feat: Add M1 mirror Zernike optimization with correct RMS calculation
Major improvements to telescope mirror optimization workflow: Assembly FEM Workflow (solve_simulation.py): - Fixed multi-part assembly FEM update sequence - Use ImportFromFile() for reliable expression updates - Add DuplicateNodesCheckBuilder with MergeOccurrenceNodes=True - Switch to Foreground solve mode for multi-subcase solutions - Add detailed logging and diagnostics for node merge operations Zernike RMS Calculation: - CRITICAL FIX: Use correct surface-based RMS formula - Global RMS = sqrt(mean(W^2)) from actual WFE values - Filtered RMS = sqrt(mean(W_residual^2)) after removing low-order fit - This matches zernike_Post_Script_NX.py (optical standard) - Previous WRONG formula was: sqrt(sum(coeffs^2)) - Add compute_rms_filter_j1to3() for optician workload metric Subcase Mapping: - Fix subcase mapping to match NX model: - Subcase 1 = 90 deg (polishing orientation) - Subcase 2 = 20 deg (reference) - Subcase 3 = 40 deg - Subcase 4 = 60 deg New Study: M1 Mirror Zernike Optimization - Full optimization config with 11 design variables - 3 objectives: rel_filtered_rms_40_vs_20, rel_filtered_rms_60_vs_20, mfg_90_optician_workload - Neural surrogate support for accelerated optimization Documentation: - Update ZERNIKE_INTEGRATION.md with correct RMS formula - Update ASSEMBLY_FEM_WORKFLOW.md with expression import and node merge details - Add reference scripts from original zernike_Post_Script_NX.py 🤖 Generated with [Claude Code](https://claude.com/claude-code) Co-Authored-By: Claude <noreply@anthropic.com>
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Antoine
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{
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"$schema": "Atomizer M1 Mirror Zernike Optimization",
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"study_name": "m1_mirror_zernike_optimization",
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"description": "Telescope primary mirror support structure optimization using Zernike wavefront error metrics with neural acceleration",
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"design_variables": [
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{
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"name": "lateral_inner_angle",
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"expression_name": "lateral_inner_angle",
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"min": 25.0,
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"max": 28.5,
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"baseline": 26.79,
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"units": "degrees",
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"description": "Lateral support inner angle",
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"enabled": false
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},
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{
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"name": "lateral_outer_angle",
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"expression_name": "lateral_outer_angle",
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"min": 13.0,
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"max": 17.0,
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"baseline": 14.64,
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"units": "degrees",
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"description": "Lateral support outer angle",
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"enabled": false
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},
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{
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"name": "lateral_outer_pivot",
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"expression_name": "lateral_outer_pivot",
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"min": 9.0,
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"max": 12.0,
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"baseline": 10.40,
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"units": "mm",
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"description": "Lateral outer pivot position",
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"enabled": false
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},
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{
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"name": "lateral_inner_pivot",
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"expression_name": "lateral_inner_pivot",
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"min": 9.0,
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"max": 12.0,
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"baseline": 10.07,
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"units": "mm",
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"description": "Lateral inner pivot position",
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"enabled": false
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},
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{
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"name": "lateral_middle_pivot",
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"expression_name": "lateral_middle_pivot",
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"min": 18.0,
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"max": 23.0,
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"baseline": 20.73,
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"units": "mm",
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"description": "Lateral middle pivot position",
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"enabled": false
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},
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{
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"name": "lateral_closeness",
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"expression_name": "lateral_closeness",
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"min": 9.5,
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"max": 12.5,
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"baseline": 11.02,
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"units": "mm",
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"description": "Lateral support closeness parameter",
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"enabled": false
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},
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{
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"name": "whiffle_min",
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"expression_name": "whiffle_min",
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"min": 35.0,
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"max": 55.0,
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"baseline": 40.55,
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"units": "mm",
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"description": "Whiffle tree minimum parameter",
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"enabled": true
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},
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{
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"name": "whiffle_outer_to_vertical",
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"expression_name": "whiffle_outer_to_vertical",
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"min": 68.0,
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"max": 80.0,
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"baseline": 75.67,
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"units": "degrees",
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"description": "Whiffle tree outer to vertical angle",
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"enabled": true
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},
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{
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"name": "whiffle_triangle_closeness",
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"expression_name": "whiffle_triangle_closeness",
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"min": 50.0,
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"max": 65.0,
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"baseline": 60.00,
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"units": "mm",
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"description": "Whiffle tree triangle closeness",
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"enabled": false
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},
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{
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"name": "blank_backface_angle",
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"expression_name": "blank_backface_angle",
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"min": 3.5,
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"max": 5.0,
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"baseline": 4.23,
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"units": "degrees",
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"description": "Mirror blank backface angle",
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"enabled": false
