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GenerateVolumeMesh Error  Surface Wrapper Self Interacting (?) 

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July 20, 2018, 07:38 
GenerateVolumeMesh Error  Surface Wrapper Self Interacting (?)

#1 
Member
André Pinto
Join Date: Oct 2017
Posts: 81
Rep Power: 4 
Hello Guys,
I'm trying to mesh a full F1 car, and because my previous CFD simulations were much simpler geometries (I used Regions Based Mesh), this is my first time using Parts Based Mesh. For a starting point on the mesh, I'm using Surface Wrapper and Automated Mesh (Surface Remesher, Trimmed, Prism Layer) (following some tutorials my supervisor gave me), but it's not being able to mesh: And this is the error I'm having: "  Surface Remesher Completed: CPU Time: 3053.02, Wall Time: 3056.30, Memory: 18957.27 MB  Following Parts are Self Intersecting Surface Wrapper Command: GenerateVolumeMesh error: Server Error Following Parts are Self Intersecting Surface Wrapper Command: GenerateVolumeMesh command: CommandComplete error: Server Error Design STARCCM+ simulation completed Server process exited with code : 0" I can't really identify what can be causing this. Can anyone give me some hints where I can look for problems causing this? If anyone fancies having a look here it is the file: (Keep in mind you won't be able to run this on a PC, only on cluster, as it's taking 2 hours on a cluster to get to the volume mesh!) https://drive.google.com/file/d/1Pd8...ew?usp=sharing Thank you 

