Anto01
2f3afc3813
Major Features: - Hierarchical substudy system (like NX Solutions/Subcases) * Shared model files across all substudies * Independent configuration per substudy * Continuation support from previous substudies * Real-time incremental history updates - Live history tracking with optimization_history_incremental.json - Complete bracket_displacement_maximizing study with substudy examples Core Fixes: - Fixed expression update workflow to pass design_vars through simulation_runner * Restored working NX journal expression update mechanism * OP2 timestamp verification instead of file deletion * Resolved issue where all trials returned identical objective values - Fixed LLMOptimizationRunner to pass design variables to simulation runner - Enhanced NXSolver with timestamp-based file regeneration verification New Components: - optimization_engine/llm_optimization_runner.py - LLM-driven optimization runner - optimization_engine/optimization_setup_wizard.py - Phase 3.3 setup wizard - studies/bracket_displacement_maximizing/ - Complete substudy example * run_substudy.py - Substudy runner with continuation * run_optimization.py - Standalone optimization runner * config/substudy_template.json - Template for new substudies * substudies/coarse_exploration/ - 20-trial coarse search * substudies/fine_tuning/ - 50-trial refinement (continuation example) * SUBSTUDIES_README.md - Complete substudy documentation Technical Improvements: - Incremental history saving after each trial (optimization_history_incremental.json) - Expression update workflow: .prt update → NX journal receives values → geometry update → FEM update → solve - Trial indexing fix in substudy result saving - Updated README with substudy system documentation Testing: - Successfully ran 20-trial coarse_exploration substudy - Verified different objective values across trials (workflow fix validated) - Confirmed live history updates in real-time - Tested shared model file usage across substudies 🤖 Generated with [Claude Code](https://claude.com/claude-code) Co-Authored-By: Claude <noreply@anthropic.com>
116 lines
3.8 KiB
Markdown
116 lines
3.8 KiB
Markdown
# Bracket Displacement Maximization Study
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**Study Name**: bracket_displacement_maximizing
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**Created**: 2025-11-16
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**Phase**: 3.3 - Optimization Setup Wizard
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## Overview
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This study demonstrates the complete Phase 3.3 workflow for optimizing a bracket design to maximize displacement while maintaining structural safety.
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## Problem Statement
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**Objective**: Maximize the displacement of a bracket under load
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**Constraints**:
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- Safety factor ≥ 4.0
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- Material: Aluminum 6061-T6 (Yield strength = 276 MPa)
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- Allowable stress: 69 MPa (276/4)
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**Design Variables**:
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- `tip_thickness`: 15-25 mm (baseline: 17 mm)
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- `support_angle`: 20-40° (baseline: 38°)
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## Model Information
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- **Geometry**: Bracket part with tip and support features
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- **Mesh**: 585 nodes, 316 elements (CHEXA, CPENTA)
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- **Load**: Applied force at tip
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- **Boundary Conditions**: Fixed support at base
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## Optimization Setup
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### Phase 3.3 Wizard Workflow
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1. **Model Introspection** - Read NX expressions from .prt file
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2. **Baseline Simulation** - Run initial simulation to validate setup
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3. **OP2 Introspection** - Auto-detect element types (CHEXA, CPENTA)
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4. **Workflow Configuration** - Build LLM workflow with detected element types
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5. **Pipeline Validation** - Dry-run test of all components
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6. **Optimization** - Run 20-trial TPE optimization
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### Extractors
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- **Displacement**: Extract max displacement from OP2 file
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- **Stress**: Extract von Mises stress from solid elements (auto-detected: CHEXA)
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### Calculations
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- **Safety Factor**: `SF = 276.0 / max_von_mises`
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- **Objective**: `neg_displacement = -max_displacement` (minimize for maximization)
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### Constraints
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- **Safety Factor Hook**: Enforces SF ≥ 4.0 with penalty
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## Directory Structure
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```
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bracket_displacement_maximizing/
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├── model/ # NX model files (isolated from tests/)
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│ ├── Bracket.prt # Part geometry
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│ ├── Bracket_fem1.fem # FE model
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│ └── Bracket_sim1.sim # Simulation setup
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├── results/ # Optimization results
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│ ├── optimization_history.json
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│ ├── best_design.json
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│ └── trial_*.op2 # OP2 files for each trial
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├── config/ # Study configuration
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│ └── study_config.json # Complete study setup
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├── run_optimization.py # Main optimization script
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├── optimization_log.txt # Execution log
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└── README.md # This file
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```
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## Running the Study
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```bash
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cd studies/bracket_displacement_maximizing
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python run_optimization.py
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```
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The script will:
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1. Initialize the Phase 3.3 wizard
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2. Validate the complete pipeline
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3. Run 20 optimization trials
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4. Save results to `results/` directory
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5. Generate comprehensive report
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## Results
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Results are saved in the `results/` directory:
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- **optimization_history.json**: Complete trial history
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- **best_design.json**: Best design parameters and performance
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- **optimization_report.md**: Human-readable summary
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## Key Features Demonstrated
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✅ **Phase 3.3 Wizard** - Automated validation before optimization
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✅ **Dynamic Element Detection** - Auto-detects all element types from OP2
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✅ **Self-Contained Study** - Isolated model files prevent conflicts
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✅ **Complete Logging** - Full execution trace for debugging
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✅ **Reproducible** - Configuration files enable exact reproduction
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## Notes
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- All simulations run in the `model/` directory to isolate from test files
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- OP2 files are regenerated for each trial (no caching issues)
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- Study can be re-run without affecting other tests or studies
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- Configuration is fully documented in `config/study_config.json`
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## References
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- [Phase 3.3 Wizard Documentation](../../docs/PHASE_3_3_WIZARD.md)
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- [Hook Architecture](../../docs/HOOK_ARCHITECTURE.md)
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- [LLM Integration](../../docs/PHASE_2_7_LLM_INTEGRATION.md)
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