.17016	(pressure: 1.01589	viscous: 0.154266)
        Cl       : 0.0626989	(pressure: 0.0549931	viscous: 0.0077058)
        Cl(f)    : 1.10896
        Cl(r)    : -1.04626

Time = 3

smoothSolver:  Solving for Ux, Initial residual = 0.999998, Final residual = 0.0917034, No Iterations 7
smoothSolver:  Solving for Uy, Initial residual = 1, Final residual = 0.0823003, No Iterations 6
smoothSolver:  Solving for Uz, Initial residual = 0.999999, Final residual = 0.082565, No Iterations 7
GAMG:  Solving for p, Initial residual = 0.0631383, Final residual = 0.000538029, No Iterations 5
time step continuity errors : sum local = 356440, global = -472.975, cumulative = -472.975
smoothSolver:  Solving for omega, Initial residual = 0.538479, Final residual = 1.56332e-09, No Iterations 1
bounding omega, min: -1.88285e+09 max: 1.02405e+17 average: 4.13461e+11
smoothSolver:  Solving for k, Initial residual = 0.122809, Final residual = 0.00350588, No Iterations 1
ExecutionTime = 33.98 s  ClockTime = 57 s

forces forces write:
    Sum of forces
        Total    : (8.33691e+06 3.45654e+06 5.12258e+06)
        Pressure : (8.28259e+06 3.41401e+06 5.06594e+06)
        Viscous  : (54319.9 42528.7 56645.5)
    Sum of moments
        Total    : (-188912 -252743 489737)
        Pressure : (-186260 -244123 480634)
        Viscous  : (-2652.06 -8619.31 9103.32)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : -1.13971e+06	(pressure: -1.10084e+06	viscous: -38867.7)
        Cd       : 9.02263e+06	(pressure: 8.96384e+06	viscous: 58787.8)
        Cl       : 5.54392e+06	(pressure: 5.48262e+06	viscous: 61304.6)
        Cl(f)    : 1.63225e+06
        Cl(r)    : 3.91167e+06

Time = 4

smoothSolver:  Solving for Ux, Initial residual = 0.785908, Final residual = 0.0625646, No Iterations 3
smoothSolver:  Solving for Uy, Initial residual = 0.699965, Final residual = 0.0391674, No Iterations 3
smoothSolver:  Solving for Uz, Initial residual = 0.680457, Final residual = 0.0367154, No Iterations 3
GAMG:  Solving for p, Initial residual = 0.995694, Final residual = 0.00887311, No Iterations 13
time step continuity errors : sum local = 494941, global = -10614, cumulative = -11086.9
smoothSolver:  Solving for omega, Initial residual = 0.538423, Final residual = 2.00668e-06, No Iterations 1
smoothSolver:  Solving for k, Initial residual = 0.129558, Final residual = 0.00799405, No Iterations 3
ExecutionTime = 40.09 s  ClockTime = 66 s

forces forces write:
    Sum of forces
        Total    : (-2.52031e+16 -2.54231e+16 -2.72343e+16)
        Pressure : (-2.52031e+16 -2.54231e+16 -2.72343e+16)
        Viscous  : (-4.10507e+06 -255696 538475)
    Sum of moments
        Total    : (2.08799e+15 4.05448e+15 -5.71357e+15)
        Pressure : (2.08799e+15 4.05448e+15 -5.71357e+15)
        Viscous  : (79809.7 -838476 244307)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.82832e+16	(pressure: 1.82832e+16	viscous: -3.78101e+06)
        Cd       : -2.7276e+16	(pressure: -2.7276e+16	viscous: -4.44272e+06)
        Cl       : -2.94743e+16	(pressure: -2.94743e+16	viscous: 582766)
        Cl(f)    : 3.546e+15
        Cl(r)    : -3.30203e+16

