Antoine
2fde08daab
- KB Gen 003: NX version (DesigncenterNX 2512), first real results - sol101-static.md: path resolution lessons, in-place solving, result extraction confirmed - CONTEXT.md: solver pipeline operational, first results (disp=17.93mm, stress=111.9MPa) - DECISIONS.md: DEC-HB-008 to DEC-HB-011 (backup/restore, iteration arch, history DB, git workflow) - optimization_engine/README.md: created (DesigncenterNX support, path resolution, NX file refs) - studies/01_doe_landscape/README.md: updated architecture, iteration folders, history DB - _index.md: closed gaps G3,G4,G6,G10-G14, updated generation to 003
92 lines
4.2 KiB
Markdown
92 lines
4.2 KiB
Markdown
# Knowledge Base — Hydrotech Beam
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**Project:** Hydrotech Beam Structural Optimization
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**Generation:** 003
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**Last updated:** 2026-02-11
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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 **1,133.01 kg** baseline while meeting displacement (≤ 10 mm) and stress (≤ 130 MPa) constraints.
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**Key confirmed parameters (Gen 003):**
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- Beam length: 5,000 mm (`beam_lenght` ⚠️ typo in NX), cantilever — left fixed, right loaded
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- Load: 10,000 kgf downward at free end
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- Baseline mass: **1,133.01 kg** (expression `p173: body_property147.mass`)
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- DV baselines: face=21.504mm, core=25.162mm, holes_dia=300mm, hole_count=10
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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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- **Solver:** DesigncenterNX 2512 (NX Nastran SOL 101)
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- **First results (2026-02-11):** Displacement=17.93mm, Stress=111.9MPa, Solve time ~12s/trial
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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 003 — Solver running, first results obtained |
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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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| **003** | **2026-02-11** | **First real results! NX version fix (DesigncenterNX 2512), path resolution, backup/restore architecture, history DB, mass extraction via journal** |
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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
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| # | Item | Why It Matters | Priority |
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|---|------|---------------|----------|
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| G7 | NX parametric rebuild reliability | Untested across full DV range — need corner-case testing | 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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### ✅ CLOSED (Gen 003 — 2026-02-11)
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| # | Item | Resolution | Closed In |
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|---|------|------------|-----------|
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| G3 | Displacement measurement location | Max Tz at free end, extracted via pyNastran OP2 | Gen 003 |
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| G4 | Stress constraint scope | Whole model max von Mises (CQUAD4 shell) | Gen 003 |
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| G6 | Result sensors in Beam_sim1.sim | Using pyNastran OP2 parsing, not NX sensors | Gen 003 |
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| G10 | Baseline displacement | 17.93 mm at baseline-ish DVs | Gen 003 |
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| G11 | Baseline stress | 111.9 MPa at baseline-ish DVs | Gen 003 |
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| G12 | `beam_half_height` value | 250 mm — confirmed via binary introspection | Gen 002+ |
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| G13 | `beam_half_width` value | 150 mm — confirmed via binary introspection | Gen 002+ |
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| G14 | Hole diameter expression name | `holes_diameter` — confirmed via binary introspection | Gen 002+ |
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## Open Tasks
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1. **Run full 51-trial DOE** — solver pipeline operational, execute Phase 1
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2. **Corner-case testing** — verify NX rebuild at DV extremes (G7)
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3. **Decision on `p6` as DV** — consult Manager/CEO (G15)
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4. **Phase 1 → Phase 2 gate review** — after DOE completes, assess feasibility landscape
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