Component 5, (Nacelle_Top) and Component 7 (Nacelle_Bottom) are experiencing failure to mesh. Can you take a look? It might be obvious to you.

Here's a download link to the compressed project file for your review. Please see my comment for a better Component map image for reference.

Edit: I've even tried performing the meshing operation using Salome-Meca. Meshing just one stl fails with it too, but unlike TCAE, takes several hours to fail completely. The component 5 (fuchsia) is Nacelle_Top, the patch in question is named Solid_Top_Bell-Mouth_inlet_and_Duct_Surface_08_21_25a.

I suspect Nacelle_Bottom is going to be just as bad, or worse, than Nacelle_Top. It is slightly smaller in diameter, but it's a more complicated surface.

Thanks in advance,

David

The previous iteration of this TCAE project experimented with omitting a central component from the topology, the Duct_Separator, going from the Top_Fan rim (sometimes called a hub, in this case an open outlet interface), through which air not used by the Top_Fan flows from the Top_System_Suction outlet interface, and continues directly to the inlet interface of the Bottom_Fan open rim, skipping the Duct Separator. Confusing, I know, but the Bottom_Fan is upside-down compared to the Top_Fan, so it takes in air not from the shroud inlet interface, as in the case of the Top_Fan, but from the Bottom_Fan's open rim inlet interface.

This iteration is more like the actual setup, Suction, Top_Fan, Duct_Separator, Bottom_Fan, Nacelle, Outlet_Extension. Please see my comment for a more complete image of the Component Map.

Who knows? It might eliminate some setup errors seen previously.

I'm following along with Webinar 67. When I get to the point of using Mesh all, it pukes and says there's a problem with the setup. Using Check, it lists 4448_Top_Fan_Union_Outlet_Interface_06_18_25_meters in Component 2, Top Fan, doesn't have a partner. Upon inspection, it appears that the offending patch does indeed have a partner. Please see the image. How should I proceed?

Just when I thought I had interfaces getting close to being set up with the project saved and closed....upon reloading the project, TCAE quits!

No warnings, no alerts. TCAE just quits.

In anticipation of posting this topic, I uploaded the project and STLs for your review. Please find download links in comments.

Please look for TCAE_07_27_25.zip for the project file and 4448_06_23_25_STL.zip for folders and patches.

Have you any ideas on how to proceed to fix the project?

Please let me know if you have any problems accessing or downloading the zip files.

Thanks in advance,

David

I'm amazed at the Check functionality. I've been eliminating one similar error after another until now.
From the directory for the component named "Top_Fan", I copied and pasted an interface patch (.stl) into the directory for the component named "Hull__Inlet__Outlet", same file name, same type: "outletInterface" with the intention to prevent this from happening. It seems to me that in that instance it should be an inletInterface (just saying, I tried it that way...didn't help), Static Reference frame, another, different component.
Setup Problem is displayed upon selecting Check, listing the source, the copied patch in Top_Fan as the problem.

When I go into the Top_Fan component to connect the patch to the patch of same name in the Hull__Inlet__Outlet component, I don't see it listed as a choice, nor do any of the available listed options seem to work.
Changing the name slightly of the file in Hull__Inlet__Outlet had no effect.

How can I fix this? I'm stuck. Your help is appreciated in advance.

David

A common inlet at the top feeds two (identical) centrifugal fans. I tried to connect Top_System_inlet_interface (identical to but different in name as suction outlet interface) to serve double-duty as outlet interface to both the Top_Fan (rotating) AND Bottom_Fan (rotating).

It seemed that wasn't working so it occurred to me that connecting a copy of the object with another name might. Sure enough! It seems to have worked.

How would you have done it?

The instructions are as follows:

To create two meridional slices, one for each fan in TCAE, follow these step-by-step instructions:

1. Load the Simulation Results: Open your TCAE project and load the results of your simulation for the fans.

2. Select the First Fan:

   • In the Pipeline Browser, select the mesh or results corresponding to the first fan.

3. Add a Meridional Average Filter:

   • Go to the Filters menu.
   • Select "Turbomachinery" and then choose "Meridional Average."

I am not presently seeing any geometry in the Pipeline Browser, so, I tried double-clicking the individual STLs making up the component in CFD Mesh, (later realizing selecting multiple elements is not supported) then going to the Filters menu, selecting Turbomachinery,  the option "Meridional Average."  is greyed out, please see image.

I'm still at the beginning setup phase; loading geometry and tweaking types and interfaces. I have no results of any simulation to load. I have not tried to create a mesh yet. Is that (or something else) I need to do first besides read the manual?

Thanks in advance

David

I'm not wanting to re-import geometry, although that's most certainly what I'm preparing for at the moment. All the STLs were created using the _ExportWithOrigin command with World origin as basepoint in Rhino, so I'm scratching my head, as usual. Importing the offending object back into a "top" drawing, an assembly-of-all-parts model, and aligning it to it's exact position, then re-exporting it and replace the file having the wrong origin is what I'll try next.

Is there any easy way to manipulate objects once they've been imported?

Please see my comment, button at bottom right. Thanks.

Please see my comments, below, for Fan and Duct Separator info.
Question:  For the case with a closed bottom system inlet,  is the Reference Frame of the Top Fan Open Rim interface, that's the second "surface" boundary that the incoming air encounters on it's way to join the other half; is it static, rotating, or freestream? Shared inlet air flows through it to the inlet of the bottom fan. How about it's type?

Same question for bottom fan except, because it is upside-down compared to the top fan; what is the reference frame of the Bottom Fan Open-Rim Interface? While we're at it, how about the Bottom Fan Shroud Interface? Closed bottom inlet, remember?; are they static, rotating, or freestream? Type?

From the shared inlet at the top of an axi-symmetric radial discharge duct, aka Volute or Hull, one-half of the flow first enters between the Top Fan Shroud  and  Rim, then blade passages, exits the fan, rides a cosine curve down to join the other half geometrically  mirrored about the X-axis, which has become the Bottom Fan discharge, combines radially without colliding too much, then downward smoothly toward axial, but not exactly.

I have an idea for dynamic stability, could be combined with distance between cg and center-of- lift asymmetry.

Closed Bottom Duct Surface and Duct Separator not shown for clarity. No bottom inlet opening for first simulation case. System outlet is a 0.83 [m] outside diameter annulus of appropriate area for combined fan discharge.

The Fans: each identical, one-piece solid poly-surface Boolean union of rim, shroud, and blade array has open rim, no hub, mounted to a 0.315 [m] OD carbon fiber rim bicycle wheel.

Thanks in advance.

David

I simply started a new project importing geometry from scratch, more than just a few times, with it suddenly collapsing the import window after using Ctrl-C and having selected fewer than the 17 desired STLs, an attempted correction of the duplicate issue, then having to start over from scratch. I've done that at least a half-a-dozen times. grrrr!

Hi,

I have a problem with report at the end?

Program made all 3000 iteration ( about 1.200.000 pcs), but at the end is allways problem with the report: (see picture below).

Thanks.

Hi,

I have a problem with report at the end?

Program made all 3000 iteration ( about 1.200.000 pcs), but at the end is allways problem with the report: (see picture below).

Thanks.

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Hi! I'm a beginner CFD user, and I've encountered a strange bug with my mesh. When I reduce the firstLayerThickness to a smaller value, the mesh stops working. The layer doesn't generate properly, and I get an error saying my refineBox isn't inside my blockMesh, which is incorrect.