Time = 5

smoothSolver:  Solving for Ux, Initial residual = 0.615272, Final residual = 0.0569642, No Iterations 6
smoothSolver:  Solving for Uy, Initial residual = 0.617511, Final residual = 0.0560585, No Iterations 5
smoothSolver:  Solving for Uz, Initial residual = 0.631485, Final residual = 0.0582229, No Iterations 5
GAMG:  Solving for p, Initial residual = 7.91509e-06, Final residual = 9.35461e-08, No Iterations 12
time step continuity errors : sum local = 1.87307e+06, global = 48932, cumulative = 37845
smoothSolver:  Solving for omega, Initial residual = 0.53741, Final residual = 3.92157e-05, No Iterations 1
smoothSolver:  Solving for k, Initial residual = 0.0993691, Final residual = 0.00917355, No Iterations 3
ExecutionTime = 46.19 s  ClockTime = 76 s

forces forces write:
    Sum of forces
        Total    : (-1.38778e+17 -1.96715e+17 -1.97628e+17)
        Pressure : (-1.38778e+17 -1.96715e+17 -1.97628e+17)
        Viscous  : (-1.31761e+07 1.69993e+06 1.28548e+06)
    Sum of moments
        Total    : (1.73308e+16 3.53724e+16 -4.67935e+16)
        Pressure : (1.73308e+16 3.53724e+16 -4.67935e+16)
        Viscous  : (18760 -2.3801e+06 1.38128e+06)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.59508e+17	(pressure: 1.59508e+17	viscous: -1.07328e+07)
        Cd       : -1.50193e+17	(pressure: -1.50193e+17	viscous: -1.42599e+07)
        Cl       : -2.13883e+17	(pressure: -2.13883e+17	viscous: 1.39121e+06)
        Cl(f)    : 5.2566e+16
        Cl(r)    : -2.66449e+17

Time = 6

smoothSolver:  Solving for Ux, Initial residual = 0.518912, Final residual = 0.0424792, No Iterations 57
smoothSolver:  Solving for Uy, Initial residual = 0.535962, Final residual = 0.0534381, No Iterations 56
smoothSolver:  Solving for Uz, Initial residual = 0.511037, Final residual = 0.0479979, No Iterations 58
GAMG:  Solving for p, Initial residual = 0.82888, Final residual = 0.0438469, No Iterations 1000
time step continuity errors : sum local = 3.1669e+12, global = -5.86772e+06, cumulative = -5.82988e+06
smoothSolver:  Solving for omega, Initial residual = 0.0766007, Final residual = 0.00538269, No Iterations 4
smoothSolver:  Solving for k, Initial residual = 0.193746, Final residual = 0.016646, No Iterations 3
ExecutionTime = 233.67 s  ClockTime = 364 s

forces forces write:
    Sum of forces
        Total    : (-6.51201e+22 3.71996e+22 6.49004e+22)
        Pressure : (-6.51201e+22 3.71996e+22 6.49004e+22)
        Viscous  : (8.65424e+13 -7.22325e+13 -8.40083e+12)
    Sum of moments
        Total    : (2.10418e+21 -1.26682e+22 9.40817e+21)
        Pressure : (2.10418e+21 -1.26682e+22 9.40817e+21)
        Viscous  : (8.72937e+11 3.04271e+12 -1.67541e+13)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : -5.71255e+22	(pressure: -5.71255e+22	viscous: 1.37207e+13)
        Cd       : -7.04763e+22	(pressure: -7.04763e+22	viscous: 9.36606e+13)
        Cl       : 7.02386e+22	(pressure: 7.02386e+22	viscous: -9.0918e+12)
        Cl(f)    : -2.20063e+22
        Cl(r)    : 9.22448e+22

Time = 7

smoothSolver:  Solving for Ux, Initial residual = 0.667783, Final residual = 35.3377, No Iterations 1000
smoothSolver:  Solving for Uy, Initial residual = 0.653949, Final residual = 0.0637418, No Iterations 81
smoothSolver:  Solving for Uz, Initial residual = 0.671639, Final residual = 0.0596769, No Iterations 110
-------------------------------------------------------
Primary job  terminated normally, but 1 process returned
a non-zero exit code.. Per user-direction, the job has been aborted.
-------------------------------------------------------
--------------------------------------------------------------------------
mpirun detected that one or more processes exited with non-zero status, thus causing
the job to be terminated. The first process to do so was:

  Process name: [[1404,1],1]
  Exit code:    145
--------------------------------------------------------------------------
edomalley1 is offline   Reply With Quote

Old   September 6, 2018, 21:18
Default
  #2
Senior Member
 
Peter Baskovich
Join Date: Jul 2014
Posts: 126
Rep Power: 8
pete20r2 is on a distinguished road
Quote:
Originally Posted by edomalley1 View Post
Hi -

I'm running an external aerodynamics simulation of a leg in a cycling shoe. Previous models worked fine but my new geometry fails when running simpleFoam with this error:

mpirun detected that one or more processes exited with non-zero status, thus causing
the job to be terminated. The first process to do so was:

Process name: [[1404,1],1]
Exit code: 145

In the Log.simpleFoam file for the new geometry (and in the forces.dat file) the forces and moments quickly start to spiral way way out of bounds in just a couple time steps (by E^22) and residuals go up.

Below is the new simpleFoam log. Total force in the x direction in previous models stayed between 0.2 and 1.5 through every time step.

Any idea where I should look for the error?

Code:
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v1706                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : v1706-17752679325a
Arch   : "LSB;label=32;scalar=64"
Exec   : simpleFoam -decomposeParDict system/decomposeParDict.6 -parallel
Date   : Sep 06 2018
Time   : 15:48:54
Host   : "DESKTOP-1A6ON5E"
PID    : 1016
Case   : /mnt/c/Users/edoma/CFD/ShoeCFD/ShoeCases/LuckBlankCase
nProcs : 6
Slaves : 
5
(
"DESKTOP-1A6ON5E.1017"
"DESKTOP-1A6ON5E.1018"
"DESKTOP-1A6ON5E.1019"
"DESKTOP-1A6ON5E.1020"
"DESKTOP-1A6ON5E.1021"
)

Pstream initialized with:
    floatTransfer      : 0
    nProcsSimpleSum    : 0
    commsType          : nonBlocking
    polling iterations : 0
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

Create mesh for time = 0


SIMPLE: no convergence criteria found. Calculations will run for 160 steps.

Reading field p

Reading field U

Reading/calculating face flux field phi

Selecting incompressible transport model Newtonian
Selecting turbulence model type RAS
Selecting RAS turbulence model kOmegaSST
Selecting patchDistMethod meshWave
RAS
{
    RASModel        kOmegaSST;
    turbulence      on;
    printCoeffs     on;
    alphaK1         0.85;
    alphaK2         1;
    alphaOmega1     0.5;
    alphaOmega2     0.856;
    gamma1          0.555556;
    gamma2          0.44;
    beta1           0.075;
    beta2           0.0828;
    betaStar        0.09;
    a1              0.31;
    b1              1;
    c1              10;
    F3              false;
}

No MRF models present

No finite volume options present


Starting time loop

streamLine streamLines:
    Employing velocity field U
    automatic track length specified through number of sub cycles : 5

nearWallFields near: Sampling 1 fields
wallBoundedStreamLine wallBoundedStreamLines:
    Employing velocity field UNear
wallBoundedStreamLine wallBoundedStreamLines:
Reading surface description:
    yNormal

forces forces:
    Not including porosity effects

forces forceCoeffs1:
    Not including porosity effects

forceCoeffs forceCoeffs1:
    Not including porosity effects

Time = 1

smoothSolver:  Solving for Ux, Initial residual = 0.135244, Final residual = 0.0131051, No Iterations 7
smoothSolver:  Solving for Uy, Initial residual = 0.221967, Final residual = 0.021706, No Iterations 7
smoothSolver:  Solving for Uz, Initial residual = 0.102955, Final residual = 0.00947569, No Iterations 6
GAMG:  Solving for p, Initial residual = 1, Final residual = 0.0083848, No Iterations 6
time step continuity errors : sum local = 0.00339492, global = 0.000131918, cumulative = 0.000131918
smoothSolver:  Solving for omega, Initial residual = 0.00850392, Final residual = 0.000734336, No Iterations 2
bounding omega, min: -11305.7 max: 206538 average: 1191.11
smoothSolver:  Solving for k, Initial residual = 1, Final residual = 0.0528535, No Iterations 4
ExecutionTime = 24.31 s  ClockTime = 42 s

