Melt pool dimensions (#77)

add function object for tracking melt pool dimensions provided a list of isotherms and a scan path angle

---------

Co-authored-by: Gerry Knapp <knappgl@ornl.gov>

Author: colemanjs

applications/solvers/additiveFoam/functionObjects/Make/files

@@ -1,4 +1,5 @@
 ExaCA/ExaCA.C
 solidificationData/solidificationData.C
+meltPoolDimensions/meltPoolDimensions.C
 
 LIB = $(FOAM_USER_LIBBIN)/libadditiveFoamFunctionObjects

applications/solvers/additiveFoam/functionObjects/meltPoolDimensions/meltPoolDimensions.C

@@ -0,0 +1,308 @@
+/*---------------------------------------------------------------------------*\
+  =========                 |
+  \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox
+   \\    /   O peration     | Website:  https://openfoam.org
+    \\  /    A nd           | Copyright (C) 2024 OpenFOAM Foundation
+     \\/     M anipulation  |
+-------------------------------------------------------------------------------
+                Copyright (C) 2023 Oak Ridge National Laboratory                
+-------------------------------------------------------------------------------
+License
+    This file is part of OpenFOAM.
+
+    OpenFOAM is free software: you can redistribute it and/or modify it
+    under the terms of the GNU General Public License as published by
+    the Free Software Foundation, either version 3 of the License, or
+    (at your option) any later version.
+
+    OpenFOAM is distributed in the hope that it will be useful, but WITHOUT
+    ANY WARRANTY; without even the implied warranty of MERCHANTABILITY or
+    FITNESS FOR A PARTICULAR PURPOSE.  See the GNU General Public License
+    for more details.
+
+    You should have received a copy of the GNU General Public License
+    along with OpenFOAM.  If not, see <http://www.gnu.org/licenses/>.
+
+\*---------------------------------------------------------------------------*/
+
+#include "meltPoolDimensions.H"
+#include "Time.H"
+#include "fvMesh.H"
+#include "addToRunTimeSelectionTable.H"
+#include "volFields.H"
+#include "fvc.H"
+#include "OSspecific.H"
+#include "labelVector.H"
+
+// * * * * * * * * * * * * * * Static Data Members * * * * * * * * * * * * * //
+
+namespace Foam
+{
+namespace functionObjects
+{
+    defineTypeNameAndDebug(meltPoolDimensions, 0);
+    
+    addToRunTimeSelectionTable
+    (
+        functionObject,
+        meltPoolDimensions,
+        dictionary
+    );
+}
+}
+
+// * * * * * * * * * * * * * * * * Constructors  * * * * * * * * * * * * * * //
+
+Foam::functionObjects::meltPoolDimensions::meltPoolDimensions
+(
+    const word& name,
+    const Time& runTime,
+    const dictionary& dict
+)
+:
+    fvMeshFunctionObject(name, runTime, dict),
+    T_(mesh_.lookupObject<VolField<scalar>>("T"))
+{
+    read(dict);
+    
+    if (Pstream::master())
+    {
+        const fileName probeDir
+        (
+            mesh_.time().rootPath()/mesh_.time().globalCaseName()
+           /"postProcessing"/"meltPoolDimensions"
+        );
+
+        mkDir(probeDir);
+
+        logFilePtrs_.setSize(isoValues_.size());
+
+        forAll(isoValues_, i)
+        {
+            const fileName logFileName
+            (
+                probeDir/Foam::name(isoValues_[i]) + ".csv"
+            );
+            
+            Info<< "melt pool dimensions log file name: "
+                << logFileName << endl;
+
+            logFilePtrs_.set
+            (
+                i,
+                new OFstream(logFileName)
+            );
+            
+            logFilePtrs_[i] << "time(s),length(m),width(m),depth(m)" << endl;
+        }
+    }
+}
+
+
+// * * * * * * * * * * * * * * * * Destructor  * * * * * * * * * * * * * * * //
+
+Foam::functionObjects::meltPoolDimensions::~meltPoolDimensions()
+{}
+
+
+// * * * * * * * * * * * * * * * Member Functions  * * * * * * * * * * * * * //
+
+bool Foam::functionObjects::meltPoolDimensions::read(const dictionary& dict)
+{
+    isoValues_ = dict.lookup<scalarList>("isoValues");
+    scanPathAngle_ = dict.lookupOrDefault<scalar>("scanPathAngle", 0.0);
+    
+    return true;
+}
+
+Foam::wordList Foam::functionObjects::meltPoolDimensions::fields() const
+{
+    return wordList::null();
+}
+
+bool Foam::functionObjects::meltPoolDimensions::execute()
+{
+    const labelUList& owner = mesh_.owner();
+    const labelUList& neighbour = mesh_.neighbour();
+    
+    const volVectorField& cc = mesh_.C();
+
+    const scalar radians =
+        scanPathAngle_ * ( Foam::constant::mathematical::pi / 180.0 );
+
+    const scalar s = sin(radians);
+    const scalar c = cos(radians);
+  
+    List<treeBoundBox> boundBoxes
+    (
+        isoValues_.size(),
+        treeBoundBox(point::max, point::min)
+    );
+
+    // check internal faces
+    for(label facei=0; facei < mesh_.nInternalFaces(); facei++)
+    {        
+        const label own = owner[facei];
+        const label nei = neighbour[facei];
