Knowledge Base — Hydrotech Beam
Project: Hydrotech Beam Structural Optimization
Generation: 002
Last updated: 2026-02-10
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 002 + Introspection):
- 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
Components
Materials
| Material |
File |
Status |
| Steel AISI 1005 |
steel-aisi.md |
✅ Updated Gen 002 |
FEA
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 |
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 (from Gen 001)
| # |
Item |
Why It Matters |
Priority |
| G3 |
Displacement measurement location |
Which node(s)? Which DOF? Magnitude or component? |
High |
| G4 |
Stress constraint scope |
Whole model? Exclude supports? Hole edges? |
High |
| G6 |
Result sensors in Beam_sim1.sim |
Determines extractor approach |
Medium |
| G7 |
NX parametric rebuild reliability |
Untested across DV range |
Medium |
🆕 NEW GAPS (from Gen 002)
| # |
Item |
Why It Matters |
Priority |
| G10 |
Baseline displacement re-verification |
22 mm was from old model state (974 kg). True model is 11.33 kg — displacement likely different. |
High |
| G11 |
Baseline stress value |
Never measured. Essential for optimization setup. |
High |
| G12 |
beam_half_height starting value |
Expression exists but value not captured from KBS screenshots |
Medium |
| G13 |
beam_half_width starting value |
Expression exists but value not captured from KBS screenshots |
Medium |
| G14 |
Hole diameter expression name |
Need exact NX expression name (not just the value 300) |
Medium |
| G15 |
p6 (hole_span) as potential DV |
Antoine suggested it could be optimized. Decision needed. |
Medium |
Open Tasks
- Run baseline SOL 101 — get fresh displacement and stress values (G10, G11)
- NX model introspection — extract all expression names/values, check sensors (G6, G12, G13, G14)
- Corner-case testing — verify NX rebuild at DV extremes (G7)
- Geometric feasibility constraint — implement hole collision check (G5)
- Update atomizer_spec_draft.json — mass expression
p1, baseline 11.33 kg
- Decision on
p6 as DV — consult Manager/CEO (G15)