July 20, 2018, 08:02 

#2 
Member
André Pinto
Join Date: Oct 2017
Posts: 81
Rep Power: 4 
In case it helps anyone, here is the complete slurm file!
Starting local server: /system/software/generic/brookes/CDadapco/12.04.010R8/STARCCM+12.04.010R8/star/bin/starccm+ mpi intel np 16 machinefile hostfile.txt mppflags "bootstrap slurm" server rsh ssh Perrinn_Benchmark.sim Starting STARCCM+ parallel server MPI Distribution : Intel MPI5.0.3 Host 0  cnode2079  Ranks 015 Process rank 0 cnode2079 3110 Total number of processes : 16 STARCCM+ 12.04.010 (linuxx86_642.5/gnu4.8r8) License build date: 02 February 2017 This version of the code requires license version 2017.06 or greater. Checking license file: 27000@10.4.144.10 1 copy of ccmpsuite checked out from 27000@10.4.144.10 Feature ccmpsuite expires in 74 days Thu Jul 19 11:59:19 2018 Server::start host cnode2079.arcus.arc.local:47827 Loading object database: Perrinn_Benchmark.sim Loading module: StarMeshing Loading module: MeshingSurfaceRepair Loading module: StarSurfaceWrapper Loading module: StarResurfacer Loading module: StarTrimmer Loading module: SegregatedFlowModel Loading module: KeTurbModel Simulation database saved by: STARCCM+ 12.04.010 (win64/intel16.3r8) Tue Jun 6 18:28:42 UTC 2017 Serial Loading into: STARCCM+ 12.04.010 (linuxx86_642.5/gnu4.8r8) Tue Jun 6 18:28:42 UTC 2017 Np=16 Started Parasolid modeler version 29.01.131 Object database load completed. Generating mesh Executing partsbased mesh operations  Executing Automated Mesh Operation: Surface Wrapper  Projecting to CAD geometry where possible  Executing Surface Wrapper  Checking input surface validity done, CPU Time: 0.15, Memory: 1665.66 MB, # Trias: 2960942 Computing Entity Depth computing surface proximity min:max face size 0.0005:0.2 done, CPU Time: 113.98, Memory: 1965.88 MB, # Trias: 2960942 Generating Octree Mesh Estimated size of initial output surface: 35121587 done, CPU Time: 104.87, Memory: 5469.30 MB Obtaining Initial Surface created 29501160 triangles done, CPU Time: 37.94, Memory: 7504.70 MB, # Trias: 29501160 Fixing Nonmanifold Surface done, CPU Time: 22.04, Memory: 9047.18 MB, # Trias: 29501324 Constraining Vertices to Input Surface constraining 14750420 vertices to original surface done, CPU Time: 62.82, Memory: 9159.71 MB, # Trias: 29501324 Improving Triangle Quality done, CPU Time: 23.24, Memory: 9082.70 MB, # Trias: 29110294 Marking flipped faces done, CPU Time: 18.36, Memory: 9206.54 MB, # Trias: 29109238 Defining Features Initializing data structures Retaining Features (1/4) Retaining Features (2/4) Retaining Features (3/4) Defeaturing (4/4) done, CPU Time: 482.23, Memory: 9206.54 MB, # Trias: 29335158 Imprinting Features built 1345 chains of feature edges for imprinting done, CPU Time: 22.91, Memory: 9206.54 MB, # Trias: 29404128 Fixing Baffles found 114 final baffle faces done, CPU Time: 46.68, Memory: 9206.54 MB, # Trias: 29383096 Assigning Face Types to Surface done, CPU Time: 851.12, Memory: 9206.54 MB Reassociating wrapped mesh with CAD Nonmanifold wrap edge to CAD edge mapping for CAD edge 12958 at wrap mesh vertex 3820056 done, CPU Time: 1135.12, Memory: 9206.54 MB Fixing flipped faces done, CPU Time: 35.56, Memory: 9544.16 MB, # Trias: 29311460 Checking for intersections Fixing Intersections done, CPU Time: 225.99, Memory: 9686.33 MB, # Trias: 29310720 Final surface wrap statistics: 29310720 final surface triangles 216083 special edges 0 special vertices 114 baffle faces inflated automatically 0 intersecting edges remain 0 pierced faces remain 100% of input vertices on CAD(1480549/1480549) 100% of input faces on CAD(2960942/2960942) 99.8884% of output vertices on CAD(14638772/14655128) 99.8189% of output faces on CAD(29257631/29310720)  Surface Wrapper Completed: CPU Time: 3422.77, Wall Time: 3426.29, Memory: 8643.90 MB   Automated Mesh Operation: Surface Wrapper complete. CPU Time: 3428.45, Wall Time: 3432.82, Memory: 8610.00 MB   Executing Automated Mesh Operation: Automated Mesh  Checking meshCAD association... done. Found 121 problems, all fixed.  Preparing surface for surface meshing in Parts:   finished preparing surface for surface meshing CPU Time: 28.85, Wall Time: 28.92, Memory: 11064.10 MB  Projecting to CAD geometry  Executing Surface Remesher  Face Quality Faces Percent < 0.001 21 0.0 < 0.01 464 0.0 < 0.05 1764 0.0 < 0.1 2863 0.0 < 0.2 306635 1.0 < 0.3 644209 2.2 < 0.4 1051100 3.6 < 0.5 1662626 5.7 < 0.6 2693155 9.2 < 0.7 4800317 16.4 < 0.8 8865084 30.2 < 0.9 26319407 89.8 < 1.0 29310714 100.0 Worst quality is 8.262e06 initial number of faces: 29310714 starting: Apply Global Limits current number of faces: 29200000 current number of faces: 29100000 current number of faces: 29000000 current number of faces: 28900000 current number of faces: 28800000 current number of faces: 28700000 current number of faces: 28600000 current number of faces: 28500000 current number of faces: 28400000 current number of faces: 28300000 current number of faces: 28200000 current number of faces: 28100000 current number of faces: 28000000 current number of faces: 27900000 current number of faces: 27800000 current number of faces: 