R8-c: drop zero summands from cut_wall_loads; extrapolation diagnostics beyond FAR_OUTSIDE with the worst point

Co-Authored-By: Claude Opus 5.5 (1M context) <[email protected]>

crates/specialized/rtx-cfd/src/solvers/incompressible/embedded3/interface.rs

@@ -79,18 +79,17 @@ impl Mask {
         if self.grad_weights.is_some() {
             return None;
         }
+        // The loops visit every fluid cell and face; only the non-zero
+        // summands are loads (the zero ones change no sum).
         let mut raw: Vec<(LoadKind, [f64; 3], [f64; 3])> = Vec::new();
-        let (p, s) = self
-            .cut_wall_force_parts_sink(body, f, mu, t, None, &mut |k, x, v| raw.push((k, x, v)))?;
-        let (d, c) = self.cut_wall_exchange_parts_sink(
-            body,
-            f,
-            mu,
-            self.density,
-            t,
-            None,
-            &mut |k, x, v| raw.push((k, x, v)),
-        )?;
+        let mut keep = |k: LoadKind, x: [f64; 3], v: [f64; 3]| {
+            if v != [0.0; 3] {
+                raw.push((k, x, v));
+            }
+        };
+        let (p, s) = self.cut_wall_force_parts_sink(body, f, mu, t, None, &mut keep)?;
+        let (d, c) =
+            self.cut_wall_exchange_parts_sink(body, f, mu, self.density, t, None, &mut keep)?;
         let xch = [d[0] + c[0], d[1] + c[1], d[2] + c[2]];
         let total = [
             p[0] + s[0] + xch[0],
@@ -209,6 +208,10 @@ pub struct Location {
     pub outside: f64,
 }
 
+/// The natural-coordinate distance outside an element from which a load
+/// counts as extrapolated in [`PlateTransfer`] (0.02 of the half-element).
+pub const FAR_OUTSIDE: f64 = 0.02;
+
 /// The result of one load transfer (see [`HexPlate::transfer`]).
 #[derive(Debug, Clone)]
 pub struct PlateTransfer {
@@ -223,9 +226,13 @@ pub struct PlateTransfer {
     /// The largest Newton residual (m) and the largest outside-ness.
     pub max_residual: f64,
     pub max_outside: f64,
-    /// Loads located outside every element (extrapolated), and their Σ|F|.
+    /// Loads located outside every element by more than [`FAR_OUTSIDE`]
+    /// in natural coordinates (a foot off the plate by more than a few %
+    /// of an element — the surfaces' round-off-level mismatch is excluded),
+    /// their Σ|F|, and the worst one's point.
     pub extrapolated: usize,
     pub extrapolated_load: f64,
+    pub worst_point: [f64; 3],
     /// The share of Σ|f_a| on nodes off the wetted surface (the interior
     /// layers and the clamped root face).
     pub interior_share: f64,
@@ -481,6 +488,7 @@ impl HexPlate {
         let (mut force_in, mut moment_in) = ([0.0f64; 3], [0.0f64; 3]);
         let (mut max_residual, mut max_outside) = (0.0f64, f64::NEG_INFINITY);
         let (mut extrapolated, mut extrapolated_load) = (0usize, 0.0f64);
+        let mut worst_point = [0.0f64; 3];
         for (&(p, f), loc) in loads.iter().zip(&located) {
             for (&n, &w) in loc.nodes.iter().zip(&loc.weights) {
                 for c in 0..3 {
@@ -493,8 +501,11 @@ impl HexPlate {
                 moment_in[c] += m[c];
             }
             max_residual = max_residual.max(loc.residual);
-            max_outside = max_outside.max(loc.outside);
-            if loc.outside > 1e-9 {
+            if loc.outside > max_outside {
+                max_outside = loc.outside;
+                worst_point = p;
+            }
+            if loc.outside > FAR_OUTSIDE {
                 extrapolated += 1;
                 extrapolated_load += norm(f);
             }
@@ -524,6 +535,7 @@ impl HexPlate {
             max_outside,
             extrapolated,
             extrapolated_load,
+            worst_point,
             interior_share: if total_abs > 0.0 {
                 interior_abs / total_abs
             } else {

crates/specialized/rtx-cfd/src/solvers/incompressible/embedded3/mod.rs

@@ -29,7 +29,7 @@ pub use cut::CutGeometry;
 pub use export_vtk::write_vtk;
 pub use field::Field;
 pub use grid::Grid;
-pub use interface::{HexPlate, LoadKind, PlateTransfer, WallLoad};
+pub use interface::{FAR_OUTSIDE, HexPlate, LoadKind, PlateTransfer, WallLoad};
 pub use loads::SurfaceForce;
 pub use plate::PlateSurface;
 pub use step::{Boundaries, Fluid, Parameters, Side, Solver, StepResult};

crates/specialized/rtx-cfd/tests/embedded3_flag_wake.rs

@@ -26,8 +26,8 @@ use embedded3_flag_kinematics::{Recorded, recorded};
 use rtx_cfd::solvers::incompressible::ConvectionScheme;
 use rtx_cfd::solvers::incompressible::embedded3::step::device::DeviceStep;
 use rtx_cfd::solvers::incompressible::embedded3::{
-    Body, Boundaries, DeviceSdf, Field, Fluid, Grid, HexPlate, Parameters, PlateSurface, Side,
-    Solver, WallScheme, write_vtk,
+    Body, Boundaries, DeviceSdf, FAR_OUTSIDE, Field, Fluid, Grid, HexPlate, Parameters,
+    PlateSurface, Side, Solver, WallScheme, write_vtk,
 };
 use std::io::Write as _;
 
@@ -735,7 +735,7 @@ fn flag_wake_on_the_device() {
                 let extrap_share = tr.extrapolated_load / abs_f.max(1e-300);
                 let ms = lap.elapsed().as_secs_f64() * 1e3;
                 println!(
-                    "  transfer t {t:.4}: {} loads ({} flag); route − Σ {:.1e} N; flag F {:+.4} {:+.4} {:+.4} N, M {:+.5} {:+.5} {:+.5} N m; |ΔF|/Σ|F| {rel_f:.1e}, |ΔM|/(Σ|F| L) {rel_m:.1e}; Newton ≤ {:.1e} m, outside ≤ {:.2e} ({} extrapolated, {:.1e} of Σ|F|), interior share {:.3}; {ms:.0} ms",
+                    "  transfer t {t:.4}: {} loads ({} flag); route − Σ {:.1e} N; flag F {:+.4} {:+.4} {:+.4} N, M {:+.5} {:+.5} {:+.5} N m; |ΔF|/Σ|F| {rel_f:.1e}, |ΔM|/(Σ|F| L) {rel_m:.1e}; Newton ≤ {:.1e} m, outside ≤ {:.2e} at ({:.4}, {:.4}, {:.4}) ({} beyond {FAR_OUTSIDE}, {:.1e} of Σ|F|), interior share {:.3}; {ms:.0} ms",
                     loads.len(),
                     flag.len(),
                     nrm([route[0] - sum[0], route[1] - sum[1], route[2] - sum[2]]),
@@ -747,6 +747,9 @@ fn flag_wake_on_the_device() {
                     tr.moment_in[2],
                     tr.max_residual,
                     tr.max_outside,
+                    tr.worst_point[0],
+                    tr.worst_point[1],
+                    tr.worst_point[2],
                     tr.extrapolated,
                     extrap_share,
                     tr.interior_share