Atomizer/studies/bracket_stiffness_optimization_V3

Bracket Stiffness Optimization Study

Multi-objective optimization to maximize bracket stiffness while minimizing mass.

Objectives

1. Maximize Stiffness (Primary)

   • Structural stiffness calculated as k = F/δ
   • Units: N/mm
   • Higher is better

2. Minimize Mass (Secondary + Constraint)

   • Total bracket mass
   • Units: kg
   • Hard Constraint: Mass ≤ 0.2 kg (200 grams)

Design Variables

Variable	Min	Max	Initial	Unit	Description
support_angle	30.0	90.0	60.0	degrees	Angle of support arm relative to base
tip_thickness	15.0	40.0	25.0	mm	Thickness of bracket tip where load is applied

Study Structure

bracket_stiffness_optimization/
├── README.md                           # This file
├── optimization_config.json            # Optimization settings
├── workflow_config.json                # Workflow definition
├── run_optimization.py                 # Main runner script
├── bracket_stiffness_extractor.py     # Results extractor
│
├── 1_setup/
│   └── model/
│       ├── Bracket.prt                 # NX part file
│       ├── Bracket_fem1_i.prt          # Idealized geometry
│       ├── Bracket_fem1.fem            # FEM definition
│       ├── Bracket_sim1.sim            # Simulation file
│       └── export_displacement_field.py # NX journal for field export
│
└── 2_results/
    ├── study.db                        # Optuna study database
    ├── optimization_summary.json       # Results summary
    ├── workflow.log                    # Execution log
    └── errors.log                      # Error log

Generic Extractors Used

This study uses reusable generic extractors from optimization_engine/extractors/:

1. field_data_extractor.py

   • Parses NX exported field data (.fld files)
   • Works for: displacement, stress, strain, temperature, any scalar field
   • Multiple aggregation methods: max_abs, max, min, mean, std

2. op2_extractor.py

   • Extracts data from Nastran OP2 files using pyNastran
   • Mass properties (with unit conversion ton→kg)
   • Grid point forces (fx, fy, fz, resultant)
   • ~10000x faster than F06 parsing

3. stiffness_calculator.py

   • Generic stiffness calculator: k = F/δ
   • Works for any structure: bracket, beam, plate, etc.
   • Combines field data and OP2 extractors

The bracket_stiffness_extractor.py is a thin wrapper that orchestrates these generic tools with bracket-specific parameters.

Workflow

Each optimization trial follows these steps:

1. Update Design Variables

   • Modify NX model expressions: support_angle, tip_thickness

2. Solve Simulation

   • Run NX Nastran SOL 101 (linear static analysis)
   • Output: .op2 and .f06 files

3. Export Displacement Field

   • Execute NX journal to export z-displacement
   • Output: export_field_dz.fld

4. Extract Results

   • Parse displacement field (max absolute z-displacement)
   • Extract applied force from OP2
   • Calculate stiffness: k = Force / Displacement
   • Extract mass from OP2 grid point weight

5. Evaluate Constraints

   • Check: mass ≤ 0.2 kg
   • If violated: prune trial

6. Report Results

   • Send to Optuna study database
   • Broadcast to dashboard via WebSocket

Running the Optimization

Basic Usage

cd studies/bracket_stiffness_optimization
python run_optimization.py

Advanced Options

# Custom number of trials
python run_optimization.py --trials 100

# Enable real-time dashboard
python run_optimization.py --dashboard

# Both
python run_optimization.py --trials 50 --dashboard

Testing Before Full Run

Test the extractors with a single trial first:

# Test extractor independently
python bracket_stiffness_extractor.py

Results Analysis

View in Dashboard

The React dashboard provides real-time monitoring:

• Convergence plot (stiffness over trials)
• Parameter space exploration
• Pareto front visualization
• Mass constraint violations

Access at: http://localhost:3001

Database Query

Results are stored in SQLite database 2_results/study.db:

import optuna

study = optuna.load_study(
    study_name="bracket_stiffness_optimization",
    storage="sqlite:///2_results/study.db"
)

# Get Pareto-optimal solutions
best_trials = study.best_trials

for trial in best_trials:
    stiffness_neg, mass = trial.values
    stiffness = -stiffness_neg
    print(f"Trial {trial.number}: Stiffness={stiffness:.2f} N/mm, Mass={mass:.6f} kg")
    print(f"  Params: {trial.params}")

Export Results

# Export to CSV
import pandas as pd

df = study.trials_dataframe()
df.to_csv('2_results/trials.csv', index=False)

# Export to JSON
import json
with open('2_results/trials.json', 'w') as f:
    json.dump([t.params | {'values': t.values} for t in study.trials], f, indent=2)

Optimization Settings

• Framework: Protocol 10 - Intelligent Multi-Strategy Optimization (IMSO)
• Adaptive Features:
  • Landscape characterization (analyzes problem structure)
  • Strategy selection (picks best algorithm automatically)
  • Dynamic switching (changes strategy when stagnating)
  • Adaptive surrogate modeling
• Strategies Available: TPE, CMA-ES, QMC, Random, NSGA-II
• Default trials: 50
• Parallelization: 1 job (sequential)

How Protocol 10 Works:

1. Characterization Phase (first 10 trials)

   • Random sampling to explore landscape
   • Analyzes: smoothness, multimodality, noise, dimensionality

2. Strategy Selection

   • Automatically picks best optimizer based on landscape
   • Example: Smooth → CMA-ES, Multimodal → TPE

3. Adaptive Optimization

   • Monitors progress every 10 trials
   • Switches strategies if stagnating
   • All history kept for surrogate modeling

Expected Performance

• Trial duration: ~2-5 minutes (depends on mesh size)
• 50 trials: ~2-4 hours
• Infeasibility rate: ~20-30% (trials violating mass constraint, but kept for surrogate)

Constraints

1. Mass Constraint: mass ≤ 0.2 kg
   • Trials exceeding this are NOT pruned - they complete normally
   • Kept in history for surrogate modeling (valuable search information)
   • Marked as infeasible in database with constraint_satisfied=False attribute
   • Not eligible for Pareto front - only feasible solutions reported as optimal
   • This approach preserves knowledge while enforcing hard constraints

Notes

• Simulation uses NX Nastran SOL 101 (linear static)
• Force units: Newtons (N)
• Displacement units: millimeters (mm)
• Mass units: kilograms (kg), converted from ton-mm-sec system
• Stiffness units: N/mm

Troubleshooting

NX Session Issues

If NX hangs or crashes:

# Kill all NX processes
taskkill /F /IM NXBIN.exe

Extractor Failures

Check that:

• ResultProbe is defined in simulation for z-displacement
• OP2 file is generated (check solver settings)
• Field export journal has correct path

Database Locked

If database is locked:

# Close all connections and restart
rm 2_results/study.db-journal

References

• Generic extractors: optimization_engine/extractors/
• NX solver: optimization_engine/nx_solver.py
• pyNastran docs: https://pynastran-git.readthedocs.io/