added support for multilayer tutorial to use multiple scan paths from…

applications/utilities/createScanPath/createFields.H

@@ -43,6 +43,8 @@ namespace Foam
                             Struct Point Definition
 \*---------------------------------------------------------------------------*/
 
+const scalar tolerance = 1e-10;
+
 struct Point
 {
     scalar x;
@@ -171,8 +173,10 @@ struct BoundBox
     // Function to check if a point is inside the bounding box
     bool isInside( Point p )
     {
-        return p.x >= minPoint.x && p.x <= maxPoint.x && p.y >= minPoint.y &&
-               p.y <= maxPoint.y;
+        return p.x >= minPoint.x - tolerance &&
+               p.x <= maxPoint.x + tolerance &&
+               p.y >= minPoint.y - tolerance &&
+               p.y <= maxPoint.y + tolerance;
     }
 
     Line cropLine( const Line& line )
@@ -231,7 +235,7 @@ struct BoundBox
             ( x1 - x2 ) * ( y3 - y4 ) - ( y1 - y2 ) * ( x3 - x4 );
 
         // Lines are parallel or colinear, no intersection
-        if ( denominator == 0 )
+        if ( std::abs(denominator) < tolerance )
         {
             return intersection;
         }
@@ -242,7 +246,11 @@ struct BoundBox
         scalar u = -( ( x1 - x2 ) * ( y1 - y3 ) - ( y1 - y2 ) * ( x1 - x3 ) ) /
                    denominator;
 
-        if ( t >= 0 && t <= 1 && u >= 0 && u <= 1 )
+        if
+        (
+            ( t >= -tolerance && t <= 1.0 + tolerance )
+         && ( u >= -tolerance && u <= 1.0 + tolerance )
+        )
         {
             intersection.x = x1 + t * ( x2 - x1 );
             intersection.y = y1 + t * ( y2 - y1 );
@@ -342,6 +350,9 @@ struct Path
     {
         std::ofstream file( filename );
 
+        int precision = static_cast<int>(std::ceil(-std::log10(tolerance)));
+        file << std::fixed << std::setprecision(precision);
+
         file << "Mode\tX(m)\tY(m)\tZ(m)\tPower(W)\ttParam" << std::endl;
 
         for ( size_t i = 0; i < lines.size(); ++i )

applications/utilities/multiLayer/runLayers

@@ -88,22 +88,49 @@ done
 
 args_check $nLayers $layerThickness $nCellsPerLayer
 
-# create case directories
+
+# 1. Find available scan path files
+scanPathFiles=(constant/scanPath_*)
+
+# Check if the globbing found any actual files.
+if [ -e "${scanPathFiles[0]}" ]; then
+    numScanPathFiles=${#scanPathFiles[@]}
+    echo "Found $numScanPathFiles numbered scanPath file(s) to cycle through."
+
+elif [ -f "constant/scanPath" ]; then
+    scanPathFiles=("constant/scanPath")
+    numScanPathFiles=1
+    echo "Found single 'scanPath' file. This will be used for all layers."
+
+else
+    echo "Error: No 'scanPath_*' files or 'scanPath' file found." >&2
+    exit 1
+fi
+
+# 2. Create case directories
+shopt -s extglob
 baseDir=${PWD}
 caseList=()
 for (( layer=0; layer<$nLayers; layer++ ))
 do
     case="$baseDir/layer$layer"
-    caseList+=($case)
-    if [ -d $case ]; then rm -rf $case; fi
-    mkdir $case
+    caseList+=("$case")
+    if [ -d "$case" ]; then rm -rf "$case"; fi
+    mkdir -p "$case/constant" "$case/system"
+
+    cp -r "$baseDir/0" "$case/"
+    cp -r "$baseDir/system"/* "$case/system/"
+
+    cp -r "$baseDir/constant"/!(scanPath|scanPath_*) "$case/constant/"
+    scanPathIndex=$(( layer % numScanPathFiles ))
+    sourceScanPathFile=${scanPathFiles[$scanPathIndex]}
 
-    cp -r "$baseDir/0" $case
-    cp -r "$baseDir/constant" $case
-    cp -r "$baseDir/system" $case
+    echo "Layer $layer: using $sourceScanPathFile"
+    cp "$sourceScanPathFile" "$case/constant/scanPath"
 done
+shopt -u extglob
 
-# extrude mesh in each directory
+# 3. Extrude mesh in case directories
 for (( layer=0; layer<$nLayers; layer++ ))
 do
     case=${caseList[$layer]}
@@ -122,7 +149,7 @@ do
     fi
 done
 
