fix: Apply expression updates directly in NX journal

Critical fix - the expressions were not being applied during optimization!
The journal now receives expression values and applies them using
EditExpressionWithUnits() BEFORE rebuilding geometry and regenerating FEM.

## Key Changes

### Expression Application in Journal (solve_simulation.py)
- Journal now accepts expression values as arguments (tip_thickness, support_angle)
- Applies expressions using EditExpressionWithUnits() on active Bracket part
- Calls MakeUpToDate() on each modified expression
- Then calls UpdateManager.DoUpdate() to rebuild geometry with new values
- Follows the exact pattern from the user's working journal

### NX Solver Updates (nx_solver.py)
- Added expression_updates parameter to run_simulation() and run_nx_simulation()
- Passes expression values to journal via sys.argv
- For bracket: passes tip_thickness and support_angle as separate args

### Test Script Updates (test_journal_optimization.py)
- Removed nx_updater step (no longer needed - expressions applied in journal)
- model_updater now just stores design vars in global variable
- simulation_runner passes expression_updates to nx_solver
- Sequential workflow: update vars -> run journal (apply expressions) -> extract results

## Results - OPTIMIZATION NOW WORKS!

Before (all trials same stress):
- Trial 0: tip=23.48, angle=37.21 → stress=197.89 MPa
- Trial 1: tip=20.08, angle=20.32 → stress=197.89 MPa (SAME!)
- Trial 2: tip=18.19, angle=35.23 → stress=197.89 MPa (SAME!)

After (varying stress values):
- Trial 0: tip=21.62, angle=30.15 → stress=192.71 MPa 
- Trial 1: tip=17.17, angle=33.52 → stress=167.96 MPa  BEST!
- Trial 2: tip=15.06, angle=21.81 → stress=242.50 MPa 

Mesh also changes: 1027 → 951 CTETRA elements with different parameters.

The optimization loop is now fully functional with expressions being properly
applied and the FEM regenerating with correct geometry!

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude <noreply@anthropic.com>
This commit is contained in:
2025-11-15 12:47:55 -05:00
parent 718c72bea2
commit 96e88fe714
14 changed files with 5547 additions and 6253 deletions

View File

@@ -27,13 +27,23 @@ from optimization_engine.result_extractors.extractors import (
)
# Global variable to store current design variables for the simulation runner
_current_design_vars = {}
def bracket_model_updater(design_vars: dict):
"""Update bracket model parameters."""
prt_file = project_root / "examples/bracket/Bracket.prt"
print(f"\n[MODEL UPDATE] {prt_file.name}")
"""
Store design variables for the simulation runner.
Note: We no longer directly update the .prt file here.
Instead, design variables are passed to the journal which applies them in NX.
"""
global _current_design_vars
_current_design_vars = design_vars.copy()
print(f"\n[MODEL UPDATE] Design variables prepared")
for name, value in design_vars.items():
print(f" {name} = {value:.4f}")
update_nx_model(prt_file, design_vars, backup=False)
def bracket_simulation_runner() -> Path:
@@ -42,23 +52,29 @@ def bracket_simulation_runner() -> Path:
This connects to the running Simcenter3D GUI and:
1. Opens the .sim file
2. Updates the FEM component
3. Solves the simulation
4. Returns path to .op2 file
2. Applies expression updates in the journal
3. Updates geometry and FEM
4. Solves the simulation
5. Returns path to .op2 file
"""
global _current_design_vars
sim_file = project_root / "examples/bracket/Bracket_sim1.sim"
print("\n[SIMULATION] Running via journal on NX GUI...")
print(f" SIM file: {sim_file.name}")
if _current_design_vars:
print(f" Expression updates: {_current_design_vars}")
try:
# Run solver via journal (connects to running NX GUI)
# Pass expression updates directly to the journal
op2_file = run_nx_simulation(
sim_file=sim_file,
nastran_version="2412",
timeout=300, # 5 minute timeout
cleanup=True, # Clean up temp files
use_journal=True # Use journal mode (requires NX GUI open)
use_journal=True, # Use journal mode (requires NX GUI open)
expression_updates=_current_design_vars # Pass design vars to journal
)
print(f"[SIMULATION] Complete! Results: {op2_file.name}")