forces forces write:
    Sum of forces
        Total    : (1.28156 -0.0580492 0.0871446)
        Pressure : (1.11856 -0.0592977 0.0782166)
        Viscous  : (0.162997 0.00124855 0.00892796)
    Sum of moments
        Total    : (0.00961546 0.275512 -0.0834014)
        Pressure : (0.00900869 0.246646 -0.0737632)
        Viscous  : (0.000606767 0.0288652 -0.00963815)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.24239(pressure: 1.11222viscous: 0.130164)
        Cd       : 1.38697(pressure: 1.21057viscous: 0.176403)
        Cl       : 0.0943123(pressure: 0.08465viscous: 0.00966229)
        Cl(f)    : 1.28954
        Cl(r)    : -1.19523

Time = 2

smoothSolver:  Solving for Ux, Initial residual = 0.88129, Final residual = 0.0111583, No Iterations 2
smoothSolver:  Solving for Uy, Initial residual = 0.256073, Final residual = 0.00154053, No Iterations 2
smoothSolver:  Solving for Uz, Initial residual = 0.527083, Final residual = 0.00880131, No Iterations 2
GAMG:  Solving for p, Initial residual = 0.0732592, Final residual = 0.000555328, No Iterations 5
time step continuity errors : sum local = 0.00184624, global = 2.23016e-05, cumulative = 0.00015422
smoothSolver:  Solving for omega, Initial residual = 0.0372897, Final residual = 0.00204077, No Iterations 4
bounding omega, min: -7.48187 max: 3.4135e+17 average: 1.37094e+12
smoothSolver:  Solving for k, Initial residual = 0.0729652, Final residual = 0.00606091, No Iterations 1
ExecutionTime = 29.08 s  ClockTime = 49 s

forces forces write:
    Sum of forces
        Total    : (1.08122 -0.0393872 0.0579338)
        Pressure : (0.938682 -0.0404867 0.0508137)
        Viscous  : (0.142542 0.00109949 0.00712015)
    Sum of moments
        Total    : (0.00535194 0.238972 -0.067452)
        Pressure : (0.00482941 0.211936 -0.05898)
        Viscous  : (0.000522525 0.027036 -0.00847204)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.07761(pressure: 0.955698viscous: 0.121916)
        Cd       : 1.17016(pressure: 1.01589viscous: 0.154266)
        Cl       : 0.0626989(pressure: 0.0549931viscous: 0.0077058)
        Cl(f)    : 1.10896
        Cl(r)    : -1.04626

Time = 3

smoothSolver:  Solving for Ux, Initial residual = 0.999998, Final residual = 0.0917034, No Iterations 7
smoothSolver:  Solving for Uy, Initial residual = 1, Final residual = 0.0823003, No Iterations 6
smoothSolver:  Solving for Uz, Initial residual = 0.999999, Final residual = 0.082565, No Iterations 7
GAMG:  Solving for p, Initial residual = 0.0631383, Final residual = 0.000538029, No Iterations 5
time step continuity errors : sum local = 356440, global = -472.975, cumulative = -472.975
smoothSolver:  Solving for omega, Initial residual = 0.538479, Final residual = 1.56332e-09, No Iterations 1
bounding omega, min: -1.88285e+09 max: 1.02405e+17 average: 4.13461e+11
smoothSolver:  Solving for k, Initial residual = 0.122809, Final residual = 0.00350588, No Iterations 1
ExecutionTime = 33.98 s  ClockTime = 57 s

forces forces write:
    Sum of forces
        Total    : (8.33691e+06 3.45654e+06 5.12258e+06)
        Pressure : (8.28259e+06 3.41401e+06 5.06594e+06)
        Viscous  : (54319.9 42528.7 56645.5)
    Sum of moments
        Total    : (-188912 -252743 489737)
        Pressure : (-186260 -244123 480634)
        Viscous  : (-2652.06 -8619.31 9103.32)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : -1.13971e+06(pressure: -1.10084e+06viscous: -38867.7)
        Cd       : 9.02263e+06(pressure: 8.96384e+06viscous: 58787.8)
        Cl       : 5.54392e+06(pressure: 5.48262e+06viscous: 61304.6)
        Cl(f)    : 1.63225e+06
        Cl(r)    : 3.91167e+06

