feat: Implement Study Organization System (Organization v2.0)
Reorganized simple_beam_optimization study and created templates for future
studies following best practices for clarity, chronology, and self-documentation.
## Study Reorganization (simple_beam_optimization)
**New Directory Structure**:
```
studies/simple_beam_optimization/
├── 1_setup/ # Pre-optimization setup
│ ├── model/ # Reference CAD/FEM model
│ └── benchmarking/ # Baseline validation results
├── 2_substudies/ # Optimization runs (numbered chronologically)
│ ├── 01_initial_exploration/
│ ├── 02_validation_3d_3trials/
│ ├── 03_validation_4d_3trials/
│ └── 04_full_optimization_50trials/
└── 3_reports/ # Study-level analysis
└── COMPREHENSIVE_BENCHMARK_RESULTS.md
```
**Key Changes**:
1. **Numbered Substudies**: 01_, 02_, 03_, 04_ indicate chronological order
2. **Reorganized Setup**: model/ and benchmarking/ moved to 1_setup/
3. **Centralized Reports**: Study-level docs moved to 3_reports/
4. **Substudy Documentation**: Each substudy has README.md explaining purpose/results
## Updated Metadata
**study_metadata.json** (v2.0):
- Tracks all 4 substudies with creation date, status, purpose
- Includes result summaries (best objective, feasible count)
- Documents new organization version
**Substudies Documented**:
- 01_initial_exploration - Initial design space exploration
- 02_validation_3d_3trials - Validate 3D parameter updates
- 03_validation_4d_3trials - Validate 4D updates including hole_count
- 04_full_optimization_50trials - Full 50-trial optimization
## Templates for Future Studies
**templates/study_template/** - Complete study structure:
- README.md template with study overview format
- study_metadata.json template with v2.0 schema
- Pre-created 1_setup/, 2_substudies/, 3_reports/ directories
**templates/substudy_README_template.md** - Standardized substudy documentation:
- Purpose and hypothesis
- Configuration changes from previous run
- Expected vs actual results
- Validation checklist
- Lessons learned
- Next steps
**templates/HOW_TO_CREATE_A_STUDY.md** - Complete guide:
- Quick start (9 steps from template to first run)
- Substudy workflow
- Directory structure reference
- Naming conventions
- Best practices
- Troubleshooting guide
- Examples
## Benefits
**Clarity**:
- Numbered substudies show chronological progression (01 → 02 → 03 → 04)
- Clear separation: setup vs. optimization runs vs. analysis
- Self-documenting via substudy READMEs
**Discoverability**:
- study_metadata.json provides complete substudy registry
- Each substudy README explains what was tested and why
- Easy to find results for specific runs
**Scalability**:
- Works for small studies (3 substudies) or large studies (50+)
- Chronological numbering scales to 99 substudies
- Template system makes new studies quick to set up
**Reproducibility**:
- Each substudy documents configuration changes
- Purpose and results clearly stated
- Lessons learned captured for future reference
## Implementation Details
**reorganize_study.py** - Migration script:
- Handles locked files gracefully
- Moves files to new structure
- Provides clear progress reporting
- Safe to run multiple times
**Organization Version**: 2.0
- Tracked in study_metadata.json
- Future studies will use this structure by default
- Existing studies can migrate or keep current structure
## Files Added
- templates/study_template/ - Complete study template
- templates/substudy_README_template.md - Substudy documentation template
- templates/HOW_TO_CREATE_A_STUDY.md - Comprehensive creation guide
- reorganize_study.py - Migration script for existing studies
## Files Reorganized (simple_beam_optimization)
**Moved to 1_setup/**:
- model/ → 1_setup/model/ (CAD/FEM reference files)
- substudies/benchmarking/ → 1_setup/benchmarking/
- baseline_validation.json → 1_setup/
**Renamed and Moved to 2_substudies/**:
- substudies/initial_exploration/ → 2_substudies/01_initial_exploration/
- substudies/validation_3trials/ → 2_substudies/02_validation_3d_3trials/
- substudies/validation_4d_3trials/ → 2_substudies/03_validation_4d_3trials/
- substudies/full_optimization_50trials/ → 2_substudies/04_full_optimization_50trials/
**Moved to 3_reports/**:
- COMPREHENSIVE_BENCHMARK_RESULTS.md → 3_reports/
**Substudy-Specific Docs** (moved to substudy directories):
- OPTIMIZATION_RESULTS_50TRIALS.md → 2_substudies/04_full_optimization_50trials/OPTIMIZATION_RESULTS.md
## Documentation Created
Each substudy now has README.md documenting:
- **01_initial_exploration**: Initial exploration purpose
- **02_validation_3d_3trials**: 3D parameter update validation
- **03_validation_4d_3trials**: hole_count validation success
- **04_full_optimization_50trials**: Full results, no feasible designs found
## Next Steps
**For Future Studies**:
1. Copy templates/study_template/
2. Follow templates/HOW_TO_CREATE_A_STUDY.md
3. Use numbered substudies (01_, 02_, ...)
4. Document each substudy with README.md
**For Existing Studies**:
- Can migrate using reorganize_study.py
- Or apply organization v2.0 to new substudies only
- See docs/STUDY_ORGANIZATION.md for migration guide
🤖 Generated with [Claude Code](https://claude.com/claude-code)
Co-Authored-By: Claude <noreply@anthropic.com>
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# Comprehensive Benchmark Analysis - Simple Beam Optimization
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**Date**: 2025-11-17
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**Study**: simple_beam_optimization
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**Model**: Beam.prt (CQUAD4 shell elements)
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## 🔍 Complete Results Analysis
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### Expression Discovery (via .exp export)
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**Total Expressions**: 30 (100% captured with seamless .exp export!)
