ENH: blockMesh: generate duplicate boundary faces. Fixes #1516

src/OpenFOAM/meshes/polyMesh/polyMeshFromShapeMesh.C

@@ -285,6 +285,7 @@ void Foam::polyMesh::setTopology
     }
 
     // Do boundary faces
+    const label nInternalFaces = nFaces;
 
     patchSizes.setSize(boundaryFaces.size(), -1);
     patchStarts.setSize(boundaryFaces.size(), -1);
@@ -305,6 +306,9 @@ void Foam::polyMesh::setTopology
         // Grab the start label
         label curPatchStart = nFaces;
 
+        // Suppress multiple warnings per patch
+        bool patchWarned = false;
+
         forAll(patchFaces, facei)
         {
             const face& curFace = patchFaces[facei];
@@ -320,25 +324,75 @@ void Foam::polyMesh::setTopology
             {
                 if (face::sameVertices(facesOfCellInside[cellFacei], curFace))
                 {
-                    if (cells[cellInside][cellFacei] >= 0)
+                    found = true;
+
+                    const label meshFacei = cells[cellInside][cellFacei];
+
+                    if (meshFacei >= 0)
+                    {
+                        // Already have mesh face for this side of the
+                        // cellshape. This can happen for duplicate faces.
+                        // It might be
+                        // an error or explicitly desired (e.g. duplicate
+                        // baffles or acmi). We could have a special 7-faced
+                        // hex shape instead so we can have additional patches
+                        // but that would be unworkable. 
+                        // So now either
+                        // - exit with error
+                        // - or warn and append face to addressing
+                        // Note that duplicate baffles
+                        // - cannot be on an internal faces
+                        // - cannot be on the same patch (for now?)
+
+                        if
+                        (
+                            meshFacei < nInternalFaces
+                         || meshFacei >= curPatchStart
+                        )
                         {
                             FatalErrorInFunction
-                            << "Trying to specify a boundary face " << curFace
+                                << "Trying to specify a boundary face "
+                                << curFace
                                 << " on the face on cell " << cellInside
-                            << " which is either an internal face or already "
+                                << " which is either an internal face"
-                            << "belongs to some other patch.  This is face "
+                                << " or already belongs to the same patch."
-                            << facei << " of patch "
+                                << " This is face " << facei << " of patch "
                                 << patchi << " named "
                                 << boundaryPatchNames[patchi] << "."
-                            << abort(FatalError);
+                                << exit(FatalError);
                         }
 
-                    found = true;
+
+                        if (!patchWarned)
+                        {
+                            WarningInFunction
+                                << "Trying to specify a boundary face "
+                                << curFace
+                                << " on the face on cell " << cellInside
+                                << " which is either an internal face"
+                                << " or already belongs to some other patch."
+                                << " This is face " << facei << " of patch "
+                                << patchi << " named "
+                                << boundaryPatchNames[patchi] << "."
+                                //<< abort(FatalError);
+                                << endl;
+                            patchWarned = true;
+                        }
+
+                        faces_.setSize(faces_.size()+1);
 
                         // Set the patch face to corresponding cell-face
                         faces_[nFaces] = facesOfCellInside[cellFacei];
 
+                        cells[cellInside].append(nFaces);
+                    }
+                    else
+                    {
+                        // Set the patch face to corresponding cell-face
+                        faces_[nFaces] = facesOfCellInside[cellFacei];
+
                         cells[cellInside][cellFacei] = nFaces;
+                    }
 
                     break;
                 }
@@ -384,8 +438,6 @@ void Foam::polyMesh::setTopology
 
     // Reset the size of the face list
     faces_.setSize(nFaces);
-
-    return ;
 }
 
 

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/0/U

@@ -21,6 +21,8 @@ internalField   uniform (0 0 0);
 
 boundaryField
 {
+    #includeEtc "caseDicts/setConstraintTypes"
+
     inlet
     {
         type            fixedValue;
@@ -37,28 +39,14 @@ boundaryField
         type            movingWallVelocity;
         value           uniform (0 0 0);
     }
-    defaultFaces
-    {
-        type            empty;
-    }
     ACMI1_blockage
     {
         type            noSlip;
     }
-    ACMI1_couple
-    {
-        type            cyclicACMI;
-        value           uniform (0 0 0);
-    }
     ACMI2_blockage
     {
         type            noSlip;
     }
-    ACMI2_couple
-    {
-        type            cyclicACMI;
-        value           uniform (0 0 0);
-    }
 }
 
 

