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fixes to xfem 3d cutter mesh#32780

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lynnmunday wants to merge 17 commits intoidaholab:nextfrom
lynnmunday:xfem_3D_cutter_tangle
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fixes to xfem 3d cutter mesh#32780
lynnmunday wants to merge 17 commits intoidaholab:nextfrom
lynnmunday:xfem_3D_cutter_tangle

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closes #32779

@lynnmunday lynnmunday requested a review from bwspenc as a code owner April 16, 2026 21:50
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moosebuild commented Apr 17, 2026

Job Documentation, step Docs: sync website on 81e8d17 wanted to post the following:

View the site here

This comment will be updated on new commits.

@lynnmunday lynnmunday force-pushed the xfem_3D_cutter_tangle branch 5 times, most recently from 4a5e03c to 4c99b61 Compare April 22, 2026 20:49
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All jobs on 4c99b61 : invalidated by @lynnmunday

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moosebuild commented Apr 23, 2026

Job Coverage, step Generate coverage on 81e8d17 wanted to post the following:

Framework coverage

Coverage did not change

Modules coverage

Xfem

5b391d #32780 81e8d1
Total Total +/- New
Rate 83.07% 83.39% +0.32% 100.00%
Hits 7188 7218 +30 129
Misses 1465 1438 -27 0

Diff coverage report

Full coverage report

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This comment will be updated on new commits.

lynnmunday and others added 12 commits April 29, 2026 16:32
Inactive crack front nodes now get their growth direction copied from
their connected active neighbor instead of zero. growFront() now grows
all nodes including boundary nodes, eliminating the need for
findFrontIntersection(). For REPORTER growth increment, boundary nodes
use the increment from their nearest active neighbor.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
…correct double cantilever results even though the test diffs.
…e elements are found,

it also grows the crack using time dependent functions.
It also correctly grows surface nodes.
closes idaholab#32779
…ont growth

Also modify domain to avoid xfem double cutting edge errors that happen intermittently.
Setting map to default of true in tests that exodiff a cutter mesh because locations of the nodes will stay the same but their order may change.
Only the cutter mesh can use map = true, regular xfem meshes must use map=false for exodiff because geometric matching will not work when the cut mesh produces new elements in the exact same location which causes exodiff to fail.
I re-arranged the comments in the test file to be at the top.
…ent for crack front segments that contain an inactive node. Added examples for stress corrosion cracking and brittle fracture.
… with the improved surface movement. Adding tests for different cutting scenarios.
@lynnmunday lynnmunday force-pushed the xfem_3D_cutter_tangle branch 3 times, most recently from 1c41617 to 68753d1 Compare May 2, 2026 05:17
When adjacent face/neighbor propagation rediscovers the same physical edge
at the same parametric position, reuse the embedded node already stored on that
edge instead of throwing a duplicate-edge-intersection error.

Add a unit test covering the shared-edge face reuse case and assert
that only one embedded cut remains on the edge -- it cannot create two edges, that would be an error.

The unit test is a simplified version of what was occuring in test:solid_mechanics_basic.mesh_cutter_3d/double_cut_edge
@lynnmunday lynnmunday force-pushed the xfem_3D_cutter_tangle branch from 68753d1 to de192e9 Compare May 2, 2026 16:29
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Job Precheck, step Clang format on de192e9 wanted to post the following:

Your code requires style changes.

A patch was auto generated and copied here
You can directly apply the patch by running, in the top level of your repository:

curl -s https://mooseframework.inl.gov/docs/PRs/32780/clang_format/style.patch | git apply -v

Alternatively, with your repository up to date and in the top level of your repository:

git clang-format 5b391dfa415c373a9403cb2efcc533150486c98d

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Job Test, step Results summary on 81e8d17 wanted to post the following:

Framework test summary

Compared against 5b391df in job civet.inl.gov/job/3787211.

No added tests

Run time changes

Test Base (s) Head (s) +/- Base (MB) Head (MB)
problems/reference_residual_problem.zero_tolerance_ref 3.97 6.75 +69.96% 147.95 145.97
convergence/reference_residual_convergence.zero_tolerance_ref 4.05 6.68 +64.95% 148.02 144.61
time_integrators/convergence.implicit_astabledirk4/level2 3.71 5.81 +56.59% 138.66 146.37
time_integrators/convergence.implicit_midpoint/level2 2.74 4.28 +56.49% 139.93 144.51
time_integrators/convergence.implicit_lstabledirk3/level2 3.41 5.24 +53.50% 168.26 150.78
executioners/multisys-ss-detection.multi-sys-ss 5.27 8.01 +51.98% 135.09 141.05
multiapps/steffensen.variables_transient/app_begin_transfers_end 3.23 4.90 +51.45% 135.39 144.31
time_integrators/convergence.implicit_astabledirk4/level1 2.32 3.49 +50.70% 132.39 141.70

Modules test summary

Compared against 5b391df in job civet.inl.gov/job/3787211.

