forked from 1b-agent/fieldcraft-upstream
jyvikoandClaude Opus 5.5
90948833e0
crank-arm (and crank-mirror, kept as the same model under the name of its mirror workflow) now cut the crank on its symmetry plane and the half into seven cells: across the arm at x = 30, 60, 110 and 148, and on two diagonals radial to the pocket's corner fillets. Every cell's cross-section maps (four-sided blocks, the half O-grids round the bores, triangle primitives at the pocket's corners); exact edge seeds give each cut the same divisions on both sides, so mesh.cells merges all six cuts and mesh.mirror reflects the half: 7 710 hex20, scaled Jacobian min 0.37 (was 0.17, and 0.009 for the swept mirrored half), edge ratio at most 7.0. Root σxx ±62.43 MPa against M/Z 62.6 MPa, the spindle carries the 1500 N. The test asserts the quality floor. Gallery images regenerated. Fixes #247 Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_01UhhZMBTviDQxZvwnyP89fo
982 lines
54 KiB
Rust
982 lines
54 KiB
Rust
//! Sample models as scripts of ordinary commands, so they build the same way a user's script
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//! does.
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//!
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//! [`script`], the model the desktop app opens with `--sample`: two parts side by side, a
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//! 40 × 20 × 10 block of 5 mm hex8 cells, and a 15 mm cube split into 162 tet4 elements (each
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//! 5 mm cell into six tetrahedra around its main diagonal, the Kuhn subdivision, which is
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//! conforming between neighbouring cells). Every element is positively oriented.
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//!
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//! [`cantilever`], a model ready to solve: a steel beam clamped at one end with a load on the
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//! other, a static and a frequency step. [`impact`]: the same beam flying onto a rigid wall, an
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//! explicit dynamic step.
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//!
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//! The examples gallery (docs/examples.md), each ready to solve with `solve.run`:
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//! [`drop_test`], [`rubber_seal`], [`flow_past`], [`heated_bracket`], [`bracket_hex`] and [`crank_arm`]. Their
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//! geometry is a SolidCraft script run when the sample opens ([`Sample::design`]): a corpus
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//! recipe (`tests/corpus`) or [`UPRIGHT_BRACKET`].
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use fieldcraft_geometry::Shape;
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use serde_json::{Value, json};
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/// A sample the app offers (Help › Samples, the empty viewport, `file.sample`, `--sample NAME`).
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pub struct Sample {
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pub name: &'static str,
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pub label: &'static str,
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/// One line: what it shows.
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pub about: &'static str,
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/// The SolidCraft script (`{"commands": [...]}`, the corpus recipe form) that builds the
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/// sample's geometry, opened as its design before [`Sample::script`] runs.
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pub design: Option<&'static str>,
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/// Commands run on the opened design before [`Sample::script`] (datums and partitions), so
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/// the script is given the bodies as they cut it.
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pub prepare: Option<fn() -> Value>,
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/// The model's commands, given the design's bodies (none without a design).
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pub script: fn(&[Shape]) -> Value,
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}
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/// Every sample, the default first.
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pub const SAMPLES: &[Sample] = &[
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Sample {
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name: "parts",
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label: "Hex and Tet Parts",
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about: "A hex8 block beside a tet4 cube: meshes to look at, nothing to solve",
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design: None,
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prepare: None,
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script: |_| script(),
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},
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Sample {
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name: "cantilever",
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label: "Cantilever",
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about: "A clamped steel beam with an end load: a static and a frequency step, ready to solve",
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design: None,
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prepare: None,
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script: |_| cantilever(),
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},
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Sample {
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name: "impact",
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label: "Bar Impact",
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about: "The steel beam flying onto a rigid wall: an explicit dynamic step, ready to solve",
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design: None,
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prepare: None,
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script: |_| impact(),
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},
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Sample {
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name: "drop-test",
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label: "Drop Test",
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about: "An aluminium L-bracket dropped 2 m onto a tilted rigid floor: explicit dynamics, the strike and its stress waves",
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design: Some(UPRIGHT_BRACKET),
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prepare: None,
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script: |_| drop_test(),
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},
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Sample {
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name: "rubber-seal",
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label: "Rubber Seal",
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about: "A rubber gasket ring squeezed 25 % between bonded plates: nonlinear static, Mooney–Rivlin, large strain",
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design: None,
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prepare: None,
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script: |_| rubber_seal(),
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},
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Sample {
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name: "flow-past",
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label: "Flow Past a Bracket",
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about: "Air flowing past an L-bracket on the floor: lattice Boltzmann flow and the force on each face",
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design: Some(UPRIGHT_BRACKET),
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prepare: None,
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script: |_| flow_past(),
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},
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Sample {
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name: "heated-bracket",
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label: "Heated Bracket",
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about: "A steel bracket clamped at its holes and heated at one end: steady heat conduction and the thermal stress",
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design: Some(FILLETED_BRACKET),
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prepare: None,
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script: |_| heated_bracket(),
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},
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Sample {
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name: "bracket-hex",
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label: "Hex-Meshed Bracket",
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about: "The filleted bracket split into 30 cells and meshed all-hex (hex20): clamped, loaded, von Mises",
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design: Some(PARTITIONED_BRACKET),
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prepare: None,
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script: bracket_hex,
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},
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Sample {
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name: "crank-mirror",
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label: "Mirrored Crank Arm",
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about: "The crank arm of crank-arm under the name of its mirror workflow: a partitioned half meshed structured all-hex (hex20) and mirrored into one conforming mesh",
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design: Some(CRANK_ARM),
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prepare: Some(crank_prepare),
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script: crank_arm,
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},
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Sample {
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name: "crank-arm",
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label: "Bicycle Crank Arm",
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about: "An aluminium bicycle crank meshed structured all-hex (hex20) from a partitioned half and its mirror image: square bore fixed, a rider's weight on the pedal, von Mises",
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design: Some(CRANK_ARM),
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prepare: Some(crank_prepare),
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script: crank_arm,
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},
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];
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/// The sample called `name`.
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pub fn find(name: &str) -> Option<&'static Sample> {
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SAMPLES.iter().find(|s| s.name == name)
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}
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/// Hex block: cells along x, y, z and the cell size (mm).
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const HEX_CELLS: [u32; 3] = [8, 4, 2];
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/// Tet cube: cells per side and its offset from the origin (mm).
