CFD · VERIFICATION + NEGATIVE CONTROLS
MIXEDVerification Bench Rev 1.0
0.053% fine-grid error. Two real failures.
Three pipe grids agree with Poiseuille within 2%. Their errors decrease from 0.996% to 0.243% to 0.053%. The negative controls miss by 13.963% and 99.605%.
Both nozzle treatments fail near-wall readiness. y+ and all-component residual histories distinguish an active-field convergence problem from an ill-conditioned negligible component.
7 new OpenFOAM runs · 295 hashed archive files, including CAD and 5 retained CalculiX decks · 7-page paper. Criteria correction disclosed; not a blinded preregistration.
Scope, reference and retained artifacts
Analytical pipe verification and numerical-readiness rejection, not an experiment or a general nozzle validation. The original Rev 1.0 page, results, and bundle remain frozen.
CFD · ANALYTICAL BENCHMARK
BOUNDED PASSChannel pressure-budget study
2.5 mm is the smallest tested passing gap.
9 OpenFOAM solves: 3 gaps × 3 grids. At 25 mL/s and a 40 Pa budget, the fine-grid losses are 177.964, 75.078, 38.440 Pa for 1.5, 2.0 and 2.5 mm gaps.
The smaller gaps fail the budget even though numerical checks pass. The 2.5 mm recommendation includes the declared numerical allowance.
200 hashed paper-package artifacts · analytical parallel-plate comparison, profile, residual and conservation checks. Not a sidewall, fitting-loss, or hardware validation.
Conditions, distinct examples and artifacts
This capability study uses 25 mL/s / 40 Pa. The separate interactive default uses 20 mL/s / 70 Pa; their recommendations are not interchangeable.
THERMAL · ANALYTICAL SCREENING
BOUNDED PASSCooling-channel layout decision
Layout B: two 2 mm passages.
Three layouts assessed under a 100 W load, 72 °C inner-wall limit and 2 kPa straight-channel pressure budget. Nominal and adverse scenarios are retained.
Energy closure error: 0. The final radial heat-transfer check differs from its analytical reference by 0.001942%.
41 hashed paper-package artifacts. Analytical thermal screening—not thermal CFD or experimental validation. Manifold, contact and boiling effects remain outside the model.
Calculation sources and artifacts
THERMAL + STRUCTURAL · SYNTHETIC PREBENCHMARK
PREBENCHMARKSamarmad-derived PCHE gate pack
10 runnable gates passed; paper-specific gates remain separate.
A source-derived printed-circuit heat-exchanger packet exercises prediction freezing, criteria hashing, curved-interface pressure and heat-rate transfer, generic OpenFOAM CHT, and generic three-level CalculiX acceptance.
These six operating points are synthetic pipeline tests—not publication results. The later Samarmad-specific run has its own failed numerical outcome and unscored experimental comparison.
STRUCTURAL · NUMERICAL ADEQUACY + REJECTION
MIXEDCalculiX structural extension
21 retained solves. Seven configurations.
Bracket, pressure tubes, a port and thermal restraint were tested at three mesh levels. The port fails mesh sensitivity. The thermal-gradient case passes numerical checks but fails its stress requirement.
Pressure-tube numerical acceptability remains NOT ESTABLISHED with reaction-balance evidence missing. Every configuration retains design readiness NOT ESTABLISHED.
CalculiX 2.20 · Gmsh / CadQuery. Decks and analytical comparisons are bounded evidence, not validated structural design capability.
Per-configuration gates and manifests
All 7 public configuration manifests were checked against their retained files: 0 mismatches. The Verification Bench bundle contains 5 of these retained solve decks, not all 21.
Download retained deck subset ↓CAD / GEOMETRY · NEGATIVE CONTROL
FAIL — correctly rejectedImported manifold with a detached sliver
2 solids. Solver not submitted.
The STEP fixture has intersecting ports and fillets. The intact reimport passes topology only; the defective variant violates the single-solid intake contract. No silent deletion or automatic repair.
Two synthetic STEP reimports · OpenCASCADE / CadQuery. This does not establish general imported-CAD robustness.