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},
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{
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"name": "inner_circular_rib_dia",
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"expression_name": "inner_circular_rib_dia",
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"min": 480.0,
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"max": 620.0,
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"baseline": 534.00,
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"units": "mm",
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"description": "Inner circular rib diameter",
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"enabled": true
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}
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],
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"objectives": [
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{
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"name": "rel_filtered_rms_40_vs_20",
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"description": "Filtered RMS WFE at 40 deg relative to 20 deg reference",
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"direction": "minimize",
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"weight": 5.0,
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"target": 4.0,
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"units": "nm",
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"extractor": "zernike_relative",
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"extractor_config": {
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"target_subcase": "40",
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"reference_subcase": "20",
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"metric": "relative_filtered_rms_nm"
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}
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},
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{
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"name": "rel_filtered_rms_60_vs_20",
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"description": "Filtered RMS WFE at 60 deg relative to 20 deg reference",
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"direction": "minimize",
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"weight": 5.0,
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"target": 10.0,
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"units": "nm",
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"extractor": "zernike_relative",
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"extractor_config": {
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"target_subcase": "60",
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"reference_subcase": "20",
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"metric": "relative_filtered_rms_nm"
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}
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},
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{
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"name": "mfg_90_optician_workload",
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"description": "Optician workload at 90 deg polishing orientation (filtered RMS with J1-J3)",
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"direction": "minimize",
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"weight": 1.0,
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"target": 20.0,
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"units": "nm",
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"extractor": "zernike",
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"extractor_config": {
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"subcase": "90",
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"metric": "rms_filter_j1to3",
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"reference_subcase": "20"
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}
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}
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],
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"constraints": [
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{
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"name": "max_stress",
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"description": "Maximum von Mises stress in mirror assembly",
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"type": "upper_bound",
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"threshold": 10.0,
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"units": "MPa",
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"enabled": false
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}
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],
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"zernike_settings": {
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"n_modes": 50,
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"filter_low_orders": 4,
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"displacement_unit": "mm",
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"subcases": ["1", "2", "3", "4"],
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"subcase_labels": {"1": "90deg", "2": "20deg", "3": "40deg", "4": "60deg"},
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"reference_subcase": "2",
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"polishing_subcase": "1",
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"output_full_coefficients": true,
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"_note": "Subcase mapping matches NX: 1=90deg, 2=20deg(ref), 3=40deg, 4=60deg"
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},
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"optimization_settings": {
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"n_trials": 100,
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"n_fea_trials": 40,
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"n_neural_trials": 500,
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"sampler": "TPE",
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"seed": 42,
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"n_startup_trials": 15,
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"tpe_n_ei_candidates": 150,
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"tpe_multivariate": true,
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"objective_strategy": "weighted_sum",
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"objective_direction": "minimize"
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},
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"surrogate_settings": {
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"enabled": true,
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"model_type": "ParametricZernikePredictor",
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"training_config": {
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"hidden_channels": 128,
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"num_layers": 4,
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"learning_rate": 0.001,
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"epochs": 200,
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"batch_size": 8,
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"train_split": 0.8
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},
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"outputs": {
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"description": "50 Zernike coefficients x 4 subcases = 200 outputs",
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"coefficients_per_subcase": 50,
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"subcases": ["20", "40", "60", "90"]
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}
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},
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"nx_settings": {
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"nx_install_path": "C:\\Program Files\\Siemens\\NX2506",
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"model_dir": "C:\\Users\\Antoine\\CADTOMASTE\\Atomizer\\M1-Gigabit\\Latest",
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"sim_file": "ASSY_M1_assyfem1_sim1.sim",
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"solution_name": "Solution 1",
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"solve_all_subcases": true,
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"op2_pattern": "*-solution_1.op2",
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"op2_timeout_s": 1800,
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"op2_stable_s": 5,
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"post_solve_delay_s": 5
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},
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"output_settings": {
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"save_zernike_coefficients": true,
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"save_field_data": true,
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"generate_reports": true,
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"archive_results": true
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}
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}
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