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const TET_CELLS: u32 = 3;
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const TET_ORIGIN: [f64; 3] = [50.0, 2.5, 0.0];
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const CELL: f64 = 5.0;
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/// The script: `mesh.node.add` and `mesh.element.add` steps.
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pub fn script() -> Value {
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let mut steps = Vec::new();
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let mut node = 0u32;
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let mut element = 0u32;
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// Hex block.
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let [nx, ny, nz] = HEX_CELLS;
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let first = node + 1;
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let hid = |i: u32, j: u32, k: u32| first + i + j * (nx + 1) + k * (nx + 1) * (ny + 1);
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for k in 0..=nz {
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for j in 0..=ny {
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for i in 0..=nx {
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node += 1;
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steps.push(json!({"command": "mesh.node.add", "params": {"label": node, "xyz": [f64::from(i) * CELL, f64::from(j) * CELL, f64::from(k) * CELL]}}));
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}
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}
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}
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for k in 0..nz {
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for j in 0..ny {
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for i in 0..nx {
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element += 1;
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let nodes = [
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hid(i, j, k),
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hid(i + 1, j, k),
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hid(i + 1, j + 1, k),
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hid(i, j + 1, k),
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hid(i, j, k + 1),
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hid(i + 1, j, k + 1),
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hid(i + 1, j + 1, k + 1),
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hid(i, j + 1, k + 1),
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];
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steps.push(json!({"command": "mesh.element.add", "params": {"label": element, "kind": "hex8", "nodes": nodes}}));
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}
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}
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}
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// Tet cube.
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let n = TET_CELLS;
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let first = node + 1;
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let tid = |i: u32, j: u32, k: u32| first + i + j * (n + 1) + k * (n + 1) * (n + 1);
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let at = |i: u32, j: u32, k: u32| [TET_ORIGIN[0] + f64::from(i) * CELL, TET_ORIGIN[1] + f64::from(j) * CELL, TET_ORIGIN[2] + f64::from(k) * CELL];
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for k in 0..=n {
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for j in 0..=n {
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for i in 0..=n {
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node += 1;
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steps.push(json!({"command": "mesh.node.add", "params": {"label": node, "xyz": at(i, j, k)}}));
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}
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}
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}
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// The six axis orders: each walks from the cell's corner (0,0,0) to (1,1,1) one axis at a time.
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const ORDERS: [[usize; 3]; 6] = [[0, 1, 2], [0, 2, 1], [1, 0, 2], [1, 2, 0], [2, 0, 1], [2, 1, 0]];
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for k in 0..n {
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for j in 0..n {
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for i in 0..n {
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for order in ORDERS {
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let mut c = [0u32; 3];
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let mut corners = vec![c];
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for axis in order {
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if let Some(x) = c.get_mut(axis) {
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*x = 1;
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}
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corners.push(c);
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}
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let mut nodes: Vec<u32> = corners.iter().map(|c| tid(i + c[0], j + c[1], k + c[2])).collect();
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let p: Vec<[f64; 3]> = corners.iter().map(|c| at(i + c[0], j + c[1], k + c[2])).collect();
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if signed_volume(&p) < 0.0 {
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nodes.swap(1, 2);
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}
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element += 1;
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steps.push(json!({"command": "mesh.element.add", "params": {"label": element, "kind": "tet4", "nodes": nodes}}));
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}
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}
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}
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}
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Value::Array(steps)
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}
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/// The cantilever's length (x), width (y) and height (z) in mm, and its hex8 cells along each.
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pub const CANTILEVER_SIZE: [f64; 3] = [100.0, 10.0, 20.0];
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const CANTILEVER_CELLS: [u32; 3] = [20, 2, 4];
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/// The beam's mesh in steel (E = 210 GPa, ν = 0.3, ρ = 7.85 t/m³ in mm, t, s, N, MPa): nodes,
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/// hex8 elements, sets `beam` (elements), `root` (nodes at x = 0) and `tip` (at x = L), the
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/// material `Steel` and a solid section `Beam` with the given formulation.
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fn beam(formulation: Value) -> Vec<Value> {
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let [nx, ny, nz] = CANTILEVER_CELLS;
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let [lx, ly, lz] = CANTILEVER_SIZE;
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let id = |i: u32, j: u32, k: u32| 1 + i + j * (nx + 1) + k * (nx + 1) * (ny + 1);
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let mut steps = vec![json!({"command": "model.units", "params": {"system": "mm-t-s-N-MPa"}})];
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for k in 0..=nz {
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for j in 0..=ny {
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for i in 0..=nx {
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let xyz = [lx * f64::from(i) / f64::from(nx), ly * f64::from(j) / f64::from(ny), lz * f64::from(k) / f64::from(nz)];
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steps.push(json!({"command": "mesh.node.add", "params": {"label": id(i, j, k), "xyz": xyz}}));
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}
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}
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}
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let mut element = 0u32;
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for k in 0..nz {
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for j in 0..ny {
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for i in 0..nx {
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element += 1;
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let nodes = [
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id(i, j, k),
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id(i + 1, j, k),
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id(i + 1, j + 1, k),
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id(i, j + 1, k),
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id(i, j, k + 1),
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id(i + 1, j, k + 1),
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id(i + 1, j + 1, k + 1),
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id(i, j + 1, k + 1),
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];
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steps.push(json!({"command": "mesh.element.add", "params": {"label": element, "kind": "hex8", "nodes": nodes}}));
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}
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}
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}
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let end = |i: u32| -> Vec<u32> { (0..=nz).flat_map(|k| (0..=ny).map(move |j| id(i, j, k))).collect() };
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steps.extend([
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json!({"command": "model.set.create", "params": {"name": "beam", "elements": (1..=element).collect::<Vec<_>>()}}),
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json!({"command": "model.set.create", "params": {"name": "root", "nodes": end(0)}}),
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json!({"command": "model.set.create", "params": {"name": "tip", "nodes": end(nx)}}),
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json!({"command": "model.material.create", "params": {"name": "Steel", "elastic": {"type": "isotropic", "young": 210000, "poisson": 0.3}, "density": 7.85e-9}}),
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json!({"command": "model.section.create", "params": {"name": "Beam", "set": "beam", "material": "Steel", "kind": {"type": "solid"}, "formulation": formulation}}),
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]);
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steps
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}
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/// A steel cantilever of hex8 elements with incompatible modes ([`CANTILEVER_SIZE`]), clamped at
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/// x = 0 (set `root`), with a total force of 1000 N down on the free end (set `tip`); step
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/// `Load` (static) and step `Modes` (six modes). Euler–Bernoulli puts the tip
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/// 4 P L³ / (E w h³) = 0.238 mm down.
