snappyHexMesh type castellatedBufferLayer crashes when using addBufferLayers false and true for adjacent patches

Summary

The new buffer layer feature of SnappyHexMesh looks awesome, but there are still some bugs to fix. This one is about fatal error crashing, which takes place when addBufferLayers false is specified for one patch, addBufferLayers true is specified for another patch, and the patches are next to each other, sharing some edges.

Steps to reproduce

See example case

Example case

This example case has walls patch, and top patch of a cube, with different setting of addBufferLayers. Run blockMesh, surfaceFeatureExtract and snappyHexMesh to reproduce

bugcase.zip

What is the current bug behaviour?

Crashing with following fatal error:

--> FOAM FATAL ERROR: (openfoam-2412)
Inconsistent sizes. samples:2482 search-radius:2402

    From static void Foam::searchableSurfacesQueries::findNearest(const Foam::PtrList<Foam::searchableSurface>&, const Foam::labelList&, const Foam::pointField&, const Foam::scalarField&, Foam::labelList&, Foam::List<Foam::PointIndexHit<Foam::Vector<double> > >&)
    in file searchableSurfaces/searchableSurfacesQueries/searchableSurfacesQueries.C at line 362.

What is the expected correct behavior?

No crashing. Buffer layers added to specified patches only.

Environment information

• OpenFOAM version : v2412, installed from prebuilt deb packages
• Operating system : ubuntu
• Hardware info : x64
• Compiler : gcc

added community label

@Mattijs

I confirm that the case attached above crashes using:

runApplication blockMesh
runApplication surfaceFeatureExtract
runApplication snappyHexMesh

Environment:

    base1    = develop
    api      = 2412
    HEAD     = 2e1552dd30
    version  = v2412
    compiler = Clang (system)
             = clang version 15.0.7
    mpi      = SYSTEMOPENMPI
             = mpirun (Open MPI) 1.10.7.0.5e373bf1fd
    OS       = Description:     openSUSE Leap 15.5
    opts     = linux64ClangDPInt32Opt

mentioned in issue #3302

#3302 shows similar crashing error message

Does it work with the fix from #3302 ?

Sorry I don't see any fix for #3302..?

Maybe this one : #3297 (closed)

I compiled Build: 4fe3f55e-20250110 OPENFOAM=2412 version=v2412 which contains the fix for #3297 (closed), and using that the issue seems to fixed! Thanks! I will check if it fixes also #3302 tomorrow.

closed