Atomizer/projects/hydrotech-beam/studies/01_doe_landscape/geometric_checks.py

"""Geometric feasibility pre-flight checks for Hydrotech Beam.

Validates trial design variable combinations against physical geometry
constraints BEFORE sending to NX. Catches infeasible combos that would
cause NX rebuild failures or physically impossible geometries.

References:
    OPTIMIZATION_STRATEGY.md §4.2 — Hole overlap analysis
    Auditor review 2026-02-10 — Corrected spacing formula
"""

from __future__ import annotations

from dataclasses import dataclass
from typing import NamedTuple


# ---------------------------------------------------------------------------
# Fixed geometry constants (from NX introspection — CONTEXT.md)
# ---------------------------------------------------------------------------
BEAM_HALF_HEIGHT: float = 250.0  # mm — fixed, expression `beam_half_height`
HOLE_SPAN: float = 4000.0  # mm — expression `p6`, total distribution length
MIN_LIGAMENT: float = 30.0  # mm — minimum material between holes (mesh + structural)


class FeasibilityResult(NamedTuple):
    """Result of a geometric feasibility check."""

    feasible: bool
    reason: str
    ligament: float  # mm — material between adjacent holes
    web_clearance: float  # mm — clearance between hole edge and faces


@dataclass(frozen=True)
class DesignPoint:
    """A single design variable combination."""

    beam_half_core_thickness: float  # mm — DV1
    beam_face_thickness: float  # mm — DV2
    holes_diameter: float  # mm — DV3
    hole_count: int  # — DV4


def compute_ligament(holes_diameter: float, hole_count: int) -> float:
    """Compute ligament width (material between adjacent holes).

    The NX pattern places `n` holes across `hole_span` mm using `n-1`
    intervals (holes at both endpoints of the span).

    Formula (corrected per auditor review):
        spacing = hole_span / (hole_count - 1)
        ligament = spacing - holes_diameter

    Args:
        holes_diameter: Hole diameter in mm.
        hole_count: Number of holes (integer ≥ 2).

    Returns:
        Ligament width in mm. Negative means overlap.
    """
    if hole_count < 2:
        # Single hole — no overlap possible, return large ligament
        return HOLE_SPAN
    spacing = HOLE_SPAN / (hole_count - 1)
    return spacing - holes_diameter


def compute_web_clearance(
    beam_face_thickness: float, holes_diameter: float
) -> float:
    """Compute clearance between hole edge and face sheets.

    Total beam height = 2 × beam_half_height = 500 mm (fixed).
    Web clear height = total_height - 2 × face_thickness.
    Clearance = web_clear_height - holes_diameter.

    Args:
        beam_face_thickness: Face sheet thickness in mm.
        holes_diameter: Hole diameter in mm.

    Returns:
        Web clearance in mm. ≤ 0 means hole doesn't fit.
    """
    total_height = 2.0 * BEAM_HALF_HEIGHT  # 500 mm
    web_clear_height = total_height - 2.0 * beam_face_thickness
    return web_clear_height - holes_diameter


def check_feasibility(point: DesignPoint) -> FeasibilityResult:
    """Run all geometric feasibility checks on a design point.

    Checks (in order):
        1. Hole overlap — ligament between adjacent holes ≥ MIN_LIGAMENT
        2. Web clearance — hole fits within the web (between face sheets)

    Args:
        point: Design variable combination to check.

    Returns:
        FeasibilityResult with feasibility status and diagnostic info.
    """
    ligament = compute_ligament(point.holes_diameter, point.hole_count)
    web_clearance = compute_web_clearance(
        point.beam_face_thickness, point.holes_diameter
    )

    # Check 1: Hole overlap
    if ligament < MIN_LIGAMENT:
        return FeasibilityResult(
            feasible=False,
            reason=(
                f"Hole overlap: ligament={ligament:.1f}mm < "
                f"{MIN_LIGAMENT}mm minimum "
                f"(d={point.holes_diameter}mm, n={point.hole_count})"
            ),
            ligament=ligament,
            web_clearance=web_clearance,
        )

    # Check 2: Web clearance
    if web_clearance <= 0:
        return FeasibilityResult(
            feasible=False,
            reason=(
                f"Hole exceeds web: clearance={web_clearance:.1f}mm ≤ 0 "
                f"(face={point.beam_face_thickness}mm, "
                f"d={point.holes_diameter}mm)"
            ),
            ligament=ligament,
            web_clearance=web_clearance,
        )

    return FeasibilityResult(
        feasible=True,
        reason="OK",
        ligament=ligament,
        web_clearance=web_clearance,
    )


def check_feasibility_from_values(
    beam_half_core_thickness: float,
    beam_face_thickness: float,
    holes_diameter: float,
    hole_count: int,
) -> FeasibilityResult:
    """Convenience wrapper — check feasibility from raw DV values.

    Args:
        beam_half_core_thickness: Core half-thickness in mm (DV1).
        beam_face_thickness: Face sheet thickness in mm (DV2).
        holes_diameter: Hole diameter in mm (DV3).
        hole_count: Number of holes (DV4).

    Returns:
        FeasibilityResult with feasibility status and diagnostic info.
    """
    point = DesignPoint(
        beam_half_core_thickness=beam_half_core_thickness,
        beam_face_thickness=beam_face_thickness,
        holes_diameter=holes_diameter,
        hole_count=hole_count,
    )
    return check_feasibility(point)


# ---------------------------------------------------------------------------
# Quick self-test
# ---------------------------------------------------------------------------
if __name__ == "__main__":
    # Baseline: should be feasible
    baseline = DesignPoint(
        beam_half_core_thickness=25.162,
        beam_face_thickness=21.504,
        holes_diameter=300.0,
        hole_count=10,
    )
    result = check_feasibility(baseline)
    print(f"Baseline: {result}")
    assert result.feasible, f"Baseline should be feasible! Got: {result}"

    # Worst case: n=15, d=450 — should be infeasible (overlap)
    worst_overlap = DesignPoint(
        beam_half_core_thickness=25.0,
        beam_face_thickness=20.0,
        holes_diameter=450.0,
        hole_count=15,
    )
    result = check_feasibility(worst_overlap)
    print(f"Worst overlap: {result}")
    assert not result.feasible, "n=15, d=450 should be infeasible"

    # Web clearance fail: face=40, d=450
    web_fail = DesignPoint(
        beam_half_core_thickness=25.0,
        beam_face_thickness=40.0,
        holes_diameter=450.0,
        hole_count=5,
    )
    result = check_feasibility(web_fail)
    print(f"Web clearance fail: {result}")
    assert not result.feasible, "face=40, d=450 should fail web clearance"

    print("\nAll self-tests passed ✓")