27700000 current number of faces: 27600000 current number of faces: 27500000 current number of faces: 27400000 current number of faces: 27300000 current number of faces: 27200000 current number of faces: 27100000 current number of faces: 27000000 current number of faces: 26900000 current number of faces: 26800000 current number of faces: 26700000 current number of faces: 26600000 current number of faces: 26500000 current number of faces: 26400000 current number of faces: 26300000 current number of faces: 26200000 current number of faces: 26100000 current number of faces: 26000000 current number of faces: 25900000 current number of faces: 25800000 current number of faces: 25700000 current number of faces: 25600000 current number of faces: 25500000 current number of faces: 25400000 current number of faces: 25300000 current number of faces: 25200000 current number of faces: 25100000 current number of faces: 25000000 current number of faces: 24900000 current number of faces: 24800000 current number of faces: 24700000 current number of faces: 24600000 current number of faces: 24500000 current number of faces: 24400000 current number of faces: 24300000 current number of faces: 24200000 current number of faces: 24100000 current number of faces: 24000000 current number of faces: 23900000 current number of faces: 23800000 current number of faces: 23700000 current number of faces: 23600000 current number of faces: 23500000 current number of faces: 23400000 current number of faces: 23300000 current number of faces: 23200000 current number of faces: 23100000 current number of faces: 23000000 current number of faces: 22900000 current number of faces: 22800000 current number of faces: 22700000 current number of faces: 22600000 current number of faces: 22500000 current number of faces: 22400000 current number of faces: 22300000 Face Quality Faces Percent < 0.001 172 0.0 < 0.01 529 0.0 < 0.05 1435 0.0 < 0.1 2245 0.0 < 0.2 28805 0.1 < 0.3 73070 0.3 < 0.4 146684 0.7 < 0.5 272150 1.2 < 0.6 502080 2.3 < 0.7 1195178 5.4 < 0.8 3914575 17.6 < 0.9 19105801 86.0 < 1.0 22208572 100.0 Worst quality is 0 starting: Improve Grading current number of faces: 22200000 current number of faces: 22100000 current number of faces: 22000000 current number of faces: 21900000 current number of faces: 21800000 current number of faces: 21700000 current number of faces: 21600000 current number of faces: 21500000 current number of faces: 21400000 current number of faces: 21300000 current number of faces: 21200000 current number of faces: 21100000 current number of faces: 21000000 current number of faces: 20900000 current number of faces: 20800000 current number of faces: 20700000 current number of faces: 20600000 current number of faces: 20500000 current number of faces: 20400000 current number of faces: 20300000 current number of faces: 20200000 current number of faces: 20100000 current number of faces: 20000000 current number of faces: 19900000 current number of faces: 19800000 current number of faces: 19700000 current number of faces: 19600000 current number of faces: 19500000 current number of faces: 19400000 current number of faces: 19300000 current number of faces: 19200000 current number of faces: 19100000 current number of faces: 19000000 current number of faces: 18900000 current number of faces: 18800000 current number of faces: 18700000 current number of faces: 18600000 current number of faces: 18500000 current number of faces: 18400000 current number of faces: 18300000 current number of faces: 18200000 current number of faces: 18100000 current number of faces: 18000000 current number of faces: 17900000 current number of faces: 17800000 current number of faces: 17700000 current number of faces: 17600000 current number of faces: 17500000 current number of faces: 17400000 current number of faces: 17300000 current number of faces: 17200000 current number of faces: 17100000 current number of faces: 17000000 current number of faces: 16900000 current number of faces: 16800000 current number of faces: 16700000 current number of faces: 16600000 current number of faces: 16500000 current number of faces: 16400000 current number of faces: 16300000 current number of faces: 16200000 current number of faces: 16100000 current number of faces: 16000000 current number of faces: 15900000 current number of faces: 15800000 current number of faces: 15700000 current number of faces: 15600000 current number of faces: 15500000 current number of faces: 15400000 current number of faces: 15300000 current number of faces: 15200000 current number of faces: 15100000 current number of faces: 15000000 current number of faces: 14900000 current number of faces: 14800000 current number of faces: 14700000 current number of faces: 14600000 current number of faces: 14500000 current number of faces: 14400000 current number of faces: 14300000 current number of faces: 14200000 current number of faces: 14100000 current number of faces: 14000000 current number of faces: 13900000 current number of faces: 13800000 current number of faces: 13700000 current number of faces: 13600000 current number of faces: 13500000 current number of faces: 13400000 