Added tests

Test Time (s) Memory (MB)
xfem/test:solid_mechanics_basic.mesh_cutter_3d/face_cut_mid_hoopStress 8.68 158.18
xfem/test:solid_mechanics_basic.mesh_cutter_3d/face_cut_mid_scc 8.38 156.09
xfem/test:solid_mechanics_basic.mesh_cutter_3d/double_cut_edge 8.36 156.54
xfem/test:solid_mechanics_basic.mesh_cutter_3d/face_cut_corner_scc 8.00 163.75
xfem/test:solid_mechanics_basic.mesh_cutter_3d/face_cut_mid_function 7.70 153.91
xfem/test:solid_mechanics_basic.mesh_cutter_3d/inactive_refine 4.11 145.75
xfem/test:solid_mechanics_basic.mesh_cutter_3d/inactive_no_refine 4.04 157.49

Run time changes

Test Base (s) Head (s) +/- Base (MB) Head (MB)
solid_mechanics/test:combined_creep_plasticity.stress_prescribed 3.47 5.87 +69.20% 124.49 123.55
solid_mechanics/test:combined_creep_plasticity.creepWithPlasticity 5.24 8.85 +68.81% 121.92 122.79
solid_mechanics/test:combined_creep_plasticity.combined_start_time 5.72 9.49 +66.01% 118.07 126.45
solid_mechanics/test:temperature_dependent_hardening.test 2.17 3.56 +63.67% 121.70 124.81
stochastic_tools/test:transfers/sampler_reporter.transfer/normal 6.76 11.04 +63.26% 158.47 169.60
solid_mechanics/test:dynamics/acceleration_bc.acceleration_bc 3.47 5.57 +60.63% 135.66 153.52
solid_mechanics/test:smeared_cracking.rz_exponential 11.03 17.69 +60.42% 126.14 131.72
solid_mechanics/test:combined_creep_plasticity.combined 5.84 9.31 +59.43% 120.34 124.86
combined/test:adaptive_timestepping.test_function_change 3.49 5.57 +59.33% 160.62 165.15
combined/test:combined_plasticity_temperature.ad_temp_dep_yield-jac 6.55 10.34 +57.77% 173.21 172.49
stochastic_tools/test:web_server_control.stochastic_control/batch_reset_multi 2.33 3.65 +56.85% 247.32 260.41
solid_mechanics/test:rate_independent_cyclic_hardening.nonlin_isokinharden_symmetric_strain_controlled 10.13 15.83 +56.27% 150.94 133.13
combined/test:combined_plasticity_temperature.temp_dep_yield 2.06 3.22 +56.13% 148.95 155.00
solid_mechanics/test:rate_independent_cyclic_hardening.linear_kinharden_nonsymmetric_stress_controlled 4.34 6.69 +54.00% 122.60 126.36
solid_mechanics/test:smeared_cracking.cracking_rotation_pres_dir_x 3.82 5.84 +52.82% 136.85 130.29
solid_mechanics/test:beam/static.euler_finite_rot_y 3.11 4.76 +52.71% 126.28 131.79
solid_mechanics/test:rate_independent_cyclic_hardening.nonlin_kinharden_nonsymmetric_strain_controlled 5.80 8.86 +52.69% 130.95 126.10
solid_mechanics/test:beam/static.euler_finite_rot_z 3.32 5.06 +52.44% 124.22 128.59
solid_mechanics/test:smeared_cracking.cracking_rotation_pres_dir_z 3.87 5.90 +52.40% 132.21 126.64
solid_mechanics/test:rate_independent_cyclic_hardening.linear_kinharden_nonsymmetric_strain_controlled 10.14 15.36 +51.58% 130.89 155.70
solid_mechanics/test:dynamics/acceleration_bc.acceleration_bc_ti 3.45 5.23 +51.40% 130.91 129.41
solid_mechanics/test:rate_independent_cyclic_hardening.1D_ratcheting_nonlin_kinharden_stress_controlled 3.73 5.63 +51.21% 116.25 114.46
solid_mechanics/test:rate_independent_cyclic_hardening.linear_kinharden_symmetric_strain_controlled 4.83 7.30 +51.13% 144.16 123.17

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Job Conda moose linux on 81e8d17 : invalidated by @lynnmunday

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Job Conda mac on 81e8d17 : invalidated by @lynnmunday

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Job Conda rocky mpich on 81e8d17 : invalidated by @lynnmunday

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3d xfem cutter mesh improvements

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