+
+        scalar minFace = min(T_[own], T_[nei]);
+        scalar maxFace = max(T_[own], T_[nei]);
+
+        forAll(isoValues_, i)
+        {
+            const scalar iso_ = isoValues_[i];
+
+            // update the bounding box
+            if ((minFace < iso_) && (maxFace >= iso_))
+            {
+                vector d = cc[nei] - cc[own];
+                
+                vector p =
+                    cc[own] + d*(iso_ - T_[own])/(T_[nei] - T_[own]);
+
+                    vector p_rotated
+                    (
+                        p.x() * c + p.y() * s,
+                        p.y() * c - p.x() * s,
+                        p.z()
+                    );
+                
+                boundBoxes[i].min() =
+                    min(p_rotated, boundBoxes[i].min());
+
+                boundBoxes[i].max() =
+                    max(p_rotated, boundBoxes[i].max());
+            }
+        }
+    }
+
+    // check boundary faces
+    const volScalarField::Boundary& TBf = T_.boundaryField();
+    
+    forAll(TBf, patchi)
+    {   
+        const fvPatchScalarField& TPf = TBf[patchi];
+
+        const labelUList& faceCells = TPf.patch().faceCells();
+
+        if (TPf.coupled())
+        {
+            // processor boundary : interpolate across face
+            const vectorField ccn
+            (
+                cc.boundaryField()[patchi].patchNeighbourField()
+            );
+            
+            const scalarField fn(TPf.patchNeighbourField());
+
+            forAll(faceCells, facei)
+            {
+                label own = faceCells[facei];
+
+                scalar minFace = min(T_[own], fn[facei]);
+                scalar maxFace = max(T_[own], fn[facei]);
+
+
+                forAll(isoValues_, i)
+                {
+                    const scalar iso_ = isoValues_[i];
+                    
+                    // update the bounding box
+                    if ((minFace < iso_) && (maxFace >= iso_))
+                    {
+                        vector d = ccn[facei] -  cc[own];
+                        
+                        vector p = 
+                            cc[own] + d*(iso_ - T_[own])/(fn[facei] - T_[own]);
+
+                        vector p_rotated
+                        (
+                            p.x() * c + p.y() * s,
+                            p.y() * c - p.x() * s,
+                            p.z()
+                        );
+                        
+                        boundBoxes[i].min() =
+                            min(p_rotated, boundBoxes[i].min());
+
+                        boundBoxes[i].max() =
+                            max(p_rotated, boundBoxes[i].max());
+                    }
+                }
+            }
+        }
+        else
+        {
+            // physical boundary : take face point if above iso value
+            const vectorField& Cf = mesh_.Cf().boundaryField()[patchi];
+          
+            const scalarField& pif(TPf.patchInternalField());
+            
+            forAll(faceCells, facei)
+            {
+                scalar maxFace = max(pif[facei], TPf[facei]);
+                
+                forAll(isoValues_, i)
+                {
+                    const scalar iso_ = isoValues_[i];
+                    
+                    if (maxFace >= iso_)
+                    {
+                        const vector& p = Cf[facei];
+                        
+                        vector p_rotated
+                        (
+                            p.x() * c + p.y() * s,
+                            p.y() * c - p.x() * s,
+                            p.z()
+                        );
+                        
+                        boundBoxes[i].min() =
+                            min(p_rotated, boundBoxes[i].min());
+
+                        boundBoxes[i].max() =
+                            max(p_rotated, boundBoxes[i].max());
+                    }
+                }
+            }
+        }
+    }
+    
+    forAll(isoValues_, i)
+    {
+        reduce(boundBoxes[i].min(), minOp<point>());
+        reduce(boundBoxes[i].max(), maxOp<point>());
+    }
+    
+    // update the melt pool dimensions log files
+    if (Pstream::master())
+    {
+        forAll(isoValues_, i)
+        {
+            vector dimensions = max(boundBoxes[i].span(), vector::zero);
+            
+            OFstream& logFile = logFilePtrs_[i];
+                        
+            logFile<< mesh_.time().value() << ","
+                   << dimensions.x() << ","
+                   << dimensions.y() << ","
+                   << dimensions.z() << endl;
+        }
+    }
+
+    return true;
+}
+
+bool Foam::functionObjects::meltPoolDimensions::end()
+{
+    return true;
+}
+
+
+bool Foam::functionObjects::meltPoolDimensions::write()
+{
+    return true;
+}
+
+
+// ************************************************************************* //