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**Key Design Variables**:
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- `beam_half_core_thickness`: 20.0 mm
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- `beam_face_thickness`: 20.0 mm
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- `holes_diameter`: 300.0 mm
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- `hole_count`: 10 (unitless)
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**Mass Expression**:
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- `p173`: **973.968 kg** ✅
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### OP2 File Analysis
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**File**: beam_sim1-solution_1.op2
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**Available Results**:
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| Result Type | Status | Subcases | Notes |
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|-------------|--------|----------|-------|
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| Displacement | ✅ YES | [1] | Max: 22.12 mm at node 5186 |
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| Stress | ✅ YES | [1] | Max von Mises: 131.507 MPa at element 454 |
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| Strain | ❌ NO | - | Not configured in NX simulation |
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| Element Forces | ❌ NO | - | Not configured in NX simulation |
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| SPC Forces | ✅ YES | [1] | Reaction forces at constraints |
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**Element Types**: CQUAD4 (shell elements, 9782 elements)
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### F06 File Analysis
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**File**: beam_sim1-solution_1.f06
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**Available Results**:
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- ❌ NO displacement output
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- ❌ NO stress output
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- ❌ NO strain output
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- ❌ NO force output
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**Conclusion**: F06 file does not contain tabular results. All usable results are in OP2.
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## 📊 Baseline Performance
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**Current Design**:
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- beam_half_core_thickness = 20 mm
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- beam_face_thickness = 20 mm
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- holes_diameter = 300 mm
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- hole_count = 10
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**Measured Results**:
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- **Max Displacement**: 22.12 mm (exceeds 10mm target!)
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- **Max von Mises Stress**: 131.507 MPa (at element 454)
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- **Mass**: 973.97 kg
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## 🎯 Available Optimization Objectives
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Based on what's actually in the output files:
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### Can Optimize NOW:
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1. **Displacement** (from OP2)
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- Minimize max displacement
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- Constrain to < 10mm
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- Current: 22.12 mm (VIOLATES constraint!)
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2. **Stress** (from OP2)
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- Minimize max von Mises stress
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- Current: 131.507 MPa
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- Element type: CQUAD4 (shells)
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3. **Mass** (from p173 expression)
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- Minimize weight
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- Current: 973.97 kg
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4. **SPC Forces** (from OP2)
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- Reaction forces at constraints
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- Could be used as objective or constraint
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### Cannot Optimize (yet):
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1. **Strain** - Not in output files
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2. **Element Forces** - Not in output files
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## 📝 Recommended Configuration
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**Full Multi-Objective Optimization (All 3 objectives available NOW!)**
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```json
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{
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"extractors": [
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{
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"name": "max_displacement",
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"action": "extract_displacement"
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},
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{
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"name": "max_stress",
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"action": "extract_solid_stress"
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},
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{
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"name": "mass",
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"action": "extract_expression",
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"parameters": {
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"expression_name": "p173"
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}
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}
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],
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"objectives": [
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{
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"name": "minimize_displacement",
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"extractor": "max_displacement",
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"goal": "minimize",
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"weight": 0.33
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},
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{
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"name": "minimize_stress",
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"extractor": "max_stress",
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"goal": "minimize",
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"weight": 0.33
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},
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{
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"name": "minimize_mass",
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"extractor": "mass",
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"goal": "minimize",
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"weight": 0.34
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}
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],
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"constraints": [
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{
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"name": "displacement_limit",
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"extractor": "max_displacement",
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"type": "less_than",
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"value": 10.0
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}
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]
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}
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```
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## ✅ What Works
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- ✅ Expression gathering (30/30 expressions captured seamlessly!)
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- ✅ Displacement extraction from OP2 (max: 22.12 mm)
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- ✅ Stress extraction from OP2 (max von Mises: 131.507 MPa) **FIXED!**
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- ✅ Mass extraction from expressions (p173: 973.97 kg)
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- ✅ Proper unit system handling (MN-MM → MPa conversion)
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- ✅ SPC forces available if needed
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- ✅ Load from folder settings working
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- ✅ FEM file loading working
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## 🔄 Next Steps
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**Immediate (Ready to start!)**:
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1. Update optimization config to use all 3 objectives (displacement + stress + mass)
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2. Run validation trials to test complete pipeline
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3. If successful, run full optimization (50 trials)
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**Baseline to Beat**:
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- Displacement: 22.12 mm → target < 10 mm
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- Stress: 131.507 MPa → minimize
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- Mass: 973.97 kg → minimize
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