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pub fn cantilever() -> Value {
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let mut steps = beam(json!({"incompatible_modes": true}));
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steps.extend([
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json!({"command": "model.boundary_condition.create", "params": {"name": "Clamp", "type": "fixed", "target": {"set": "root"}}}),
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json!({"command": "model.load.create", "params": {"name": "Push", "type": "force", "target": {"set": "tip"}, "vector": [0, 0, -1000]}}),
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json!({"command": "model.step.create", "params": {"name": "Load", "procedure": {"type": "static"}, "boundary_conditions": ["Clamp"], "loads": ["Push"]}}),
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json!({"command": "model.step.create", "params": {"name": "Modes", "procedure": {"type": "frequency", "modes": 6}, "boundary_conditions": ["Clamp"]}}),
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]);
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Value::Array(steps)
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}
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/// The same steel beam in one-point hex8 elements, flying at 10 m/s onto a rigid wall at x = 0:
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/// step `Impact` (explicit dynamics, 40 µs, ten field frames, energies and the tip's history).
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/// The compression wave runs the 100 mm bar in about 19 µs (c = √(E/ρ) ≈ 5.2 mm/µs).
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pub fn impact() -> Value {
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let mut steps = beam(json!({"integration": "reduced"}));
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let step = json!({
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"type": "explicit_dynamic", "end_time": 4e-5, "output_interval": 4e-6, "history_interval": 2e-7, "history_nodes": "tip",
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"initial_velocities": [{"set": "all_nodes", "velocity": [-10000, 0, 0]}],
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"rigid_walls": [{"set": "root", "point": [0, 0, 0], "normal": [1, 0, 0]}]
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});
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let [nx, ny, nz] = CANTILEVER_CELLS;
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let nodes = (nx + 1) * (ny + 1) * (nz + 1);
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steps.extend([
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json!({"command": "model.set.create", "params": {"name": "all_nodes", "nodes": (1..=nodes).collect::<Vec<_>>()}}),
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json!({"command": "model.step.create", "params": {"name": "Impact", "procedure": step}}),
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]);
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Value::Array(steps)
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}
|
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|
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/// An L-bracket standing on its foot, Z up, as a SolidCraft script: a 60 × 40 mm foot and a 50 mm
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/// upright, both 8 mm thick, with an R6 fillet inside the bend (the corpus `filleted-bracket`'s
|
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/// profile without its holes, sketched on XZ so it sweeps along y). Body `Bracket`; its faces
|
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/// `F2:side:l1` (the foot's underside, z = 0), `l2` (the foot's end, x = 60), `l3` (the foot's top),
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/// `l4` (the upright's inside, x = 8), `l5` (the upright's top, z = 50) and `l6` (its back, x = 0).
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pub const UPRIGHT_BRACKET: &str = r#"{"commands": [
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{"command": "sketch.create", "params": {"plane": "XZ", "name": "Profile"}},
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{"command": "sketch.line", "params": {"points": [[0, 0], [60, 0], [60, -8], [8, -8], [8, -50], [0, -50]], "closed": true}},
|
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{"command": "sketch.finish", "params": {}},
|
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{"command": "solid.extrude", "params": {"distance": 40, "body_name": "Bracket"}},
|
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{"command": "solid.fillet", "params": {"edges": [[8, 20, 8]], "radius": 6}}
|
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]}"#;
|
||
|
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/// Aluminium (E = 70 GPa, ν = 0.33, ρ = 2.7 t/m³, yield 240 MPa with 700 MPa linear hardening),
|
||
/// in mm, t, s, N, MPa.
|
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fn aluminium(name: &str) -> Value {
|
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json!({"command": "model.material.create", "params": {"name": name, "elastic": {"type": "isotropic", "young": 70000, "poisson": 0.33}, "density": 2.7e-9,
|
||
"plastic": {"type": "bilinear", "yield_stress": 240, "hardening_modulus": 700, "hardening": "isotropic"}}})
|
||
}
|
||
|
||
/// Standard gravity, mm/s².
|
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pub const GRAVITY: f64 = 9810.0;
|
||
/// The drop test's height of fall, mm: the bracket meets the floor at √(2 g h) = 6.26 m/s.
|
||
pub const DROP_HEIGHT: f64 = 2000.0;
|
||
/// The drop test's floor tilt about y, degrees: the foot's end strikes first.
|
||
const DROP_TILT: f64 = 15.0;
|
||
|
||
/// [`UPRIGHT_BRACKET`] in aluminium, hex8 elements swept 3 mm (one-point, stiffness hourglass
|
||
/// control), falling at √(2 g h) onto a rigid floor tilted 15° so the foot's end lands first,
|
||
/// 0.1 mm below that corner; gravity on. Step `Drop` (explicit dynamics, 1 ms: the strike, the
|
||
/// stress waves through the bend and the bracket pivoting onto its foot; 20 field frames, the
|
||
/// upright's top (set `top`) in the histories).
|
||
pub fn drop_test() -> Value {
|
||
let speed = (2.0 * GRAVITY * DROP_HEIGHT).sqrt();
|
||
let tilt = DROP_TILT.to_radians();
|
||
let step = json!({
|
||
"type": "explicit_dynamic", "end_time": 1e-3, "output_interval": 5e-5, "history_interval": 5e-6, "history_nodes": "top",
|
||
"initial_velocities": [{"set": "bracket", "velocity": [0, 0, -speed]}],
|
||
"rigid_walls": [{"set": "bracket", "point": [60, 0, -0.1], "normal": [-tilt.sin(), 0, tilt.cos()]}],
|
||
"hourglass": {"type": "stiffness", "coefficient": 0.05}
|
||
});
|
||
json!([
|
||
{"command": "model.units", "params": {"system": "mm-t-s-N-MPa"}},
|
||
{"command": "mesh.hex.generate", "params": {"body": "Bracket", "size": 3, "method": "extrude"}},
|
||
{"command": "model.set.create", "params": {"name": "bracket", "geometry": [{"body": "Bracket"}]}},
|
||
{"command": "model.set.create", "params": {"name": "top", "geometry": [{"body": "Bracket", "face": "F2:side:l5"}]}},
|
||
aluminium("Aluminium"),
|
||
{"command": "model.section.create", "params": {"name": "Bracket", "set": "bracket", "material": "Aluminium", "kind": {"type": "solid"}, "formulation": {"integration": "reduced"}}},
|
||
{"command": "model.load.create", "params": {"name": "Gravity", "type": "gravity", "acceleration": [0, 0, -GRAVITY]}},
|
||
{"command": "model.step.create", "params": {"name": "Drop", "procedure": step, "loads": ["Gravity"]}},
|
||
])
|
||
}
|
||
|
||
/// The rubber seal: inner and outer radius and height of the ring (mm), and how far it is squeezed.