-# update simulation times and run layers sequentially
+# 4. Run all layers
 layerTime="$(cd ${caseList[0]} && foamDictionary -entry endTime -value system/controlDict)"
 
 for (( layer=0; layer<$nLayers; layer++ ))
@@ -142,7 +169,7 @@ do
         foamDictionary -entry startTime -set $time system/controlDict
         foamDictionary -entry endTime -set $endTime system/controlDict
 
-        # update wait time for scan path (assumes repeating scan)
+        # update wait time for scan path
         path=(`sed '2q;d' constant/scanPath`)
         path[5]=$time
         path=`echo $(echo ${path[@]}) | tr ' ' '\t\t'`

tutorials/multiLayerPBF/0/T

@@ -22,7 +22,7 @@ boundaryField
 {
     bottom
     {
-        type            zeroGradient;
+        type            fixedValue;
         value           uniform 300;
     }
     top
@@ -35,7 +35,7 @@ boundaryField
     }
     sides
     {
-        type            zeroGradient;
+        type            fixedValue;
         value           uniform 300;
     }
 }

tutorials/multiLayerPBF/Allclean

@@ -7,6 +7,8 @@ cd ${0%/*} || exit 1    # Run from this directory
 cleanCase
 
 rm -rf layer*
+rm -rf constant/scanPath_*
+
 #------------------------------------------------------------------------------
 rm -rf ExaCA/Output*
 rm -rf ExaCA/time-temperature.csv

tutorials/multiLayerPBF/Allrun

@@ -26,10 +26,14 @@ fi
 # AdditiveFOAM
 runApplication blockMesh
 
-# Change to AdditiveFOAM install path
-path="$WM_PROJECT_INST_DIR/AdditiveFOAM/applications/utilities/multiLayer"
+# Set $ADDITIVEFOAM_INST_DIR path: defaults to $WM_PROJECT_INST_DIR.
+projectDir="${ADDITIVEFOAM_INST_DIR:-$WM_PROJECT_INST_DIR/AdditiveFOAM}"
+path="$projectDir/applications/utilities/multiLayer"
 
-$path/runLayers -nLayers 4 -nCellsPerLayer 4 -layerThickness 40e-6
+# Create scan paths from constant/createScanPathDict
+createScanPath
+
+$path/runLayers -nLayers 2 -nCellsPerLayer 4 -layerThickness 40e-6
 $path/reconstructLayers
 
 #------------------------------------------------------------------------------

tutorials/multiLayerPBF/constant/createScanPathDict

@@ -0,0 +1,36 @@
+/*--------------------------------*- C++ -*----------------------------------*\
+  =========                 |
+  \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox
+   \\    /   O peration     | Website:  https://openfoam.org
+    \\  /    A nd           | Version:  10
+     \\/     M anipulation  |
+\*---------------------------------------------------------------------------*/
+FoamFile
+{
+    version     2.0;
+    format      ascii;
+    class       dictionary;
+    object      createScanPathDict;
+}
+
+// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
+
+minPoint    (0.0 -1e-4);
+
+maxPoint    (0.002 1e-4);
+
+angle       180;
+
+hatch       1e-4;
+
+nRotations  2;
+
+power       195;
+
+speed       0.8;
+
+dwellTime   5e-4;
+
+biDirection true;
+
+// ************************************************************************* //

tutorials/multiLayerPBF/constant/heatSourceDict

@@ -14,15 +14,15 @@ FoamFile
 }
 
 // * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
-
-sources (beam);
-
 /*---------------------------------------------------------------------------*\
 Citation:
     J. Coleman, G.L. Knapp, B. Stump, M. Rolchigo, K. Kincaid, A. Plotkowski,
     A dynamic volumetric heat source model for laser additive manufacturing,
     Additive Manufacturing (2024), https://doi.org/10.1016/j.addma.2024.104531.
 \*---------------------------------------------------------------------------*/
+
+sources (beam);
+
 beam
 {
     pathName            scanPath;

tutorials/multiLayerPBF/system/controlDict

@@ -23,13 +23,13 @@ startTime       0;
 
 stopAt          endTime;
 
-endTime         0.004;
+endTime         0.015;
 
 deltaT          1e-07;
 
 writeControl    adjustableRunTime;
 
-writeInterval   0.001;
+writeInterval   0.0025;
 
 purgeWrite      0;
 
@@ -49,13 +49,12 @@ adjustTimeStep  yes;
 
 maxCo           0.5;
 
-maxDi           10;
+maxDi           100;
 
 maxAlphaCo      1;
 
 functions
 {
-    #includeFunc    ExaCA
 }
 
 

tutorials/multiLayerPBF/system/fvSolution

@@ -54,6 +54,7 @@ PIMPLE
     nThermoCorrectors   20;
     thermoTolerance     1e-8;
     explicitSolve       true;
+    Tmax                3300.0;
 }
 
 relaxationFactors