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>
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@@ -127,7 +127,8 @@ class NXSolver:
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self,
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sim_file: Path,
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working_dir: Optional[Path] = None,
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cleanup: bool = True
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cleanup: bool = True,
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expression_updates: Optional[Dict[str, float]] = None
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) -> Dict[str, Any]:
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"""
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Run NX Nastran simulation.
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@@ -136,6 +137,9 @@ class NXSolver:
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sim_file: Path to .sim file
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working_dir: Working directory for solver (defaults to sim file dir)
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cleanup: Remove intermediate files after solving
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expression_updates: Dict of expression name -> value to update
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(only used in journal mode)
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e.g., {'tip_thickness': 22.5, 'support_angle': 35.0}
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Returns:
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Dictionary with:
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@@ -218,10 +222,23 @@ class NXSolver:
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with open(journal_template, 'r') as f:
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journal_content = f.read()
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# Create a custom journal that passes the sim file path
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# Create a custom journal that passes the sim file path and expression values
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# Build argv list with expression updates
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argv_list = [f"r'{sim_file.absolute()}'"]
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# Add expression values if provided
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if expression_updates:
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# For bracket example, we expect: tip_thickness, support_angle
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if 'tip_thickness' in expression_updates:
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argv_list.append(str(expression_updates['tip_thickness']))
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if 'support_angle' in expression_updates:
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argv_list.append(str(expression_updates['support_angle']))
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argv_str = ', '.join(argv_list)
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custom_journal = f'''# Auto-generated journal for solving {sim_file.name}
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import sys
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sys.argv = ['', r'{sim_file.absolute()}'] # Set argv for the main function
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sys.argv = ['', {argv_str}] # Set argv for the main function
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{journal_content}
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'''
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with open(temp_journal, 'w') as f:
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@@ -442,7 +459,8 @@ def run_nx_simulation(
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nastran_version: str = "2412",
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timeout: int = 600,
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cleanup: bool = True,
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use_journal: bool = True
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use_journal: bool = True,
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expression_updates: Optional[Dict[str, float]] = None
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) -> Path:
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"""
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Convenience function to run NX simulation and return OP2 file path.
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@@ -453,6 +471,7 @@ def run_nx_simulation(
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timeout: Solver timeout in seconds
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cleanup: Remove temp files
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use_journal: Use NX journal for solving (recommended for licensing)
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expression_updates: Dict of expression name -> value to update in journal
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Returns:
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Path to output .op2 file
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@@ -461,7 +480,7 @@ def run_nx_simulation(
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RuntimeError: If simulation fails
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"""
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solver = NXSolver(nastran_version=nastran_version, timeout=timeout, use_journal=use_journal)
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result = solver.run_simulation(sim_file, cleanup=cleanup)
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result = solver.run_simulation(sim_file, cleanup=cleanup, expression_updates=expression_updates)
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if not result['success']:
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error_msg = '\n'.join(result['errors']) if result['errors'] else 'Unknown error'
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@@ -15,18 +15,30 @@ import NXOpen.CAE
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def main(args):
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"""
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Open and solve a simulation file.
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Open and solve a simulation file with updated expression values.
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Args:
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args: Command line arguments, args[0] should be the .sim file path
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args: Command line arguments
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args[0]: .sim file path
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args[1]: tip_thickness value (optional)
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args[2]: support_angle value (optional)
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"""
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if len(args) < 1:
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print("ERROR: No .sim file path provided")
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print("Usage: run_journal.exe solve_simulation.py <sim_file_path>")
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print("Usage: run_journal.exe solve_simulation.py <sim_file_path> [tip_thickness] [support_angle]")
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return False
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sim_file_path = args[0]
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# Parse expression values if provided
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tip_thickness = float(args[1]) if len(args) > 1 else None
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support_angle = float(args[2]) if len(args) > 2 else None
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print(f"[JOURNAL] Opening simulation: {sim_file_path}")
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if tip_thickness is not None:
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print(f"[JOURNAL] Will update tip_thickness = {tip_thickness}")
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if support_angle is not None:
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print(f"[JOURNAL] Will update support_angle = {support_angle}")
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try:
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theSession = NXOpen.Session.GetSession()
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@@ -62,7 +74,7 @@ def main(args):
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simPart1 = workSimPart
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theSession.Post.UpdateUserGroupsFromSimPart(simPart1)
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# STEP 1: Switch to Bracket.prt and update geometry with new expression values
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# STEP 1: Switch to Bracket.prt and update expressions, then update geometry
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print("[JOURNAL] STEP 1: Updating Bracket.prt geometry...")
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try:
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# Find the Bracket part
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@@ -76,7 +88,44 @@ def main(args):
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)
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partLoadStatus.Dispose()
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workPart = theSession.Parts.Work
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# CRITICAL: Apply expression changes BEFORE updating geometry
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expressions_updated = []
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if tip_thickness is not None:
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print(f"[JOURNAL] Applying tip_thickness = {tip_thickness}")
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expr_tip = workPart.Expressions.FindObject("tip_thickness")
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if expr_tip:
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unit_mm = workPart.UnitCollection.FindObject("MilliMeter")
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workPart.Expressions.EditExpressionWithUnits(expr_tip, unit_mm, str(tip_thickness))
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expressions_updated.append(expr_tip)
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print(f"[JOURNAL] tip_thickness updated")
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else:
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print(f"[JOURNAL] WARNING: tip_thickness expression not found!")
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if support_angle is not None:
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print(f"[JOURNAL] Applying support_angle = {support_angle}")
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expr_angle = workPart.Expressions.FindObject("support_angle")
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if expr_angle:
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unit_deg = workPart.UnitCollection.FindObject("Degrees")
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workPart.Expressions.EditExpressionWithUnits(expr_angle, unit_deg, str(support_angle))
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expressions_updated.append(expr_angle)
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print(f"[JOURNAL] support_angle updated")
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else:
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print(f"[JOURNAL] WARNING: support_angle expression not found!")
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# Make expressions up to date
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if expressions_updated:
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print(f"[JOURNAL] Making {len(expressions_updated)} expression(s) up to date...")
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for expr in expressions_updated:
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markId_expr = theSession.SetUndoMark(NXOpen.Session.MarkVisibility.Invisible, "Make Up to Date")
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objects1 = [expr]
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theSession.UpdateManager.MakeUpToDate(objects1, markId_expr)
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theSession.DeleteUndoMark(markId_expr, None)
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# CRITICAL: Update the geometry model - rebuilds features with new expressions
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print(f"[JOURNAL] Rebuilding geometry with new expression values...")
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markId_update = theSession.SetUndoMark(NXOpen.Session.MarkVisibility.Invisible, "NX update")
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nErrs = theSession.UpdateManager.DoUpdate(markId_update)
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theSession.DeleteUndoMark(markId_update, "NX update")
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@@ -85,6 +134,8 @@ def main(args):
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print("[JOURNAL] WARNING: Could not find Bracket part")
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except Exception as e:
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print(f"[JOURNAL] ERROR updating Bracket.prt: {e}")
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import traceback
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traceback.print_exc()
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# STEP 2: Switch to Bracket_fem1 and update FE model
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print("[JOURNAL] STEP 2: Opening Bracket_fem1.fem...")
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