|
||
pub const SEAL: [f64; 3] = [20.0, 30.0, 10.0];
|
||
pub const SEAL_SQUEEZE: f64 = 2.5;
|
||
|
||
/// A rubber gasket ring ([`SEAL`]: 20 mm inside radius, 30 mm outside, 10 mm high) of hybrid hex8
|
||
/// elements, four mapped quarter blocks with arc edges (body `Seal`, block faces `bottom` and
|
||
/// `top`), squeezed by [`SEAL_SQUEEZE`] (25 %) between plates bonded to it: `bottom` fixed, `top`
|
||
/// moved down with its in-plane motion held. Generic rubber: E = 6 MPa, ν = 0.49, Mooney–Rivlin
|
||
/// with C01 = 0.2 MPa (C10 = μ/2 − C01 = 0.81 MPa). Step `Squeeze` (nonlinear static).
|
||
pub fn rubber_seal() -> Value {
|
||
let [inner, outer, height] = SEAL;
|
||
let mut steps = vec![json!({"command": "model.units", "params": {"system": "mm-t-s-N-MPa"}})];
|
||
for quarter in 0..4u8 {
|
||
let (a0, a1) = (f64::from(quarter) * std::f64::consts::FRAC_PI_2, f64::from(quarter + 1) * std::f64::consts::FRAC_PI_2);
|
||
let at = |r: f64, a: f64, z: f64| [r * a.cos(), r * a.sin(), z];
|
||
let corners = [
|
||
at(inner, a0, 0.0),
|
||
at(outer, a0, 0.0),
|
||
at(outer, a1, 0.0),
|
||
at(inner, a1, 0.0),
|
||
at(inner, a0, height),
|
||
at(outer, a0, height),
|
||
at(outer, a1, height),
|
||
at(inner, a1, height),
|
||
];
|
||
let arc = |a: u8, b: u8, z: f64| json!({"corners": [a, b], "arc": {"center": [0, 0, z]}});
|
||
steps.push(json!({"command": "mesh.block", "params": {
|
||
"body": "Seal", "kind": "hex8", "corners": corners, "divisions": [5, 10, 5],
|
||
"edges": [arc(1, 4, 0.0), arc(2, 3, 0.0), arc(5, 8, height), arc(6, 7, height)],
|
||
"faces": {"1": "bottom", "2": "top"}
|
||
}}));
|
||
}
|
||
steps.extend([
|
||
json!({"command": "model.set.create", "params": {"name": "seal", "geometry": [{"body": "Seal"}]}}),
|
||
json!({"command": "model.set.create", "params": {"name": "bottom", "geometry": [{"body": "Seal", "face": "bottom"}]}}),
|
||
json!({"command": "model.set.create", "params": {"name": "top", "geometry": [{"body": "Seal", "face": "top"}]}}),
|
||
json!({"command": "model.material.create", "params": {"name": "Rubber", "elastic": {"type": "isotropic", "young": 6, "poisson": 0.49}, "density": 1.1e-9,
|
||
"hyperelastic": {"type": "mooney_rivlin", "c01": 0.2}}}),
|
||
json!({"command": "model.section.create", "params": {"name": "Seal", "set": "seal", "material": "Rubber", "kind": {"type": "solid"}, "formulation": {"hybrid": true}}}),
|
||
json!({"command": "model.boundary_condition.create", "params": {"name": "Base", "type": "fixed", "target": {"set": "bottom"}}}),
|
||
json!({"command": "model.boundary_condition.create", "params": {"name": "Press", "type": "displacement", "target": {"set": "top"}, "values": [0, 0, -SEAL_SQUEEZE, null, null, null]}}),
|
||
json!({"command": "model.step.create", "params": {"name": "Squeeze", "procedure": {"type": "nonlinear_static", "initial_increment": 0.1}, "boundary_conditions": ["Base", "Press"]}}),
|
||
]);
|
||
Value::Array(steps)
|
||
}
|
||
|
||
/// The flow sample's free-stream speed, mm/s.
|
||
pub const FLOW_SPEED: f64 = 25.0;
|
||
/// Air at 20 °C: density (t/mm³) and dynamic viscosity (MPa s).
|
||
const AIR: [f64; 2] = [1.2e-12, 1.8e-11];
|
||
|
||
/// Air at [`FLOW_SPEED`] past [`UPRIGHT_BRACKET`] standing on the floor, the upright's back face
|
||
/// to the wind: a 240 × 120 × 100 mm box of 2.5 mm cells (184 320), a uniform inlet at x_min, an
|
||
/// outlet at zero pressure at x_max, a no-slip floor and slip walls at the sides and top. Reynolds
|
||
/// number ρ U h / μ = 83 on the upright's 50 mm height: laminar, a steady wake. Step `Flow` (16 s,
|
||
/// about 6.7 flow-throughs; ten frames) reports the force on each named face of the bracket.
