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KB Gen 002: Process KBS sessions, update model parameters

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Sources: 3 KBS capture sessions (20260210-132817, 20260210-161401, 20260210-163801)

Key changes:
- Mass corrected: 974 kg (p173) → 11.33 kg (p1) — KBS ground truth
- Beam length confirmed: 5,000 mm cantilever
- BCs confirmed: left fixed, right 10,000 kgf downward
- Material confirmed: AISI Steel 1005, density 7.3 g/cm³
- Mesh confirmed: CQUAD4 thin shell, 33.7 mm elements
- Hole geometry: span 4,000 mm (p6), offsets 500 mm fixed
- 3 gaps closed (G1, G2, G8), 6 new gaps identified (G10-G15)
- New expressions: beam_half_height, beam_half_width, beam_length, p6

Files: CONTEXT.md, kb/_index.md, kb/_history.md, kb/components/sandwich-beam.md,
       kb/materials/steel-aisi.md, kb/fea/models/sol101-static.md, kb/dev/gen-002.md
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Antoine
2026-02-10 21:49:39 +00:00
parent 3ab1cad4e1
commit b88657b00c
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projects/hydrotech-beam/kb/fea/models/sol101-static.md
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# SOL 101 — Static Analysis
**Simulation:** Beam_sim1.sim
**Solver:** NX Nastran SOL 101 (Linear Static)
**Status:** Pending gap resolution
---
## Setup
| Item | Value | Notes |
|------|-------|-------|
| Solution type | SOL 101 (Linear Static) | Appropriate for this problem |
| Element type | ❓ TBD | Gap G8: CQUAD4/CQUAD8 (shell) or CTETRA/CHEXA (solid)? |
| Mesh density | ❓ TBD | Gap G8: convergence checked? |
| Loading | ❓ TBD | Gap G2: point load? distributed? self-weight? |
| BCs | ❓ TBD | Gap G1: cantilever? simply-supported? |
## Result Extraction
| Output | Method | Expression/Sensor | Status |
|--------|--------|-------------------|--------|
| Mass | NX expression | `p173` | ✅ Known |
| Tip displacement | ❓ Sensor or .f06 parse | TBD | Gap G3, G6 |
| Von Mises stress | ❓ Sensor or .f06 parse | TBD | Gap G4, G6 |
## Solver Considerations
*From Technical Breakdown:*
- **Linear assumption:** 22 mm displacement on likely 2+ m beam → L/δ probably OK. Verify.
- **Mesh sensitivity:** Stress at hole edges is mesh-dependent. Need convergence check (Gap G8).
- **Mesh morphing vs remesh:** Parametric NX models typically remesh on update. Need to confirm behavior across DV range (Gap G7).
- **Runtime estimate:** Single beam, ~10K–100K DOF → probably seconds to low minutes per evaluation.
## Validation Checklist
- [ ] Baseline mass matches NX expression `p173`
- [ ] Baseline displacement matches reported ~22 mm
- [ ] Mesh convergence verified at baseline
- [ ] Mesh quality acceptable at DV range extremes
- [ ] Model rebuilds cleanly at all 4 corners of design space
## History
- **Gen 001** (2026-02-09): Initial documentation from technical breakdown. All solver details pending gap resolution.
# SOL 101 — Static Analysis
**Simulation:** Beam_sim1.sim
**Solver:** NX Nastran SOL 101 (Linear Static)
**Status:** Setup confirmed from KBS session (Gen 002). Baseline run needed.
---
## Setup — Confirmed
| Item | Value | Source | Notes |
|------|-------|--------|-------|
| Solution type | **SOL 101** (Linear Static) | KBS session | "Solution 1 — static subcase" |
| Element type | **CQUAD4** (4-node quad shell) | KBS session | ✅ Confirmed — thin shell collectors |
| Property type | Thin shell | KBS session | Material inherited from "beam material" |
| Mesh density | Element size = **33.7 mm** (67.4 / 2) | KBS session | Subdivision-based. Future refinement planned. |