current number of faces: 13300000 current number of faces: 13200000 current number of faces: 13100000 current number of faces: 13000000 current number of faces: 12900000 current number of faces: 12800000 current number of faces: 12700000 current number of faces: 12600000 current number of faces: 12500000 current number of faces: 12400000 current number of faces: 12300000 current number of faces: 12200000 current number of faces: 12100000 current number of faces: 12000000 current number of faces: 11900000 current number of faces: 11800000 current number of faces: 11700000 current number of faces: 11600000 current number of faces: 11500000 current number of faces: 11400000 current number of faces: 11300000 current number of faces: 11200000 current number of faces: 11100000 current number of faces: 11000000 current number of faces: 10900000 current number of faces: 10800000 current number of faces: 10700000 current number of faces: 10600000 current number of faces: 10500000 current number of faces: 10400000 current number of faces: 10300000 current number of faces: 10200000 current number of faces: 10100000 current number of faces: 10000000 current number of faces: 9900000 current number of faces: 9800000 current number of faces: 9700000 current number of faces: 9600000 current number of faces: 9500000 current number of faces: 9400000 current number of faces: 9300000 current number of faces: 9200000 current number of faces: 9100000 current number of faces: 9000000 current number of faces: 8900000 current number of faces: 8800000 current number of faces: 8700000 current number of faces: 8600000 current number of faces: 8500000 current number of faces: 8400000 current number of faces: 8300000 current number of faces: 8200000 current number of faces: 8100000 current number of faces: 8000000 current number of faces: 7900000 current number of faces: 7800000 current number of faces: 7700000 current number of faces: 7600000 current number of faces: 7500000 current number of faces: 7400000 current number of faces: 7300000 current number of faces: 7200000 current number of faces: 7100000 current number of faces: 7000000 current number of faces: 6900000 current number of faces: 6800000 current number of faces: 6700000 current number of faces: 6600000 current number of faces: 6500000 current number of faces: 6400000 current number of faces: 6300000 current number of faces: 6200000 current number of faces: 6100000 current number of faces: 6000000 current number of faces: 5900000 current number of faces: 5800000 current number of faces: 5700000 current number of faces: 5600000 current number of faces: 5500000 current number of faces: 5400000 current number of faces: 5300000 current number of faces: 5200000 current number of faces: 5100000 current number of faces: 5000000 current number of faces: 4900000 current number of faces: 5000000 current number of faces: 4900000 current number of faces: 4800000 current number of faces: 4700000 current number of faces: 4600000 current number of faces: 4500000 current number of faces: 4400000 current number of faces: 4300000 current number of faces: 4200000 current number of faces: 4100000 current number of faces: 4000000 current number of faces: 4100000 current number of faces: 4200000 current number of faces: 4300000 current number of faces: 4400000 current number of faces: 4500000 current number of faces: 4600000 Face Quality Faces Percent < 0.001 668 0.0 < 0.01 1140 0.0 < 0.05 2086 0.0 < 0.1 3310 0.1 < 0.2 7927 0.2 < 0.3 14634 0.3 < 0.4 24830 0.5 < 0.5 47539 1.0 < 0.6 111392 2.4 < 0.7 268694 5.7 < 0.8 855480 18.2 < 0.9 3050971 65.0 < 1.0 4694456 100.0 Worst quality is 0 starting: Improve Quality current number of faces: 4700000 current number of faces: 4800000 current number of faces: 4900000 Postprocessing found 684 intersections, involving 587 edges, 334 faces, in 39 groups split 60 edges moved 98 vertices now have 681 intersections, involving 618 edges, 347 faces, in 34 groups removed 3 intersections collapsed 6 edges 584 faces with quality below 0.05 fixing poor quality and remaining intersections 177 pierced faces remaining 139 pierced faces remaining 137 pierced faces remaining 4 faces with quality below 0.05 Warning: 247 intersecting edges remaining Warning: 137 intersected faces remaining Face Quality Faces Percent < 0.001 1 0.0 < 0.01 1 0.0 < 0.05 4 0.0 < 0.1 174 0.0 < 0.2 1077 0.0 < 0.3 2151 0.0 < 0.4 4466 0.1 < 0.5 6741 0.1 < 0.6 11711 0.2 < 0.7 35947 0.7 < 0.8 311663 6.4 < 0.9 1673011 34.6 < 1.0 4839098 100.0 Worst quality is 0.0001336 final number of faces: 4839098 Aligned mesh created for 312 surfaces out of a total of 9945 surfaces. 2689 thin surfaces fully removed out of 4097 candidate thin surfaces (out of a total of 9945 surfaces).  Surface Remesher Completed: CPU Time: 3053.02, Wall Time: 3056.30, Memory: 18957.27 MB  Following Parts are Self Intersecting Surface Wrapper Command: GenerateVolumeMesh error: Server Error Following Parts are Self Intersecting Surface Wrapper Command: GenerateVolumeMesh command: CommandComplete error: Server Error Design STARCCM+ simulation completed Server process exited with code : 0 