|
||
pub fn flow_past() -> Value {
|
||
let [density, viscosity] = AIR;
|
||
json!([
|
||
{"command": "model.units", "params": {"system": "mm-t-s-N-MPa"}},
|
||
{"command": "model.material.create", "params": {"name": "Air", "density": density, "fluid": {"type": "newtonian", "viscosity": viscosity}}},
|
||
{"command": "model.fluid_domain.create", "params": {
|
||
"name": "Wind", "material": "Air", "min": [-60, -40, 0], "max": [180, 80, 100], "spacing": 2.5,
|
||
"faces": {
|
||
"x_min": {"type": "velocity", "velocity": [FLOW_SPEED, 0, 0]}, "x_max": {"type": "pressure", "pressure": 0},
|
||
"y_min": {"type": "slip"}, "y_max": {"type": "slip"}, "z_min": {"type": "wall"}, "z_max": {"type": "slip"}
|
||
},
|
||
"obstacles": ["Bracket"], "initial_velocity": [FLOW_SPEED, 0, 0]
|
||
}},
|
||
{"command": "model.step.create", "params": {"name": "Flow", "procedure": {"type": "fluid", "domain": "Wind", "end_time": 16, "frames": 10}}},
|
||
])
|
||
}
|
||
|
||
/// The corpus filleted bracket (`tests/corpus/filleted-bracket`): an 8 mm L-bracket, foot along
|
||
/// x (60 mm) and upright along y (50 mm), extruded 40 mm along z, an R6 fillet, an 8 mm hole
|
||
/// through each leg (`F4` through the foot at x = 40, `F5` through the upright at y = 32).
|
||
pub const FILLETED_BRACKET: &str = include_str!("../../../tests/corpus/filleted-bracket/recipe.json");
|
||
|
||
/// The heated bracket: the heater's and the surrounding air's temperatures (°C, also the stress
|
||
/// free temperature), and steel's expansion coefficient (1/K).
|
||
pub const HEATER: f64 = 120.0;
|
||
pub const AMBIENT: f64 = 20.0;
|
||
pub const STEEL_EXPANSION: f64 = 1.2e-5;
|
||
|
||
/// [`FILLETED_BRACKET`] in steel (k = 50 W/(m K), α = 12 × 10⁻⁶/K, stress free at 20 °C), tet10
|
||
/// elements of 4 mm: its upright's end (`F2:side:l5`, set `hot`) held at [`HEATER`], the rest of
|
||
/// its outside (set `skin`) cooled by still air at [`AMBIENT`] (h = 10 W/(m² K)), both hole bores
|
||
/// clamped (set `holes`). Step `Heat` (coupled temperature–displacement, steady): the
|
||
/// temperature field and the stress of the expansion the clamps hold back. In mm, t, s, N, MPa:
|
||
/// k in mW/(mm K), h in mW/(mm² K).
|
||
pub fn heated_bracket() -> Value {
|
||
let face = |f: &str| json!({"body": "Bracket", "face": f});
|
||
let skin: Vec<Value> =
|
||
["F2:start", "F2:top", "F2:side:l1", "F2:side:l2", "F2:side:l3", "F2:side:l4", "F2:side:l6", "F3:blend:F2:side:l3|F2:side:l4"]
|
||
.into_iter()
|
||
.map(face)
|
||
.collect();
|
||
let holes: Vec<Value> = ["F4:bore:side:0", "F4:bore:side:1", "F5:bore:side:0", "F5:bore:side:1"].into_iter().map(face).collect();
|
||
json!([
|
||
{"command": "model.units", "params": {"system": "mm-t-s-N-MPa"}},
|
||
{"command": "mesh.tet.generate", "params": {"body": "Bracket", "size": 4, "order": "quadratic", "tolerance": 0.05}},
|
||
{"command": "model.set.create", "params": {"name": "bracket", "geometry": [{"body": "Bracket"}]}},
|
||
{"command": "model.set.create", "params": {"name": "holes", "geometry": holes}},
|
||
{"command": "model.set.create", "params": {"name": "hot", "geometry": [face("F2:side:l5")]}},
|
||
{"command": "model.set.create", "params": {"name": "skin", "geometry": skin}},
|
||
{"command": "model.material.create", "params": {"name": "Steel", "elastic": {"type": "isotropic", "young": 210000, "poisson": 0.3}, "density": 7.85e-9,
|
||
"thermal": {"conductivity": 50, "specific_heat": 4.6e8, "expansion": STEEL_EXPANSION, "reference_temperature": AMBIENT}}},
|
||
{"command": "model.section.create", "params": {"name": "Bracket", "set": "bracket", "material": "Steel", "kind": {"type": "solid"}}},
|
||
{"command": "model.boundary_condition.create", "params": {"name": "Clamp", "type": "fixed", "target": {"set": "holes"}}},
|
||
{"command": "model.boundary_condition.create", "params": {"name": "Heater", "type": "temperature", "target": {"set": "hot"}, "value": HEATER}},
|
||
{"command": "model.load.create", "params": {"name": "Air", "type": "convection", "set": "skin", "film": 0.01, "sink": AMBIENT}},
|
||
{"command": "model.step.create", "params": {"name": "Heat", "procedure": {"type": "coupled_temperature_displacement"}, "boundary_conditions": ["Clamp", "Heater"], "loads": ["Air"]}},
|
||
])
|
||
}
|
||
|
||
/// The corpus filleted bracket split into 30 cells (`tests/corpus/filleted-bracket-blocks`),
|
||
/// each a mapped block: the part `mesh.hex.blocks` meshes all-hex.
|
||
pub const PARTITIONED_BRACKET: &str = include_str!("../../../tests/corpus/filleted-bracket-blocks/recipe.json");
|
||
|
||
/// [`PARTITIONED_BRACKET`] meshed all-hex as one conforming mesh of hex20 elements of 3 mm, in
|
||
/// steel: the upright's end (`F2:side:l5` in every cell that has it, set `top`) clamped, 1 kN down
|
||
/// (−y) on the foot's end (`F2:side:l2`, set `tip`). Step `Load` (linear static). `bodies` are the
|
||
/// design's cells.
