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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/materials/steel-aisi.md
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# Steel (AISI)
**Status:** Placeholder — needs full material card details
---
## Properties
| Property | Value | Units | Source |
|----------|-------|-------|--------|
| Standard | AISI | — | Intake |
| Grade | ❓ TBD | — | Need from NX model |
| Yield strength | ❓ TBD | MPa | — |
| E (Young's modulus) | ❓ TBD | GPa | — |
| Density | ❓ TBD | kg/m³ | — |
| Poisson's ratio | ❓ TBD | — | — |
## Notes
- Stress allowable of 130 MPa was given as constraint — need to confirm basis (Gap G9)
- If yield is ~250 MPa, then 130 MPa implies SF ≈ 1.9 — conservative
- Material card should be extracted from NX model during introspection
## History
- **Gen 001** (2026-02-09): Placeholder from intake — "Steel (AISI)" is all we have
# Steel — AISI 1005
**Status:** Baseline material confirmed (Gen 002)
**NX Material Name:** "beam material" (inherited by thin shell property)
---
## Properties
| Property | Value | Units | Source | Confidence |
|----------|-------|-------|--------|------------|
| Standard | AISI / SAE | — | KBS session | ✅ Confirmed |
| Grade | **1005** | — | KBS session ("NSE steel 10 or 5" = ANSI Steel 1005) | ✅ Confirmed |
| Density | **7.3** | g/cm³ (7,300 kg/m³) | KBS session — Antoine stated directly | ✅ Confirmed |
| E (Young's modulus) | ~200 | GPa | Typical for AISI 1005 — **needs NX verification** | 🟡 Estimated |
| Yield strength | ~285 | MPa | Typical for AISI 1005 (cold-drawn) — **needs NX verification** | 🟡 Estimated |
| UTS | ~330 | MPa | Typical for AISI 1005 — **needs NX verification** | 🟡 Estimated |
| Poisson's ratio | ~0.29 | — | Typical for carbon steel — **needs NX verification** | 🟡 Estimated |
| Elongation | ~20 | % | Typical for AISI 1005 — **needs verification** | 🟡 Estimated |
## Notes on AISI 1005
- AISI 1005 is a **low-carbon plain steel** (0.06% max C) in the 10xx series
- Commonly used for structural applications — good weldability, moderate strength
- NX material library designation may vary (Antoine said "NSE steel 10 or 5" which maps to ANSI/AISI Steel 1005)
- **Density note:** Antoine stated 7.3 g/cm³. Standard steel is 7.85 g/cm³. The 7.3 value may be the NX library default or a specific setting. This affects mass calculation directly.
## Stress Allowable
| Parameter | Value | Basis | Status |
|-----------|-------|-------|--------|
| Stress constraint | 130 MPa | From intake — Gap G9 | 🟡 Not yet confirmed for Gen 002 |
| Implied safety factor | ~2.2 | vs. 285 MPa yield (estimated) | Conservative |
> ⚠️ Need to confirm whether the 130 MPa stress limit from Gen 001 intake still applies given the mass discrepancy resolution. The 130 MPa may have been set for the ~974 kg model.
## Future Material Expansion
Antoine explicitly requested future material support (KBS session 20260210-163801):
| Material | Standard | Priority | Notes |
|----------|----------|----------|-------|
| **Aluminum 6061** | — | Future | Antoine: "change this type of material for aluminum, 6061" |
| **Stainless Steel ANSI 310** | ANSI 310 | Future | Antoine: "stainless steel. ANSI, let's say 310" |
> Antoine's instruction: "Don't start with [these]. Just add this as a future expansion for the optimization process."
### Material Expansion Implications
- Multi-material optimization would change the problem fundamentally:
- Different E, ρ, σ_y for each material → different optimal geometries
- Could be handled as a categorical DV or separate optimization runs per material
- Aluminum 6061: E ≈ 69 GPa, ρ ≈ 2.7 g/cm³, σ_y ≈ 276 MPa — lighter but much less stiff
- SS 310: E ≈ 200 GPa, ρ ≈ 8.0 g/cm³, σ_y ≈ 205 MPa — heavier, similar stiffness, lower yield
## History
- **Gen 001** (2026-02-09): Placeholder — only knew "Steel (AISI)"
- **Gen 002** (2026-02-10): Confirmed AISI 1005 from KBS session. Density confirmed 7.3 g/cm³. Future materials flagged (Al 6061, SS 310). Typical mechanical properties added (pending NX verification).