Time = 4

smoothSolver:  Solving for Ux, Initial residual = 0.785908, Final residual = 0.0625646, No Iterations 3
smoothSolver:  Solving for Uy, Initial residual = 0.699965, Final residual = 0.0391674, No Iterations 3
smoothSolver:  Solving for Uz, Initial residual = 0.680457, Final residual = 0.0367154, No Iterations 3
GAMG:  Solving for p, Initial residual = 0.995694, Final residual = 0.00887311, No Iterations 13
time step continuity errors : sum local = 494941, global = -10614, cumulative = -11086.9
smoothSolver:  Solving for omega, Initial residual = 0.538423, Final residual = 2.00668e-06, No Iterations 1
smoothSolver:  Solving for k, Initial residual = 0.129558, Final residual = 0.00799405, No Iterations 3
ExecutionTime = 40.09 s  ClockTime = 66 s

forces forces write:
    Sum of forces
        Total    : (-2.52031e+16 -2.54231e+16 -2.72343e+16)
        Pressure : (-2.52031e+16 -2.54231e+16 -2.72343e+16)
        Viscous  : (-4.10507e+06 -255696 538475)
    Sum of moments
        Total    : (2.08799e+15 4.05448e+15 -5.71357e+15)
        Pressure : (2.08799e+15 4.05448e+15 -5.71357e+15)
        Viscous  : (79809.7 -838476 244307)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.82832e+16(pressure: 1.82832e+16viscous: -3.78101e+06)
        Cd       : -2.7276e+16(pressure: -2.7276e+16viscous: -4.44272e+06)
        Cl       : -2.94743e+16(pressure: -2.94743e+16viscous: 582766)
        Cl(f)    : 3.546e+15
        Cl(r)    : -3.30203e+16

Time = 5

smoothSolver:  Solving for Ux, Initial residual = 0.615272, Final residual = 0.0569642, No Iterations 6
smoothSolver:  Solving for Uy, Initial residual = 0.617511, Final residual = 0.0560585, No Iterations 5
smoothSolver:  Solving for Uz, Initial residual = 0.631485, Final residual = 0.0582229, No Iterations 5
GAMG:  Solving for p, Initial residual = 7.91509e-06, Final residual = 9.35461e-08, No Iterations 12
time step continuity errors : sum local = 1.87307e+06, global = 48932, cumulative = 37845
smoothSolver:  Solving for omega, Initial residual = 0.53741, Final residual = 3.92157e-05, No Iterations 1
smoothSolver:  Solving for k, Initial residual = 0.0993691, Final residual = 0.00917355, No Iterations 3
ExecutionTime = 46.19 s  ClockTime = 76 s

forces forces write:
    Sum of forces
        Total    : (-1.38778e+17 -1.96715e+17 -1.97628e+17)
        Pressure : (-1.38778e+17 -1.96715e+17 -1.97628e+17)
        Viscous  : (-1.31761e+07 1.69993e+06 1.28548e+06)
    Sum of moments
        Total    : (1.73308e+16 3.53724e+16 -4.67935e+16)
        Pressure : (1.73308e+16 3.53724e+16 -4.67935e+16)
        Viscous  : (18760 -2.3801e+06 1.38128e+06)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : 1.59508e+17(pressure: 1.59508e+17viscous: -1.07328e+07)
        Cd       : -1.50193e+17(pressure: -1.50193e+17viscous: -1.42599e+07)
        Cl       : -2.13883e+17(pressure: -2.13883e+17viscous: 1.39121e+06)
        Cl(f)    : 5.2566e+16
        Cl(r)    : -2.66449e+17