|
||
pub fn bracket_hex(bodies: &[Shape]) -> Value {
|
||
let faces = |name: &str| -> Vec<Value> {
|
||
bodies.iter().filter(|b| b.faces().iter().any(|f| f.name == name)).map(|b| json!({"body": b.name, "face": name})).collect()
|
||
};
|
||
let cells: Vec<Value> = bodies.iter().map(|b| json!({"body": b.name})).collect();
|
||
json!([
|
||
{"command": "model.units", "params": {"system": "mm-t-s-N-MPa"}},
|
||
{"command": "mesh.hex.blocks", "params": {"size": 3, "order": 2}},
|
||
{"command": "model.set.create", "params": {"name": "bracket", "geometry": cells}},
|
||
{"command": "model.set.create", "params": {"name": "top", "geometry": faces("F2:side:l5")}},
|
||
{"command": "model.set.create", "params": {"name": "tip", "geometry": faces("F2:side:l2")}},
|
||
{"command": "model.material.create", "params": {"name": "Steel", "elastic": {"type": "isotropic", "young": 210000, "poisson": 0.3}, "density": 7.85e-9}},
|
||
{"command": "model.section.create", "params": {"name": "Bracket", "set": "bracket", "material": "Steel", "kind": {"type": "solid"}}},
|
||
{"command": "model.boundary_condition.create", "params": {"name": "Clamp", "type": "fixed", "target": {"set": "top"}}},
|
||
{"command": "model.load.create", "params": {"name": "Push", "type": "force", "target": {"set": "tip"}, "vector": [0, -1000, 0]}},
|
||
{"command": "model.step.create", "params": {"name": "Load", "procedure": {"type": "static"}, "boundary_conditions": ["Clamp"], "loads": ["Push"]}},
|
||
])
|
||
}
|
||
|
||
/// The bicycle crank arm (`crates/engine/samples/crank-arm.json`): a 170 mm aluminium arm, 16 mm
|
||
/// thick and tapering from 38 to 24 mm, joined by tangent root arcs to a Ø46 × 22 spindle boss
|
||
/// with a 12.7 mm square bore (R1.5 corners) and a Ø30 × 20 pedal boss with a Ø14 hole, and an
|
||
/// 82 × 14 × 8 pocket in its back (R5 corners). Made to be swept all-hex by `mesh.hex.generate`
|
||
/// as a stack of extrusions along z: no pocket floor fillet or boss chamfers, and the root arcs
|
||
/// meet the bosses about 20° off tangent (tangent to a circle 0.5 mm inside each boss), since a
|
||
/// tangent meeting leaves a zero-angle cusp on the arm's top face.
|
||
pub const CRANK_ARM: &str = include_str!("../samples/crank-arm.json");
|
||
|
||
/// The crank arm's pedal load (N): a standing rider's weight on one pedal.
|
||
pub const PEDAL_LOAD: f64 = 1500.0;
|
||
|
||
/// The cells of the half `CrankArm/a` (y < 0) after [`crank_prepare`], from the spindle to the
|
||
/// pedal: the spindle boss and the arm's root (`X30`), the pocket's spindle end below the
|
||
/// diagonal `D1`, the arm between `D1` and `X60`, the middle of the arm (`X60` to `X110`), the arm
|
||
/// between `X110` and `D2`, the pocket's pedal end beyond `D2`, and the pedal boss (`X148`).
|
||
pub const CRANK_CELLS: [&str; 7] = [
|
||
"CrankArm/a/a",
|
||
"CrankArm/a/b/a",
|
||
"CrankArm/a/b/b/a",
|
||
"CrankArm/a/b/b/b/a",
|
||
"CrankArm/a/b/b/b/b/a",
|
||
"CrankArm/a/b/b/b/b/b/a",
|
||
"CrankArm/a/b/b/b/b/b/b",
|
||
];
|
||
|
||
/// The diagonals' angles from the arm's axis (degrees): `D1` through the centre of the pocket's
|
||
/// spindle-end corner fillet (53, −2), `D2` through the pedal-end one (125, −2), each radial to
|
||
/// its fillet so it meets the pocket wall square. Steeper than 45° from the pocket's floor edge
|
||
/// (y = 0) on its inner side and shallower than 45° from the arm's edge on its outer side, so the
|
||
/// pocket's middle keeps its corners there and the cells beyond it do not gain one.
|
||
const CRANK_DIAGONALS: [f64; 2] = [40.0, 32.0];
|
||
|
||
/// [`CRANK_ARM`] meshed structured all-hex (hex20 of 3 mm) from a partitioned half and mirrored,
|
||
/// in 6061-T6 aluminium: the square bore's faces and corner fillets (set `spindle`) fixed,
|
||
/// [`PEDAL_LOAD`] on the pedal hole (set `pedal`), in the crank's plane and across the arm (−y).
|
||
/// Step `Pedal` (linear static). The faces are picked by their surfaces, not their names: the
|
||
/// square bore's are the vertical planes 6.35 mm from the spindle axis and the R1.5 cylinders
|
||
/// beside it, the pedal hole is the Ø14 cylinder on the pedal axis.
|
||
///
|
||
/// The mesh: [`crank_prepare`] cuts the crank on its symmetry plane and the half `CrankArm/a`
|
||
/// into the seven [`CRANK_CELLS`], each a stack of extrusions whose cross-section splits into
|
||
/// regions that map: four-sided regions (transfinite), the half ring round each bore, and the
|
||
/// pocket's four corners cut off by the partitions, three-sided (the triangle primitive). Exact
|
||
/// edge seeds give each cut the same divisions in the two cells it divides, so `mesh.cells`
|
||
/// sweeps every cell (`extrude`) and merges them node for node; `mesh.mirror` reflects the half
|
||
/// onto `CrankArm/b`, joined on the plane.
|
||
pub fn crank_arm(bodies: &[Shape]) -> Value {
|
||
let cells = CRANK_CELLS;
|
||
let mut mesh = crank_seeds();
|
||
mesh.push(json!({"command": "mesh.cells", "params": {"bodies": cells, "default": "extrude", "size": 3, "order": 2}}));
|
||
// Each cell's image is part of the uncut half.
|
||
let images: serde_json::Map<String, Value> = cells.iter().map(|c| (c.to_string(), json!("CrankArm/b"))).collect();
|
||
mesh.push(json!({"command": "mesh.mirror", "params": {"plane": "Sym", "bodies": cells, "as": images}}));
|
||
crank_model(bodies, mesh)
|
||
}
|
||
|
||
/// The edge seeds that make every cut's divisions alike on its two sides: each cut's line in
|
||
/// the arm's cross-section (its bottom edge, z = 0) and, for the diagonals and the cuts across the
|
||
/// pocket, its line on the pocket's floor (z = 8); and the 16 mm walls of the end cells on their
|
||
/// cuts, in six layers as the pocket's floor level splits the cells between them (3 + 3). The
|
||
/// counts are those the cells' mapped regions need: the cut `X30` faces the spindle boss's arc
|
||
/// across the root (7), the arm between the diagonals is one block of five rows.
