Antoine
b88657b00c
Sources: 3 KBS capture sessions (20260210-132817, 20260210-161401, 20260210-163801)
Key changes:
- Mass corrected: 974 kg (p173) → 11.33 kg (p1) — KBS ground truth
- Beam length confirmed: 5,000 mm cantilever
- BCs confirmed: left fixed, right 10,000 kgf downward
- Material confirmed: AISI Steel 1005, density 7.3 g/cm³
- Mesh confirmed: CQUAD4 thin shell, 33.7 mm elements
- Hole geometry: span 4,000 mm (p6), offsets 500 mm fixed
- 3 gaps closed (G1, G2, G8), 6 new gaps identified (G10-G15)
- New expressions: beam_half_height, beam_half_width, beam_length, p6
Files: CONTEXT.md, kb/_index.md, kb/_history.md, kb/components/sandwich-beam.md,
kb/materials/steel-aisi.md, kb/fea/models/sol101-static.md, kb/dev/gen-002.md
90 lines
4.0 KiB
Markdown
90 lines
4.0 KiB
Markdown
# Knowledge Base — Hydrotech Beam
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**Project:** Hydrotech Beam Structural Optimization
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**Generation:** 002
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**Last updated:** 2026-02-10
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---
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## Overview
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I-beam optimization for a test fixture. Steel (AISI 1005) cantilever beam with lightening holes in the web. Goal: minimize mass from 11.33 kg baseline while meeting displacement (≤ 10 mm) and stress (≤ 130 MPa) constraints.
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**Key confirmed parameters (Gen 002):**
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- Beam length: 5,000 mm (cantilever — left fixed, right loaded)
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- Load: 10,000 kgf downward at free end
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- Baseline mass: 11.33 kg (expression `p1`)
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- Material: AISI Steel 1005 (density 7.3 g/cm³)
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- Mesh: CQUAD4 thin shell, 33.7 mm element size
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## Components
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| Component | File | Status |
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|-----------|------|--------|
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| Sandwich Beam | [sandwich-beam.md](components/sandwich-beam.md) | ✅ Updated Gen 002 |
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## Materials
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| Material | File | Status |
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|----------|------|--------|
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| Steel AISI 1005 | [steel-aisi.md](materials/steel-aisi.md) | ✅ Updated Gen 002 |
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## FEA
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| Model | File | Status |
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|-------|------|--------|
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| Static Analysis (SOL 101) | [fea/models/sol101-static.md](fea/models/sol101-static.md) | ✅ Updated Gen 002 — BCs confirmed, baseline run needed |
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## Generations
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| Gen | Date | Summary |
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|-----|------|---------|
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| 001 | 2026-02-09 | Initial KB from intake + technical breakdown |
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| **002** | **2026-02-10** | **KBS session processing — confirmed geometry, BCs, mesh, material, mass correction** |
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## Gap Tracker
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### ✅ CLOSED
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| # | Item | Resolution | Closed In |
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|---|------|------------|-----------|
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| G1 | Beam length and support conditions | 5,000 mm cantilever (left fixed, right free) | Gen 002 |
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| G2 | Loading definition | 10,000 kgf point load, downward (−Y), at free end | Gen 002 |
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| G8 | Mesh type and density | CQUAD4 thin shell, 33.7 mm element size (67.4/2) | Gen 002 |
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### 🟡 PARTIALLY RESOLVED
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| # | Item | Known | Remaining |
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|---|------|-------|-----------|
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| 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. |
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| 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. |
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### ❓ STILL OPEN (from Gen 001)
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| # | Item | Why It Matters | Priority |
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|---|------|---------------|----------|
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| G3 | Displacement measurement location | Which node(s)? Which DOF? Magnitude or component? | High |
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| G4 | Stress constraint scope | Whole model? Exclude supports? Hole edges? | High |
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| G6 | Result sensors in Beam_sim1.sim | Determines extractor approach | Medium |
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| G7 | NX parametric rebuild reliability | Untested across DV range | Medium |
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### 🆕 NEW GAPS (from Gen 002)
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| # | Item | Why It Matters | Priority |
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|---|------|---------------|----------|
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| G10 | Baseline displacement re-verification | 22 mm was from old model state (974 kg). True model is 11.33 kg — displacement likely different. | **High** |
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| G11 | Baseline stress value | Never measured. Essential for optimization setup. | **High** |
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| G12 | `beam_half_height` starting value | Expression exists but value not captured from KBS screenshots | Medium |
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| G13 | `beam_half_width` starting value | Expression exists but value not captured from KBS screenshots | Medium |
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| G14 | Hole diameter expression name | Need exact NX expression name (not just the value 300) | Medium |
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| G15 | `p6` (hole_span) as potential DV | Antoine suggested it could be optimized. Decision needed. | Medium |
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## Open Tasks
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1. **Run baseline SOL 101** — get fresh displacement and stress values (G10, G11)
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2. **NX model introspection** — extract all expression names/values, check sensors (G6, G12, G13, G14)
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3. **Corner-case testing** — verify NX rebuild at DV extremes (G7)
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4. **Geometric feasibility constraint** — implement hole collision check (G5)
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5. **Update atomizer_spec_draft.json** — mass expression `p1`, baseline 11.33 kg
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6. **Decision on `p6` as DV** — consult Manager/CEO (G15)
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