This is after a long time. Have you found any solution for this ? I have the same issue of generation of internal faces with mergeMesh and have not found a solution to stitch them.

Union of two cylinders with BlockMesh
 

Good morning to everybody.
after trying various tools to generate an optimal mesh to correctly represent my model scenario (Salome, snappy), I have come to the conclusion that the most convenient and efficient way is to use just blockMesh.

I have followed the pipe tutorial in the / tutorials / mesh / blockMesh / pipe in great detail, where a pipe is generated by following a .obj curve. After adapting the tutorial to my geometry I execute the command "blockMesh" to generate my mesh and I find the error that I attach in the image.

Do you have any idea why this is happening?
How could I solve my problem?
Thank you.

PS: I have attached the following information
1- .zip that contains the case folder
2- inside the case folder there is another folder called salome, where every geometry involved in the case is presented

Attachment 77702

Attachment 77703

Hello Andres,

The issue is that when using blockMesh and defining different hexes the interfacing blocks have to be equal. The error code state that you have inconsistent number of faces between block pair 0 and 1, meaning that the following doesn't connect correctly as the the block in the connecting plane fx xy plane is not equal (cells in x and y directions must be equal.

From you blockmesh code block pair 0 and 1 is defined as:

And i believe that hex0 is on top of hex1 therefore the block (8 10 8) must be the same as (10 100 10), by changing it to fx the following:

The same counts for the simpleGrading.