Added explicit check for zero shell thicknesses.

FEBioMech/FEMechModel.cpp

@@ -168,10 +168,10 @@ bool FEMechModel::InitMesh()
 
 //-----------------------------------------------------------------------------
 //! Initialize shells
-void FEMechModel::InitShells()
+bool FEMechModel::InitShells()
 {
 	// Base class does most of the work
-	FEModel::InitShells();
+	if (!FEModel::InitShells()) return false;
 
 	// NOTE: This was moved here because I wanted to FEMaterial::IsRigid to FESolidMaterial::IsRigid
 	//       This was part of the move to rid the FECore library of rigid stuff
@@ -206,6 +206,8 @@ void FEMechModel::InitShells()
 			}
 		}
 	}
+
+	return true;
 }
 
 //-----------------------------------------------------------------------------

FEBioMech/FEMechModel.h

@@ -60,7 +60,7 @@ class FEBIOMECH_API FEMechModel : public FEModel
 	bool InitMesh() override;
 
 	//! Initialize shells
-	void InitShells() override;
+	bool InitShells() override;
 
 	// find a parameter value
 	FEParamValue GetParameterValue(const ParamString& param) override;

FEBioMech/FESSIShellDomain.cpp

@@ -95,12 +95,29 @@ void FESSIShellDomain::Serialize(DumpStream& ar)
 //-----------------------------------------------------------------------------
 //! Calculate all shell normals (i.e. the shell directors).
 //! And find shell nodes
-void FESSIShellDomain::InitShells()
+bool FESSIShellDomain::InitShells()
 {
-    FEShellDomain::InitShells();
-
+	if (!FEShellDomain::InitShells()) return false;
+
+	FEMesh& mesh = *GetMesh();
+
+	// check for zero shell thickness
+	for (int i = 0; i < Elements(); ++i)
+	{
+		FEShellElementNew& el = ShellElement(i);
+		int nn = el.Nodes();
+		for (int j = 0; j < nn; ++j)
+		{
+			if (el.m_h0[j] <= 0.0)
+			{
+				string name = GetName();
+				feLogError("Zero shell thickness found in \"%s\"", name.c_str());
+				return false;
+			}
+		}
+	}
+
     if (!m_bnodalnormals) {
-        FEMesh& mesh = *GetMesh();
         for (int i = 0; i<Elements(); ++i)
         {
             FEShellElementNew& el = ShellElement(i);
@@ -122,7 +139,6 @@ void FESSIShellDomain::InitShells()
         }
     }
 
-	FEMesh& mesh = *GetMesh();
 	for (int i = 0; i < Elements(); ++i)
 	{
 		FEShellElementNew& el = ShellElement(i);
@@ -142,6 +158,8 @@ void FESSIShellDomain::InitShells()
 			el.m_G0[2][j] = el.m_Gt[2][j] = g0[2];
 		}
 	}
+
+	return true;
 }
 
 //-----------------------------------------------------------------------------

FEBioMech/FESSIShellDomain.h

@@ -42,19 +42,19 @@ class FEBIOMECH_API FESSIShellDomain : public FEShellDomainNew
 public:
 	FESSIShellDomain(FEModel* pfem);
 
-    //! initialize domain
-    //! one-time initialization, called during model initialization
+	//! initialize domain
+	//! one-time initialization, called during model initialization
 	bool Init() override;
 
 	//! serialization
 	void Serialize(DumpStream& ar) override;
-    
+
 	//! Update element data prior to solving time step
 	void PreSolveUpdate(const FETimeInfo& timeInfo) override;
-    
-    //! Initialize shell normals
-    void InitShells() override;
-    
+
+	//! Initialize shell normals
+	bool InitShells() override;
+
 protected:
 	//! Find interfaces between solid element faces and shell elements
 	void FindSSI();