Time = 6

smoothSolver:  Solving for Ux, Initial residual = 0.518912, Final residual = 0.0424792, No Iterations 57
smoothSolver:  Solving for Uy, Initial residual = 0.535962, Final residual = 0.0534381, No Iterations 56
smoothSolver:  Solving for Uz, Initial residual = 0.511037, Final residual = 0.0479979, No Iterations 58
GAMG:  Solving for p, Initial residual = 0.82888, Final residual = 0.0438469, No Iterations 1000
time step continuity errors : sum local = 3.1669e+12, global = -5.86772e+06, cumulative = -5.82988e+06
smoothSolver:  Solving for omega, Initial residual = 0.0766007, Final residual = 0.00538269, No Iterations 4
smoothSolver:  Solving for k, Initial residual = 0.193746, Final residual = 0.016646, No Iterations 3
ExecutionTime = 233.67 s  ClockTime = 364 s

forces forces write:
    Sum of forces
        Total    : (-6.51201e+22 3.71996e+22 6.49004e+22)
        Pressure : (-6.51201e+22 3.71996e+22 6.49004e+22)
        Viscous  : (8.65424e+13 -7.22325e+13 -8.40083e+12)
    Sum of moments
        Total    : (2.10418e+21 -1.26682e+22 9.40817e+21)
        Pressure : (2.10418e+21 -1.26682e+22 9.40817e+21)
        Viscous  : (8.72937e+11 3.04271e+12 -1.67541e+13)


forceCoeffs forceCoeffs1 execute:
    Coefficients
        Cm       : -5.71255e+22(pressure: -5.71255e+22viscous: 1.37207e+13)
        Cd       : -7.04763e+22(pressure: -7.04763e+22viscous: 9.36606e+13)
        Cl       : 7.02386e+22(pressure: 7.02386e+22viscous: -9.0918e+12)
        Cl(f)    : -2.20063e+22
        Cl(r)    : 9.22448e+22

Time = 7

smoothSolver:  Solving for Ux, Initial residual = 0.667783, Final residual = 35.3377, No Iterations 1000
smoothSolver:  Solving for Uy, Initial residual = 0.653949, Final residual = 0.0637418, No Iterations 81
smoothSolver:  Solving for Uz, Initial residual = 0.671639, Final residual = 0.0596769, No Iterations 110
-------------------------------------------------------
Primary job  terminated normally, but 1 process returned
a non-zero exit code.. Per user-direction, the job has been aborted.
-------------------------------------------------------
--------------------------------------------------------------------------
mpirun detected that one or more processes exited with non-zero status, thus causing
the job to be terminated. The first process to do so was:

  Process name: [[1404,1],1]
  Exit code:    145
--------------------------------------------------------------------------
Try writing each timestep out and use your favourite post processor to find where the fields go crazy.
Seeing as the job ran with your previous geometry, I'd suspect that your new geometry is not clean. Have you checked checkMesh results and y+?
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Old   September 6, 2018, 21:23
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Ed O'Malley
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Thanks,

I actually just ran checkMesh and got this:

Code:
/*---------------------------------------------------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v1706                                 |
|   \\  /    A nd           | Web:      www.OpenFOAM.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
Build  : v1706-17752679325a
Arch   : "LSB;label=32;scalar=64"
Exec   : checkMesh -allTopology -allGeometry
Date   : Sep 06 2018
Time   : 18:19:28
Host   : "DESKTOP-1A6ON5E"
PID    : 1307
Case   : /mnt/c/Users/edoma/CFD/ShoeCFD/ShoeCases/LuckBlankCase
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

--> FOAM Warning :
    From function static Foam::instantList Foam::timeSelector::select0(Foam::Time&, const Foam::argList&)
    in file db/Time/timeSelector.C at line 274
    No time specified or available, selecting 'constant'
Create mesh for time = constant

Enabling all (cell, face, edge, point) topology checks.

Enabling all geometry checks.

