Add Herschel-Bulkley non-Newtonian viscosity model#1298
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jasontruong2707 wants to merge 5 commits intoMFlowCode:masterfrom
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Add Herschel-Bulkley non-Newtonian viscosity model#1298jasontruong2707 wants to merge 5 commits intoMFlowCode:masterfrom
jasontruong2707 wants to merge 5 commits intoMFlowCode:masterfrom
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Review Summary by QodoAdd Herschel-Bulkley non-Newtonian viscosity model with dynamic Reynolds number computation
WalkthroughsDescription• Implements Herschel-Bulkley non-Newtonian viscosity model with Papanastasiou regularization for power-law, Bingham, and HB fluids • Replaces static viscous Reynolds arrays (Res_viscous, Res_gs, Res_pr) with dynamic computation via new m_re_visc module • Adds per-fluid non-Newtonian parameters: yield stress (tau0), consistency index (K), flow behavior index (nn), viscosity bounds (mu_max, mu_min, mu_bulk), and regularization parameter (hb_m) • Integrates non-Newtonian viscosity computation into time-stepping CFL calculations, Riemann solvers, and data output stability criteria • Adds validation for non-Newtonian fluid parameters in input checker • Extends MPI communication across pre-processing, simulation, and post-processing modules to broadcast non-Newtonian properties • Supports non-Newtonian viscosity in immersed boundary method calculations • Includes two validation cases: 2D Poiseuille flow and 2D lid-driven cavity with non-Newtonian fluids • Adds non-Newtonian parameter definitions to toolchain configuration • Maintains backward compatibility with Newtonian flows (non-Newtonian disabled by default) Diagramflowchart LR
A["Input Parameters<br/>non_newtonian, tau0, K, nn"] --> B["m_hb_function<br/>Herschel-Bulkley<br/>Viscosity Model"]
B --> C["m_re_visc<br/>Dynamic Re Computation"]
C --> D["Time Stepping<br/>CFL Calculation"]
C --> E["Riemann Solvers<br/>Viscous Fluxes"]
C --> F["Data Output<br/>Stability Criteria"]
G["Velocity Gradients"] --> C
H["Strain Rate Tensor"] --> B
File Changes1. src/simulation/m_time_steppers.fpp
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Code Review by Qodo
1. non_newtonian lacks case validation
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| _r(f"{px}non_newtonian", LOG, {"viscosity"}) | ||
| for a in ["tau0", "K", "nn", "mu_max", "mu_min", "mu_bulk", "hb_m"]: | ||
| _r(f"{px}{a}", REAL, {"viscosity"}) |
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1. non_newtonian lacks case validation 📘 Rule violation ⛯ Reliability
New HB parameters (fluid_pp(*)%non_newtonian, tau0, K, nn, mu_*, hb_m) are defined but not validated in toolchain/mfc/case_validator.py, allowing invalid configurations to pass toolchain checks. This should be validated in the toolchain since physics constraints are explicitly enforced in the Fortran input checker.
Agent Prompt
## Issue description
The PR introduces new non-Newtonian viscosity inputs (`fluid_pp(*)%non_newtonian`, `tau0`, `K`, `nn`, `mu_min`, `mu_max`, `mu_bulk`, `hb_m`) but the toolchain validator does not validate them, so invalid cases can pass toolchain checks and only fail later at runtime.
## Issue Context
Fortran-side validation was added in `src/simulation/m_checker.fpp`, indicating physics constraints apply and should also be enforced in `toolchain/mfc/case_validator.py` per the compliance checklist.
## Fix Focus Areas
- toolchain/mfc/case_validator.py[993-1024]
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| if (any_non_newtonian) then | ||
| if (igr) then | ||
| call s_compute_re_visc(q_cons_ts(1)%vf, alpha, j, k, l, Re_visc_per_phase) | ||
| else | ||
| call s_compute_re_visc(q_prim_vf, alpha, j, k, l, Re_visc_per_phase) | ||
| end if | ||
| call s_compute_mixture_re(alpha, Re_visc_per_phase, Re) |
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2. Igr uses conservative gradients 🐞 Bug ✓ Correctness
In s_compute_dt, the IGR branch calls s_compute_re_visc with q_cons_ts(1)%vf, but s_compute_re_visc differentiates q_prim_vf(momxb:), so it treats momenta as velocities and computes an incorrect shear rate and viscosity. This can yield an incorrect (potentially unstable) time step whenever any_non_newtonian and igr are enabled.
Agent Prompt
### Issue description
When `igr` is enabled, `s_compute_dt` calls `s_compute_re_visc` with `q_cons_ts(1)%vf` (conservative state). `s_compute_re_visc` assumes its first argument is primitive variables and differentiates `q_prim_vf(momxb:...)` as velocities, so the IGR path computes wrong shear rate/viscosity and thus wrong dt.
### Issue Context
`m_re_visc` computes velocity gradients directly from the provided field, without converting momenta to velocities.
### Fix Focus Areas
- src/simulation/m_time_steppers.fpp[748-754]
- src/simulation/m_re_visc.fpp[26-90]
### Suggested fix
- Option A (simplest): In `s_compute_dt`, ensure `q_prim_vf` is valid even when `igr` is true (perform conservative→primitive conversion when `any_non_newtonian` is true, or always for dt computation).
- Option B: Add a conservative-aware path in `s_compute_re_visc` (or a new routine) that computes velocities `u=mom/rho` at neighbor cells before differencing, and use that path from the IGR branch.
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Caution Review failedFailed to post review comments 📝 WalkthroughWalkthroughAdds Herschel–Bulkley non‑Newtonian support: eight new fields to the derived type physical_parameters (non_newtonian, tau0, K, nn, mu_min, mu_max, mu_bulk, hb_m); new modules m_hb_function and m_re_visc for HB viscosity and viscous/Re computations; input validation via s_check_inputs_non_newtonian; MPI broadcasts and GPU updates extended to the new fields; time‑stepper dt computation updated to use per‑phase viscous terms; pressure‑relaxation internals simplified; two example case scripts added; and CI workflow scripts reference shared frontier scripts. 🚥 Pre-merge checks | ✅ 3✅ Passed checks (3 passed)
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