FEBioOpt/FEBioParamRun.cpp

@@ -87,7 +87,7 @@ bool FEBioParamRun::Init(const char* szfile)
 		FEShellDomainNew* shellDomain = dynamic_cast<FEShellDomainNew*>(&mesh.Domain(i));
 		if (shellDomain) shellDomain->AssignDefaultShellThickness();
 	}
-	fem->InitShells();
+	if (!fem->InitShells()) return false;
 
 	return true;
 }

FECore/FEModel.cpp

@@ -995,7 +995,11 @@ bool FEModel::InitMesh()
 
 	// Initialize shell data
 	// This has to be done before the domains are initialized below
-	InitShells();
+	if (!InitShells())
+	{
+		feLogError("Errors found during initialization of shells.");
+		return false;
+	}
 
 	// reset data
 	// TODO: Not sure why this is here
@@ -1064,7 +1068,7 @@ void FEModel::ValidateMesh()
 }
 
 //-----------------------------------------------------------------------------
-void FEModel::InitShells()
+bool FEModel::InitShells()
 {
 	FEMesh& mesh = GetMesh();
 
@@ -1120,9 +1124,11 @@ void FEModel::InitShells()
 		if (dom.Class() == FE_DOMAIN_SHELL)
 		{
 			FEShellDomain& shellDom = static_cast<FEShellDomain&>(dom);
-			shellDom.InitShells();
+			if (!shellDom.InitShells()) return false;
 		}
 	}
+
+	return true;
 }
 
 //-----------------------------------------------------------------------------

FECore/FEModel.h

@@ -141,7 +141,7 @@ class FECORE_API FEModel : public FECoreBase, public CallbackHandler
 	void ValidateMesh();
 
 	//! Initialize shells
-	virtual void InitShells();
+	virtual bool InitShells();
 
 	//! Build the matrix profile for this model
 	virtual void BuildMatrixProfile(FEGlobalMatrix& G, bool breset);

FECore/FEShellDomain.cpp

@@ -62,12 +62,14 @@ void FEShellDomain::Reset()
 }
 
 //-----------------------------------------------------------------------------
-void FEShellDomain::InitShells()
+bool FEShellDomain::InitShells()
 {
 	ForEachShellElement([](FEShellElement& el) {
 		int n = el.Nodes();
 		for (int j = 0; j<n; ++j) el.m_ht[j] = el.m_h0[j];
 	});
+
+	return true;
 }
 
 //-----------------------------------------------------------------------------
@@ -205,9 +207,9 @@ double FEShellDomainOld::Volume(FEShellElement& se)
 //-----------------------------------------------------------------------------
 //! Calculate all shell normals (i.e. the shell directors).
 //! And find shell nodes
-void FEShellDomainOld::InitShells()
+bool FEShellDomainOld::InitShells()
 {
-	FEShellDomain::InitShells();
+	if (!FEShellDomain::InitShells()) return false;
 
 	FEMesh& mesh = *GetMesh();
 	for (int i = 0; i<Elements(); ++i)
@@ -221,6 +223,8 @@ void FEShellDomainOld::InitShells()
 			el.m_D0[j] = d0 * el.m_h0[j];
 		}
 	}
+
+	return true;
 }
 
 //=================================================================================================

FECore/FEShellDomain.h

@@ -58,7 +58,7 @@ class FECORE_API FEShellDomain : public FEDomain
 	virtual double CurrentVolume(FEShellElement& el) { return 0.0; }
 
 	// Initialize shell data (Called from FEMesh::InitShells)
-	virtual void InitShells();
+	virtual bool InitShells();
 
 	virtual void AssignDefaultShellThickness() {}
 
@@ -102,7 +102,7 @@ class FECORE_API FEShellDomainOld : public FEShellDomain
 
 	double Volume(FEShellElement& el) override;
 
-	void InitShells() override;
+	bool InitShells() override;
 
 protected:
 	vector<FEShellElementOld>	m_Elem;	//!< array of elements