Time = constant

Mesh stats
    points:           2998206
    faces:            8513825
    internal faces:   8396763
    cells:            2770786
    faces per cell:   6.10317
    boundary patches: 6
    point zones:      0
    face zones:       0
    cell zones:       0

Overall number of cells of each type:
    hexahedra:     2566108
    prisms:        23372
    wedges:        1830
    pyramids:      0
    tet wedges:    2599
    tetrahedra:    334
    polyhedra:     176543
    Breakdown of polyhedra by number of faces:
        faces   number of cells
            4   21823
            5   14203
            6   25489
            7   20074
            8   11736
            9   64409
           10   343
           11   94
           12   10677
           13   35
           14   51
           15   7220
           16   6
           17   7
           18   376

Checking topology...
    Boundary definition OK.
    Cell to face addressing OK.
    Point usage OK.
    Upper triangular ordering OK.
    Face vertices OK.
    Topological cell zip-up check OK.
  <<Number of faces with non-consecutive shared points: 3. This might indicate a problem.
  <<Writing 6 faces with non-standard edge connectivity to set edgeFaces
    Number of regions: 1 (OK).

Checking patch topology for multiply connected surfaces...
                   Patch    Faces   Points                  Surface topology Bounding box
            frontAndBack     2480     2624  ok (non-closed singly connected) (-0.5 -0.4 -0.5) (1.5 0.4 1)
                   inlet      496      544  ok (non-closed singly connected) (-0.5 -0.4 -0.5) (-0.5 0.4 1)
                  outlet      496      544  ok (non-closed singly connected) (1.5 -0.4 -0.5) (1.5 0.4 1)
               lowerWall      640      697  ok (non-closed singly connected) (-0.5 -0.4 -0.5) (1.5 0.4 -0.5)
               upperWall      640      697  ok (non-closed singly connected) (-0.5 -0.4 1) (1.5 0.4 1)
            shoeCFDlevel   112310   137812      ok (closed singly connected) (0.000437343 -7.86711e-06 0.00262043) (0.343709 0.118546 0.504577)

Checking geometry...
    Overall domain bounding box (-0.5 -0.4 -0.5) (1.5 0.4 1)
    Mesh has 3 geometric (non-empty/wedge) directions (1 1 1)
    Mesh has 3 solution (non-empty) directions (1 1 1)
    Boundary openness (2.61358e-17 -7.37813e-17 1.27339e-15) OK.
    Max cell openness = 1.11267e-15 OK.
    Max aspect ratio = 33.7062 OK.
    Minimum face area = 3.85016e-09. Maximum face area = 0.00260669.  Face area magnitudes OK.
    Min volume = 3.00247e-12. Max volume = 0.000127557.  Total volume = 2.39642.  Cell volumes OK.
    Mesh non-orthogonality Max: 64.9836 average: 6.78139
    Non-orthogonality check OK.
    Face pyramids OK.
    Max skewness = 3.75528 OK.
    Coupled point location match (average 0) OK.
    Face tets OK.
    Min/max edge length = 1.21077e-05 0.0524745 OK.
   *There are 2401 faces with concave angles between consecutive edges. Max concave angle = 79.9097 degrees.
  <<Writing 2401 faces with concave angles to set concaveFaces
    Face flatness (1 = flat, 0 = butterfly) : min = 0.437859  average = 0.999481
   *There are 67 faces with ratio between projected and actual area < 0.8
    Minimum ratio (minimum flatness, maximum warpage) = 0.437859
  <<Writing 67 warped faces to set warpedFaces
    Cell determinant (wellposedness) : minimum: 8.86824e-06 average: 1.3657
 ***Cells with small determinant (< 0.001) found, number of cells: 1223
  <<Writing 1223 under-determined cells to set underdeterminedCells
 ***Concave cells (using face planes) found, number of cells: 65639
  <<Writing 65639 concave cells to set concaveCells
    Face interpolation weight : minimum: 0.0241129 average: 0.483669
 ***Faces with small interpolation weight (< 0.05) found, number of faces: 1187
  <<Writing 1187 faces with low interpolation weights to set lowWeightFaces
    Face volume ratio : minimum: 0.0105059 average: 0.922668
    Face volume ratio check OK.

Failed 3 mesh checks.

End
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Old   September 7, 2018, 11:42
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Ed O'Malley
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OK, it works now! I realized that it was running OK (results bad but solving) when I had layers turned off and it broke when I added layers to snappyHexMesh. So I decided to just make the layers more robust and changed nSurfaceLayers from 1 to 2 and added more external geometry smoothing iterations. Now it works!
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