Atomizer/projects/hydrotech-beam/kb/_index.md

Knowledge Base — Hydrotech Beam

Project: Hydrotech Beam Structural Optimization Generation: 003 Last updated: 2026-02-11

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Overview

I-beam optimization for a test fixture. Steel (AISI 1005) cantilever beam with lightening holes in the web. Goal: minimize mass from 1,133.01 kg baseline while meeting displacement (≤ 10 mm) and stress (≤ 130 MPa) constraints.

Key confirmed parameters (Gen 003):

• Beam length: 5,000 mm (beam_lenght ⚠️ typo in NX), cantilever — left fixed, right loaded
• Load: 10,000 kgf downward at free end
• Baseline mass: 1,133.01 kg (expression p173: body_property147.mass)
• DV baselines: face=21.504mm, core=25.162mm, holes_dia=300mm, hole_count=10
• Material: AISI Steel 1005 (density 7.3 g/cm³)
• Mesh: CQUAD4 thin shell, 33.7 mm element size
• Solver: DesigncenterNX 2512 (NX Nastran SOL 101)
• First results (2026-02-11): Displacement=17.93mm, Stress=111.9MPa, Solve time ~12s/trial

Components

Component	File	Status
Sandwich Beam	sandwich-beam.md	✅ Updated Gen 002

Materials

Material	File	Status
Steel AISI 1005	steel-aisi.md	✅ Updated Gen 002

FEA

Model	File	Status
Static Analysis (SOL 101)	fea/models/sol101-static.md	✅ Updated Gen 003 — Solver running, first results obtained

Generations

Gen	Date	Summary
001	2026-02-09	Initial KB from intake + technical breakdown
002	2026-02-10	KBS session processing — confirmed geometry, BCs, mesh, material, mass correction
003	2026-02-11	First real results! NX version fix (DesigncenterNX 2512), path resolution, backup/restore architecture, history DB, mass extraction via journal

Gap Tracker

✅ CLOSED

#	Item	Resolution	Closed In
G1	Beam length and support conditions	5,000 mm cantilever (left fixed, right free)	Gen 002
G2	Loading definition	10,000 kgf point load, downward (−Y), at free end	Gen 002
G8	Mesh type and density	CQUAD4 thin shell, 33.7 mm element size (67.4/2)	Gen 002

🟡 PARTIALLY RESOLVED

#	Item	Known	Remaining
G5	Hole geometric feasibility	Span = 4,000 mm, offsets = 500 mm fixed. Baseline: 10 holes × 300 mm → ~144 mm ligament (OK)	Need collision check at DV extremes. 15 × 450 mm WILL overlap. Need feasibility constraint.
G9	Stress allowable basis	AISI 1005 yield ~285 MPa. 130 MPa → SF ≈ 2.2	Need confirmation that 130 MPa limit still applies to updated model.

❓ STILL OPEN

#	Item	Why It Matters	Priority
G7	NX parametric rebuild reliability	Untested across full DV range — need corner-case testing	Medium
G15	p6 (hole_span) as potential DV	Antoine suggested it could be optimized. Decision needed.	Medium

✅ CLOSED (Gen 003 — 2026-02-11)

#	Item	Resolution	Closed In
G3	Displacement measurement location	Max Tz at free end, extracted via pyNastran OP2	Gen 003
G4	Stress constraint scope	Whole model max von Mises (CQUAD4 shell)	Gen 003
G6	Result sensors in Beam_sim1.sim	Using pyNastran OP2 parsing, not NX sensors	Gen 003
G10	Baseline displacement	17.93 mm at baseline-ish DVs	Gen 003
G11	Baseline stress	111.9 MPa at baseline-ish DVs	Gen 003
G12	beam_half_height value	250 mm — confirmed via binary introspection	Gen 002+
G13	beam_half_width value	150 mm — confirmed via binary introspection	Gen 002+
G14	Hole diameter expression name	holes_diameter — confirmed via binary introspection	Gen 002+

Open Tasks

1. Run full 51-trial DOE — solver pipeline operational, execute Phase 1
2. Corner-case testing — verify NX rebuild at DV extremes (G7)
3. Decision on p6 as DV — consult Manager/CEO (G15)
4. Phase 1 → Phase 2 gate review — after DOE completes, assess feasibility landscape