| Idealization | Promote body → mid-surface extraction | KBS session | Pair mid-surface function |
## Boundary Conditions — Confirmed
| BC | Location | Type | Value | Source |
|----|----------|------|-------|--------|
| **Fixed constraint** | Left side of beam (full edge) | SPC (all 6 DOF) | Fixed | ✅ KBS session — "left side fixed" |
| **Applied force** | Right side of beam (free end) | Point/edge force | **10,000 kgf downward** (−Y) | ✅ KBS session — "project requirement" |
### Loading Details
- Force magnitude: 10,000 kgf = **98,066.5 N** (≈ 98.1 kN)
- Direction: Downward (−Y in model coordinates)
- Application: Right side (free end) of beam
- Type: This is a **cantilever beam** with end loading — classic bending problem
## Result Extraction
| Output | Method | Expression/Sensor | Status |
|--------|--------|-------------------|--------|
| Mass | NX expression | **`p1`** (NOT `p173`) | ✅ Confirmed — 11.33 kg baseline |
| Tip displacement | ❓ Sensor or .f06 parse | TBD | Gap G3, G6 — need baseline run |
| Von Mises stress | ❓ Sensor or .f06 parse | TBD | Gap G4, G6 — need baseline run |
> ⚠️ **Mass expression changed:** `p1` confirmed in KBS session, replacing previous assumption of `p173`. Extractor config must be updated.
## Mesh Details
| Property | Value | Notes |
|----------|-------|-------|
| Element type | CQUAD4 | 4-node quadrilateral, first-order |
| Element size | 33.7 mm | 67.4 / 2 — Antoine says refinement is "not for now" |
| Mesh method | Subdivision-based | Auto-mesh with size control |
| Shell formulation | Thin shell | Mid-surface extracted from solid |
| Convergence | ❓ **NOT VERIFIED** | Gap G8 partially closed (type known), but convergence check still needed |
### Mesh Estimate
- Beam length 5,000 mm / 33.7 mm ≈ 148 elements along length
- Perimeter of I-beam cross-section ≈ varies — but total mesh likely 10K–50K elements
- Expected DOF: 60K–300K → SOL 101 solve time: seconds to low minutes
## Solver Considerations
*From Technical Breakdown (Gen 001), updated with KBS data:*
- **Linear assumption:** With 11.33 kg beam under 98 kN load, deflections may be significant relative to beam dimensions. L/δ ratio needs verification from baseline run.
- **Mesh sensitivity:** Stress at hole edges is mesh-dependent. CQUAD4 at 33.7 mm may not fully resolve SCF at 300 mm diameter holes (~28 elements around circumference — probably adequate but needs verification).
- **Mesh morphing vs remesh:** Parametric NX models typically remesh on update. Need to confirm behavior across DV range (Gap G7).
- **Runtime estimate:** Single beam, CQUAD4 thin shell → likely **seconds per evaluation**. Very fast.
- **Unit system:** NX model uses kg-mm-s (kgf for force). Nastran output stress in kPa → divide by 1000 for MPa.
## Validation Checklist
- [ ] Baseline mass matches NX expression `p1` (11.33 kg)
- [ ] Baseline displacement measured (was 22 mm at old model state — **needs re-verification** G10)
- [ ] Baseline stress measured (never had a value — **G11**)
- [ ] Mesh convergence verified at baseline
- [ ] Mesh quality acceptable at DV range extremes
- [ ] Model rebuilds cleanly at all 4 corners of design space (Gap G7)
- [ ] Stress at hole edges resolved with current mesh density
## History
- **Gen 001** (2026-02-09): Initial documentation from technical breakdown. All solver details pending gap resolution.
- **Gen 002** (2026-02-10): Confirmed from KBS session — CQUAD4 thin shell, 33.7 mm element size, cantilever BCs (left fixed, right 10,000 kgf down), mass via `p1`. Material: AISI 1005.