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/0/epsilon

@@ -21,6 +21,8 @@ internalField   uniform 1.8e-3;
 
 boundaryField
 {
+    #includeEtc "caseDicts/setConstraintTypes"
+
     inlet
     {
         type            fixedValue;
@@ -37,30 +39,16 @@ boundaryField
         type            epsilonWallFunction;
         value           $internalField;
     }
-    defaultFaces
-    {
-        type            empty;
-    }
     ACMI1_blockage
     {
         type            epsilonWallFunction;
         value           $internalField;
     }
-    ACMI1_couple
-    {
-        type            cyclicACMI;
-        value           $internalField;
-    }
     ACMI2_blockage
     {
         type            epsilonWallFunction;
         value           $internalField;
     }
-    ACMI2_couple
-    {
-        type            cyclicACMI;
-        value           $internalField;
-    }
 }
 
 

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/0/k

@@ -21,6 +21,8 @@ internalField   uniform 3.75e-3;
 
 boundaryField
 {
+    #includeEtc "caseDicts/setConstraintTypes"
+
     inlet
     {
         type            fixedValue;
@@ -37,30 +39,16 @@ boundaryField
         type            kqRWallFunction;
         value           $internalField;
     }
-    defaultFaces
-    {
-        type            empty;
-    }
     ACMI1_blockage
     {
         type            kqRWallFunction;
         value           $internalField;
     }
-    ACMI1_couple
-    {
-        type            cyclicACMI;
-        value           $internalField;
-    }
     ACMI2_blockage
     {
         type            kqRWallFunction;
         value           $internalField;
     }
-    ACMI2_couple
-    {
-        type            cyclicACMI;
-        value           $internalField;
-    }
 }
 
 

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/0/nut

@@ -21,6 +21,8 @@ internalField   uniform 0;
 
 boundaryField
 {
+    #includeEtc "caseDicts/setConstraintTypes"
+
     inlet
     {
         type            fixedValue;
@@ -37,30 +39,16 @@ boundaryField
         type            nutkWallFunction;
         value           $internalField;
     }
-    defaultFaces
-    {
-        type            empty;
-    }
     ACMI1_blockage
     {
         type            nutkWallFunction;
         value           $internalField;
     }
-    ACMI1_couple
-    {
-        type            cyclicACMI;
-        value           $internalField;
-    }
     ACMI2_blockage
     {
         type            nutkWallFunction;
         value           $internalField;
     }
-    ACMI2_couple
-    {
-        type            cyclicACMI;
-        value           $internalField;
-    }
 }
 
 

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/0/p

@@ -21,6 +21,8 @@ internalField   uniform 0;
 
 boundaryField
 {
+    #includeEtc "caseDicts/setConstraintTypes"
+
     inlet
     {
         type            zeroGradient;
@@ -42,28 +44,14 @@ boundaryField
     {
         type            zeroGradient;
     }
-    defaultFaces
-    {
-        type            empty;
-    }
     ACMI1_blockage
     {
         type            zeroGradient;
     }
-    ACMI1_couple
-    {
-        type            cyclicACMI;
-        value           uniform 0;
-    }
     ACMI2_blockage
     {
         type            zeroGradient;
     }
-    ACMI2_couple
-    {
-        type            cyclicACMI;
-        value           uniform 0;
-    }
 }
 
 

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/Allclean

@@ -1,8 +0,0 @@
-#!/bin/sh
-cd "${0%/*}" || exit                                # Run from this directory
-. ${WM_PROJECT_DIR:?}/bin/tools/CleanFunctions      # Tutorial clean functions
-#------------------------------------------------------------------------------
-
-cleanCase0
-
-#------------------------------------------------------------------------------

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/Allrun

@@ -1,10 +0,0 @@
-#!/bin/sh
-cd "${0%/*}" || exit                                # Run from this directory
-. ${WM_PROJECT_DIR:?}/bin/tools/RunFunctions        # Tutorial run functions
-#------------------------------------------------------------------------------
-
-./Allrun.pre
-
-runApplication $(getApplication)
-
-#------------------------------------------------------------------------------

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/Allrun-parallel

@@ -3,7 +3,7 @@ cd "${0%/*}" || exit                                # Run from this directory
 . ${WM_PROJECT_DIR:?}/bin/tools/RunFunctions        # Tutorial run functions
 #------------------------------------------------------------------------------
 
-./Allrun.pre
+runApplication blockMesh
 
 runApplication decomposePar
 runParallel $(getApplication)

