Ensure the geometry tolerance and the planar tolerance are compatible with each other (#1389)

* Ensure the geometry tolerance and the planar tolerance are compatible with each other

* Fix msg

Author: benflexcompute

flow360/component/simulation/meshing_param/params.py

@@ -178,6 +178,42 @@ def invalid_geometry_accuracy(cls, value):
             raise ValueError("Geometry accuracy is required when geometry AI is used.")
         return value
 
+    @pd.field_validator("geometry_accuracy", mode="after")
+    @classmethod
+    def compatible_geometry_accuracy_and_planar_face_tolerance(cls, value):
+        """Ensure geometry accuracy and planar face tolerance are compatible"""
+        if value is None:
+            return value
+
+        validation_info = get_validation_info()
+
+        if (
+            validation_info is None
+            or validation_info.planar_face_tolerance is None
+            or validation_info.global_bounding_box is None
+            or validation_info.project_length_unit is None
+        ):
+            return value
+
+        absolute_tolerance_dimensioned = (
+            validation_info.global_bounding_box.largest_dimension
+            * validation_info.planar_face_tolerance
+            * validation_info.project_length_unit
+        )
+        if value > absolute_tolerance_dimensioned:
+            minimum_planar_face_tolerance = (
+                value
+                / validation_info.project_length_unit
+                / validation_info.global_bounding_box.largest_dimension
+            ).value
+            raise ValueError(
+                f"geometry_accuracy is too large for the planar_face_tolerance to take effect."
+                f" Reduce geometry_accuracy to at most {absolute_tolerance_dimensioned} "
+                f"or increase the planar_face_tolerance to at least {minimum_planar_face_tolerance}."
+            )
+
+        return value
+
     @pd.field_validator(
         "surface_max_aspect_ratio", "surface_max_adaptation_iterations", mode="after"
     )

tests/simulation/params/test_validators_params.py

@@ -7,6 +7,7 @@
 
 import flow360.component.simulation.units as u
 from flow360.component.simulation.entity_info import (
+    GeometryEntityInfo,
     SurfaceMeshEntityInfo,
     VolumeMeshEntityInfo,
 )
@@ -1843,6 +1844,7 @@ def test_beta_mesher_only_features():
 
 
 def test_geometry_AI_only_features():
+    # * Test GAI guardrails
     with SI_unit_system:
         params = SimulationParams(
             meshing=MeshingParams(
@@ -1903,6 +1905,61 @@ def test_geometry_AI_only_features():
         errors[0]["msg"] == "Value error, Geometry accuracy is required when geometry AI is used."
     )
 
+    # * Test geometry_accuracy and planar_face_tolerance compatibility
+    with SI_unit_system:
+        params_original = SimulationParams(
+            meshing=MeshingParams(
+                defaults=MeshingDefaults(
+                    geometry_accuracy=1e-5 * u.m,
+                    planar_face_tolerance=1e-10,
+                    boundary_layer_first_layer_thickness=10,
+                    surface_max_edge_length=1e-2,
+                ),
+            ),
+            private_attribute_asset_cache=AssetCache(
+                project_length_unit=1 * u.cm,
+                use_inhouse_mesher=True,
+                use_geometry_AI=True,
+                project_entity_info=GeometryEntityInfo(
+                    global_bounding_box=[[-100, -100, -100], [100, 1e-12, 100]],
+                ),
+            ),
+        )
+    params, errors, _ = validate_model(
+        params_as_dict=params_original.model_dump(mode="json"),
+        validated_by=ValidationCalledBy.LOCAL,
+        root_item_type="Geometry",
+        validation_level="VolumeMesh",
+    )
+    assert len(errors) == 1
+    # Largest dim = 200 cm
+    # with planar face tolerance = 1e-10
+    #   largest geometry accuracy = 1e-10 * 200 cm = 2e-8 cm
+    # with geometry accuracy = 1e-5m
+    #   minimum planar face tolerance = 1e-5m / 200 cm = 5e-06
+    assert errors[0]["msg"] == (
+        "Value error, geometry_accuracy is too large for the planar_face_tolerance to take effect. "
+        "Reduce geometry_accuracy to at most 2e-08 cm or increase the planar_face_tolerance to at least 5e-06."
+    )
+    params_original.meshing.defaults.geometry_accuracy = 2e-08 * u.cm
+    params, _, _ = validate_model(
+        params_as_dict=params_original.model_dump(mode="json"),
+        validated_by=ValidationCalledBy.LOCAL,
+        root_item_type="Geometry",
+        validation_level="VolumeMesh",
+    )
+    assert params
+
+    params_original.meshing.defaults.geometry_accuracy = 1e-5 * u.m
+    params_original.meshing.defaults.planar_face_tolerance = 5e-06
+    params, _, _ = validate_model(
+        params_as_dict=params_original.model_dump(mode="json"),
+        validated_by=ValidationCalledBy.LOCAL,
+        root_item_type="Geometry",
+        validation_level="VolumeMesh",
+    )
+    assert params
+
 
 def test_redefined_user_defined_fields():