Restructure Hydrotech Beam project — KB-integrated layout

New project structure with knowledge base integration:
- kb/ with components, materials, fea, dev generations
- models/ for reference NX files (golden copies)
- studies/ for self-contained optimization campaigns
- deliverables/ for final outputs
- DECISIONS.md decision log (6 decisions tracked)
- BREAKDOWN.md (moved from 1_breakdown/)
- Gen 001 created from intake + technical breakdown

KB extension file: atomizer/shared/skills/knowledge-base-atomizer-ext.md

Refs: DEC-HB-004, DEC-HB-005, DEC-HB-006
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# Sandwich Beam
**Type:** Primary structural component
**Material:** Steel (AISI) — see [steel-aisi.md](../materials/steel-aisi.md)
**Status:** Baseline documented, optimization pending
---
## Description
Sandwich I-beam serving as primary load-bearing member in a test fixture assembly. Cross-section features a core layer flanked by face sheets on top and bottom flanges. Web contains a pattern of lightening holes (circular cutouts) to reduce mass.
## Specifications
| Parameter | Value | Units | Source |
|-----------|-------|-------|--------|
| Mass (baseline) | ~974 | kg | NX expression `p173` |
| Tip displacement (baseline) | ~22 | mm | SOL 101 result |
| Half-core thickness | 20 (baseline) | mm | DV range: 1040 |
| Face thickness | 20 (baseline) | mm | DV range: 1040 |
| Hole diameter | 300 (baseline) | mm | DV range: 150450 |
| Hole count | 10 (baseline) | — | DV range: 515 (integer) |
| Beam length | ❓ TBD | mm | Gap G1 |
| Support conditions | ❓ TBD | — | Gap G1 |
## Structural Behavior
*From Technical Breakdown (Gen 001):*
The beam is **bending-dominated**:
| Behavior | Governing Parameters | Notes |
|----------|---------------------|-------|
| Bending stiffness (EI) | Face thickness, core thickness | Faces carry bending stress, core carries shear. Stiffness scales ~quadratically with distance from neutral axis |
| Mass | All four variables | Core and face add material; holes remove material from web |
| Stress concentrations | Hole diameter, hole spacing | Larger holes → higher SCF at edges. Closely spaced holes can interact |
| Shear capacity | Core thickness, hole count, diameter | Holes reduce shear-carrying area |
## Design Variable Interactions
1. **Core × Face** — classic sandwich interaction. Optimal stiffness balances core depth (lever arm) vs face material (bending resistance)
2. **Hole diameter × Hole count** — both remove web material. Large + many could leave insufficient ligament width
3. **Face × Hole diameter** — thicker faces reduce nominal stress, allowing larger holes
4. **Core × Hole diameter** — core thickness determines web height, constrains max feasible hole diameter
## Key Risk
> ⚠️ Baseline FAILS displacement constraint (22 mm vs 10 mm target). Optimizer must increase stiffness by >50% while reducing mass. Feasible region may be tight.
## History
- **Gen 001** (2026-02-09): Initial documentation from intake + technical breakdown