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/Allrun.pre

@@ -1,15 +0,0 @@
-#!/bin/sh
-cd "${0%/*}" || exit                                # Run from this directory
-. ${WM_PROJECT_DIR:?}/bin/tools/RunFunctions        # Tutorial run functions
-#------------------------------------------------------------------------------
-
-runApplication blockMesh
-
-runApplication topoSet -constant
-
-# Split the mesh to generate the ACMI coupled patches
-runApplication createBaffles -overwrite
-
-restore0Dir
-
-#------------------------------------------------------------------------------

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/README

@@ -52,7 +52,17 @@ In the above, the ACMI1_blockage and ACMI1_couple patches occupy the same space,
 with duplicate points, edges and faces.  The ACMI2_blockage and ACMI2_couple
 patches are created similarly.
 
-The duplicate patches are initially created using the createBaffles utility.
+The duplicate patches are either created within blockMesh or using the
+createBaffles utility. Using the blockMesh path will result in a warning
+message of the form
+
+    'Trying to specify a boundary face '
+    'already belongs to some other patch'
+
+since there are now in total 7 faces defined for the hex shape and blockMesh
+does not yet know whether the definition is incorrect.
+
+Using the createBaffles utility is slightly more work.
 Firstly, the original (non-duplicated) patch faces are collected into zones
 using the topoSet utility.
 
@@ -109,8 +119,8 @@ the same as when operating in serial mode.
 
 checkMesh
 ---------
-checkMesh will see the 'duplicate' boundary faces but does not know about
+Older versions of checkMesh would see the 'duplicate' boundary faces before
-the area factors so will complain:
+the area factors were know so would complain:
 
      ***Boundary openness (-0.0103092 2.3845e-17 3.80774e-17) possible hole in boundary description.
      ***Open cells found, max cell openness: 0.333333, number of open cells 136
@@ -118,6 +128,25 @@ the area factors so will complain:
 
 As long as these non-closed cells are on the ACMI they can be ignored.
 
+In current checkMesh the area factors are updated before the check:
+
+    AMI: Creating addressing and weights between 40 source faces and 96 target faces
+    AMI: Patch source sum(weights) min:1 max:1 average:1
+    AMI: Patch target sum(weights) min:0 max:1 average:0.4
+    ACMI: Patch source uncovered/blended/covered = 0, 0, 40
+    ACMI: Patch target uncovered/blended/covered = 56, 2, 38
+
+
+pimpleFoam
+----------
+In the 'createBaffles' method the ACMI patches would be created after
+the 'empty' patch. In the 'blockMesh' method however the 'empty' patch
+will be last. This results in a slight difference in face ordering which
+is enough to give a slightly different truncation error in the geometry
+calculation and hence in the results. For all practical purposes however the
+results are the same. For cases which do not have 'empty' patches (i.e. 2D)
+this limitation does not apply.
+
 
 paraFoam
 --------

tutorials/incompressible/pimpleFoam/RAS/oscillatingInletACMI2D/system/blockMeshDict

@@ -41,7 +41,7 @@ blocks
 (
 //    hex (0 1 2 3 4 5 6 7) (20 20 1) simpleGrading (1 1 1)
 //    hex (8 9 10 11 12 13 14 15) (40 48 1) simpleGrading (1 1 1)
-    hex (0 1 2 3 4 5 6 7) (80 40 1) simpleGrading (1 1 1)
+    hex (0 1 2 3 4 5 6 7) inletChannel (80 40 1) simpleGrading (1 1 1)
     hex (8 9 10 11 12 13 14 15) (80 96 1) simpleGrading (1 1 1)
 );
 
@@ -78,17 +78,37 @@ boundary
             (9 13 12 8)
         );
     }
-    couple1
+    ACMI1_couple
     {
-        type patch;
+        type            cyclicACMI;
+        neighbourPatch  ACMI2_couple;
+        nonOverlapPatch ACMI1_blockage;
         faces
         (
             (2 6 5 1)
         );
     }
-    couple2
+    ACMI1_blockage
     {
-        type patch;
+        type wall;
+        faces
+        (
+            (2 6 5 1)
+        );
+    }
+    ACMI2_couple
+    {
+        type            cyclicACMI;
+        neighbourPatch  ACMI1_couple;
+        nonOverlapPatch ACMI2_blockage;
+        faces
+        (
+            (8 12 15 11)
+        );
+    }
+    ACMI2_blockage
+    {
+        type wall;
         faces
         (
             (8 12 15 11)
@@ -96,8 +116,5 @@ boundary
     }
 );
 
-mergePatchPairs
-(
-);
 
 // ************************************************************************* //