|
||
fn crank_seeds() -> Vec<Value> {
|
||
let [c1, c2, c3, c4, c5, c6, c7] = CRANK_CELLS;
|
||
let cut = |name: &str, a: &str, b: &str, face: &str, count: u32| {
|
||
json!({"command": "mesh.seed.edge", "params": {"edges": [
|
||
{"body": a, "edge": format!("{face}|partition:{name}:a")},
|
||
{"body": b, "edge": format!("{face}|partition:{name}:b")},
|
||
], "count": count}})
|
||
};
|
||
let mut seeds = vec![cut("X30", c1, c2, "F2:start", 7), cut("X148", c6, c7, "F2:start", 5)];
|
||
for (name, a, b) in [("D1", c2, c3), ("X60", c3, c4), ("X110", c4, c5), ("D2", c5, c6)] {
|
||
seeds.push(cut(name, a, b, "F2:start", 5));
|
||
seeds.push(cut(name, a, b, "F6:top", 3));
|
||
}
|
||
seeds.push(json!({"command": "mesh.seed.edge", "params": {"edges": [
|
||
{"body": c1, "edge": "F2:side:lo|partition:X30:a"},
|
||
{"body": c7, "edge": "F2:side:lo|partition:X148:b"},
|
||
], "count": 6}}));
|
||
seeds
|
||
}
|
||
|
||
/// The crank arm's symmetry plane (`Sym`, y = 0) and the partition by it (`Half`), then the
|
||
/// half `CrankArm/a` cut into [`CRANK_CELLS`]: across the arm at x = 30 (the root, beyond the
|
||
/// spindle boss), 60 and 110 (the pocket's straight middle) and 148 (before the pedal boss), and
|
||
/// on the diagonals of [`CRANK_DIAGONALS`]. Each cut names the one cell it divides.
|
||
fn crank_prepare() -> Value {
|
||
let [d1, d2] = CRANK_DIAGONALS.map(f64::to_radians);
|
||
let across = |x: f64| json!({"type": "offset", "plane": "yz", "offset": x});
|
||
let cuts = [
|
||
("X30", across(30.0), "CrankArm/a"),
|
||
("D1", json!({"type": "point_normal", "point": [53, -2, 0], "normal": [d1.sin(), -d1.cos(), 0]}), "CrankArm/a/b"),
|
||
("X60", across(60.0), "CrankArm/a/b/b"),
|
||
("X110", across(110.0), "CrankArm/a/b/b/b"),
|
||
("D2", json!({"type": "point_normal", "point": [125, -2, 0], "normal": [d2.sin(), d2.cos(), 0]}), "CrankArm/a/b/b/b/b"),
|
||
("X148", across(148.0), "CrankArm/a/b/b/b/b/b"),
|
||
];
|
||
let mut script = vec![
|
||
json!({"command": "geometry.datum", "params": {"name": "Sym", "by": {"type": "offset", "plane": "zx", "offset": 0}}}),
|
||
json!({"command": "geometry.partition", "params": {"name": "Half", "datum": "Sym"}}),
|
||
];
|
||
for (name, by, body) in cuts {
|
||
script.push(json!({"command": "geometry.datum", "params": {"name": name, "by": by}}));
|
||
script.push(json!({"command": "geometry.partition", "params": {"name": name, "datum": name, "bodies": [body]}}));
|
||
}
|
||
Value::Array(script)
|
||
}
|
||
|
||
/// The crank's model after the `mesh` commands: material, the spindle fixed, the rider on the
|
||
/// pedal, step `Pedal`.
|
||
fn crank_model(bodies: &[Shape], mesh: Vec<Value>) -> Value {
|
||
let [spindle, pedal] = crank_faces(bodies);
|
||
let mut script = vec![json!({"command": "model.units", "params": {"system": "mm-t-s-N-MPa"}})];
|
||
script.extend(mesh);
|
||
script.extend(json_array(json!([
|
||
{"command": "model.set.create", "params": {"name": "crank", "geometry": bodies.iter().map(|b| json!({"body": b.name})).collect::<Vec<_>>()}},
|
||
{"command": "model.set.create", "params": {"name": "spindle", "geometry": spindle}},
|
||
{"command": "model.set.create", "params": {"name": "pedal", "geometry": pedal}},
|
||
{"command": "model.material.create", "params": {"name": "Al6061-T6", "elastic": {"type": "isotropic", "young": 68900, "poisson": 0.33}, "density": 2.7e-9}},
|
||
{"command": "model.section.create", "params": {"name": "Crank", "set": "crank", "material": "Al6061-T6", "kind": {"type": "solid"}}},
|
||
{"command": "model.boundary_condition.create", "params": {"name": "Spindle", "type": "fixed", "target": {"set": "spindle"}}},
|
||
{"command": "model.load.create", "params": {"name": "Rider", "type": "force", "target": {"set": "pedal"}, "vector": [0, -PEDAL_LOAD, 0]}},
|
||
{"command": "model.step.create", "params": {"name": "Pedal", "procedure": {"type": "static"}, "boundary_conditions": ["Spindle"], "loads": ["Rider"]}},
|
||
])));
|
||
Value::Array(script)
|
||
}
|
||
|
||
fn json_array(v: Value) -> Vec<Value> {
|
||
match v {
|
||
Value::Array(a) => a,
|
||
other => vec![other],
|
||
}
|
||
}
|
||
|
||
/// The crank's square-bore faces and pedal-hole faces as set members, found by their surfaces.
