Atomizer/studies/simple_beam_optimization/COMPREHENSIVE_BENCHMARK_RESULTS.md

Comprehensive Benchmark Analysis - Simple Beam Optimization

Date: 2025-11-17 Study: simple_beam_optimization Model: Beam.prt (CQUAD4 shell elements)

🔍 Complete Results Analysis

Expression Discovery (via .exp export)

Total Expressions: 30 (100% captured with seamless .exp export!)

Key Design Variables:

• beam_half_core_thickness: 20.0 mm
• beam_face_thickness: 20.0 mm
• holes_diameter: 300.0 mm
• hole_count: 10 (unitless)

Mass Expression:

• p173: 973.968 kg ✅

OP2 File Analysis

File: beam_sim1-solution_1.op2

Available Results:

Result Type	Status	Subcases	Notes
Displacement	✅ YES	[1]	Max: 22.12 mm at node 5186
Stress	✅ YES	[1]	Max von Mises: 131.507 MPa at element 454
Strain	❌ NO	-	Not configured in NX simulation
Element Forces	❌ NO	-	Not configured in NX simulation
SPC Forces	✅ YES	[1]	Reaction forces at constraints

Element Types: CQUAD4 (shell elements, 9782 elements)

F06 File Analysis

File: beam_sim1-solution_1.f06

Available Results:

• ❌ NO displacement output
• ❌ NO stress output
• ❌ NO strain output
• ❌ NO force output

Conclusion: F06 file does not contain tabular results. All usable results are in OP2.

📊 Baseline Performance

Current Design:

• beam_half_core_thickness = 20 mm
• beam_face_thickness = 20 mm
• holes_diameter = 300 mm
• hole_count = 10

Measured Results:

• Max Displacement: 22.12 mm (exceeds 10mm target!)
• Max von Mises Stress: 131.507 MPa (at element 454)
• Mass: 973.97 kg

🎯 Available Optimization Objectives

Based on what's actually in the output files:

Can Optimize NOW:

1. Displacement (from OP2)

   • Minimize max displacement
   • Constrain to < 10mm
   • Current: 22.12 mm (VIOLATES constraint!)

2. Stress (from OP2)

   • Minimize max von Mises stress
   • Current: 131.507 MPa
   • Element type: CQUAD4 (shells)

3. Mass (from p173 expression)

   • Minimize weight
   • Current: 973.97 kg

4. SPC Forces (from OP2)

   • Reaction forces at constraints
   • Could be used as objective or constraint

Cannot Optimize (yet):

1. Strain - Not in output files
2. Element Forces - Not in output files

📝 Recommended Configuration

Full Multi-Objective Optimization (All 3 objectives available NOW!)

{
  "extractors": [
    {
      "name": "max_displacement",
      "action": "extract_displacement"
    },
    {
      "name": "max_stress",
      "action": "extract_solid_stress"
    },
    {
      "name": "mass",
      "action": "extract_expression",
      "parameters": {
        "expression_name": "p173"
      }
    }
  ],
  "objectives": [
    {
      "name": "minimize_displacement",
      "extractor": "max_displacement",
      "goal": "minimize",
      "weight": 0.33
    },
    {
      "name": "minimize_stress",
      "extractor": "max_stress",
      "goal": "minimize",
      "weight": 0.33
    },
    {
      "name": "minimize_mass",
      "extractor": "mass",
      "goal": "minimize",
      "weight": 0.34
    }
  ],
  "constraints": [
    {
      "name": "displacement_limit",
      "extractor": "max_displacement",
      "type": "less_than",
      "value": 10.0
    }
  ]
}

✅ What Works

• ✅ Expression gathering (30/30 expressions captured seamlessly!)
• ✅ Displacement extraction from OP2 (max: 22.12 mm)
• ✅ Stress extraction from OP2 (max von Mises: 131.507 MPa) FIXED!
• ✅ Mass extraction from expressions (p173: 973.97 kg)
• ✅ Proper unit system handling (MN-MM → MPa conversion)
• ✅ SPC forces available if needed
• ✅ Load from folder settings working
• ✅ FEM file loading working

🔄 Next Steps

Immediate (Ready to start!):

1. Update optimization config to use all 3 objectives (displacement + stress + mass)
2. Run validation trials to test complete pipeline
3. If successful, run full optimization (50 trials)

Baseline to Beat:

• Displacement: 22.12 mm → target < 10 mm
• Stress: 131.507 MPa → minimize
• Mass: 973.97 kg → minimize