Antoine
b88657b00c
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
81 lines
4.2 KiB
Markdown
81 lines
4.2 KiB
Markdown
# 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.
|