July 20, 2018, 12:01 

#3 
Member
André Pinto
Join Date: Oct 2017
Posts: 81
Rep Power: 4 
Started by running the Surface Mesh and having a look at it. I don't know why, but I'm having problem at Contact Patch of the tyres (which I created to avoid problems when CFD!), here are some screen shots! What can/should I do at this area to avoid this distortion of the mesh?
https://imgur.com/uiGJyQW https://imgur.com/xuRrsyc https://imgur.com/vBt1eWs All the rest of the car and mesh, appear to be solid and good quality! 

July 21, 2018, 04:04 

#4 
Senior Member
Ping
Join Date: Mar 2009
Posts: 376
Rep Power: 14 
this is not the way tires are normally done since they compress on the road so it is best to have flat consuming some of the tire and also maybe a chamfer between the round of the tire and the road
cant see your road either but the surface wrapper surface is certainly not good so you can inspect it in the surface repair tool and work out how to improve the geometry or add some more local refinement or fine tune the wrapper settings 

July 23, 2018, 07:10 

#5 
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André Pinto
Join Date: Oct 2017
Posts: 81
Rep Power: 4 
Hi! Before all, let me thank you for your answer and help!
I did my contact patch based on that! I consumed 2mm of the tyre (Note that the tyres have camber, so thats why the contact patch is not in the centre), after consuming 2mm of the tires, i draw a rectangle around that area and extruded to the tyre to increase the smallest size of the geometry. THe thing is that when I used Surface Wrapper before, it was ok doing the mesh, so I never really used refinement of Surface Wrapper or any advanced repair tools! Is there any tutorial that can give me around? On Surface Wrapper I assigned a refinement on that area of contact patch (Target: 1mm, Minimum: 0.5mm), and now I'm trying to run Contact Prevention and Wrapper Defeature between the Tyre itself (not contact patch) and the floor! Is there other Wrapper settings or tweaks I can use to improve the mesh on this zone? Thank you 

July 23, 2018, 07:37 

#6 
Member
André Pinto
Join Date: Oct 2017
Posts: 81
Rep Power: 4 
Also, I'm not using Automatic Surface Repair, do you think this could help solve the problem? I'll try to put another computer to run and use this tool!


July 23, 2018, 13:16 

#7 
Member
André Pinto
Join Date: Oct 2017
Posts: 81
Rep Power: 4 
For those who face the same problem. I solved it by using contact prevention and refine a little bit more the area around the contact patch!
Also, on another computer, using the Automatic Surface Repair included in the Automated Mesh seemed to helped and fix the surface at that zone! 

July 24, 2018, 01:14 

#8 
Senior Member
Ping
Join Date: Mar 2009
Posts: 376
Rep Power: 14 
glad to hear
surface wrapping is a powerful tool with many settings but does take time to both learn to use well and even then you need to sometimes do quite a few wraps to get the detail required or fix problems read the help as it explains all the options and also has at least two good tutorials in the mesh section that new users should do 

August 1, 2018, 23:38 

#9 
New Member
Owen
Join Date: Aug 2018
Posts: 20
Rep Power: 3 
It looks like you wrapped with 29M faces and the used the remember to coarsen it down to 4M faces. The remesh surface is the one with the intersections. The wrapper reports none.
It can be common to use the remesher to coarsen a wrapped surface but this might be extreme. If you are happy with the wrapped surface: Check the remember settings for the parts which have intersecting faces (find those in manual repair) and use some customs controls to refine those areas. Maybe, however you don’t need to wrap so finely? 

August 2, 2018, 07:51 

#10  
Member
André Pinto
Join Date: Oct 2017
Posts: 81
Rep Power: 4 
Quote:


August 2, 2018, 08:48 

#11 
New Member
Owen
Join Date: Aug 2018
Posts: 20
Rep Power: 3 
They’re not the same. What is most likely happening is that you’re viewing the root description of the surface wrapper part instead of the remember description.
In the scene displayer property sheet, down at the bottom there is a field for which description to display. 

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