|
||
fn crank_faces(bodies: &[Shape]) -> [Vec<Value>; 2] {
|
||
use fieldcraft_geometry::FaceSurface;
|
||
let vertical = |axis: [f64; 3]| axis[2].abs() > 1.0 - 1e-6;
|
||
let (mut spindle, mut pedal) = (Vec::new(), Vec::new());
|
||
for body in bodies {
|
||
let surfaces = body.face_surfaces().unwrap_or_default();
|
||
for (face, surface) in body.faces().iter().zip(surfaces) {
|
||
let member = json!({"body": body.name, "face": face.name});
|
||
match surface {
|
||
Some(FaceSurface::Plane { normal, point })
|
||
if normal[2].abs() < 1e-6 && ((normal[0] * point[0] + normal[1] * point[1]).abs() - 6.35).abs() < 1e-6 =>
|
||
{
|
||
spindle.push(member)
|
||
}
|
||
Some(FaceSurface::Cylinder { origin, axis, radius })
|
||
if vertical(axis) && (radius - 1.5).abs() < 1e-6 && origin[0].hypot(origin[1]) < 8.0 =>
|
||
{
|
||
spindle.push(member)
|
||
}
|
||
Some(FaceSurface::Cylinder { origin, axis, radius })
|
||
if vertical(axis) && (radius - 7.0).abs() < 1e-6 && (origin[0] - 170.0).hypot(origin[1]) < 1e-6 =>
|
||
{
|
||
pedal.push(member)
|
||
}
|
||
_ => {}
|
||
}
|
||
}
|
||
}
|
||
[spindle, pedal]
|
||
}
|
||
|
||
/// Six times the signed volume of the tetrahedron `p[0..4]` (positive when p3 lies on the side
|
||
/// p0 → p1 → p2 turns counter-clockwise around).
|
||
fn signed_volume(p: &[[f64; 3]]) -> f64 {
|
||
let (Some(a), Some(b), Some(c), Some(d)) = (p.first(), p.get(1), p.get(2), p.get(3)) else { return 0.0 };
|
||
let u = [b[0] - a[0], b[1] - a[1], b[2] - a[2]];
|
||
let v = [c[0] - a[0], c[1] - a[1], c[2] - a[2]];
|
||
let w = [d[0] - a[0], d[1] - a[1], d[2] - a[2]];
|
||
u[0] * (v[1] * w[2] - v[2] * w[1]) - u[1] * (v[0] * w[2] - v[2] * w[0]) + u[2] * (v[0] * w[1] - v[1] * w[0])
|
||
}
|
||
|
||
#[cfg(test)]
|
||
mod tests {
|
||
use super::*;
|
||
use crate::Session;
|
||
|
||
/// The `file.sample` form offers every sample, by name.
|
||
#[test]
|
||
fn the_form_lists_every_sample() {
|
||
let Some(crate::schema::Kind::Choice(options)) = crate::cmd::forms::SAMPLE.first().map(|f| f.kind) else { panic!("not a choice") };
|
||
let mut offered: Vec<&str> = options.iter().map(|(n, _)| *n).collect();
|
||
let mut names: Vec<&str> = SAMPLES.iter().map(|s| s.name).collect();
|
||
offered.sort_unstable();
|
||
names.sort_unstable();
|
||
assert_eq!(offered, names);
|
||
}
|
||
|
||
#[test]
|
||
fn the_sample_builds_positive_elements_that_fill_both_parts() {
|
||
let mut s = Session::default();
|
||
s.run_script(&script()).unwrap();
|
||
let info = s.execute("model.info", &json!({})).unwrap();
|
||
assert_eq!(info["elements"]["hex8"], 64);
|
||
assert_eq!(info["elements"]["tet4"], 162);
|
||
assert_eq!(info["nodes"], 9 * 5 * 3 + 4 * 4 * 4);
|
||
// Tet volumes are positive and add up to the cube's.
|
||
let mut volume = 0.0;
|
||
for e in s.model.elements().values().filter(|e| e.kind == fieldcraft_model::ElementKind::Tet4) {
|
||
let p: Vec<[f64; 3]> = e.nodes.iter().map(|n| s.model.node(*n).unwrap().xyz).collect();
|
||
let v = signed_volume(&p) / 6.0;
|
||
assert!(v > 0.0);
|
||
volume += v;
|
||
}
|
||
assert!((volume - 15.0f64.powi(3)).abs() < 1e-9, "{volume}");
|
||
}
|
||
|
||
#[test]
|
||
fn the_cantilever_solves_close_to_beam_theory() {
|
||
let mut s = Session::default();
|
||
s.run_script(&cantilever()).unwrap();
|
||
let r = s.execute("solve.static", &json!({})).unwrap();
|
||
let [l, w, h] = CANTILEVER_SIZE;
|
||
let beam = 4.0 * 1000.0 * l.powi(3) / (210000.0 * w * h.powi(3));
|
||
let tip = r["max_displacement"]["value"].as_f64().unwrap();
|
||
// Shear deformation adds a little (L/h = 5).
|
||
assert!(tip > beam && tip < 1.1 * beam, "{tip} vs {beam}");
|
||
let f = s.execute("solve.frequency", &json!({})).unwrap();
|
||
assert_eq!(f["modes"].as_array().map(Vec::len), Some(6));
|
||
}
|
||
|
||
#[test]
|
||
fn the_impact_runs_and_keeps_frames_with_stresses() {
|
||
let mut s = Session::default();
|
||
s.run_script(&impact()).unwrap();
|
||
let r = s.execute("solve.explicit", &json!({})).unwrap();
|
||
assert_eq!((r["completed"].as_bool(), r["frames"].as_u64()), (Some(true), Some(11)), "{r}");
|
||
assert!(r["energy_balance"].as_f64().unwrap() < 0.05, "{r}");
|
||
}
|
||
|
||
/// `file.sample NAME`, checked clean: ready, no errors or warnings.
|
||
fn open(name: &str) -> Session {
|
||
let mut s = Session::default();
|
||
s.execute("file.sample", &json!({"name": name})).unwrap();
|
||
let check = s.execute("model.check", &json!({})).unwrap();
|
||
assert_eq!((check["ready"].as_bool(), check["errors"].as_u64(), check["warnings"].as_u64()), (Some(true), Some(0), Some(0)), "{check}");
|
||
s
|
||
}
|
||
|
||
/// The squeeze force of the ring, against the closed form for an incompressible Mooney–Rivlin
|
||
/// solid in uniaxial compression, P = 2 (λ − λ⁻²)(C10 + C01/λ) per unit of original area: the
|
||
/// same ring between frictionless plates (each face held only along z, the rigid motions
|
||
/// held at three nodes on the symmetry planes) compresses evenly and matches it within 3 %
|
||
/// (ν = 0.49 is nearly incompressible); bonded, the bulge needs more force (shape factor
|
||
/// ¼ (b − a)/h = 0.5 by the loaded over the free area), within 2.5 times.
|
||
#[test]
|
||
fn the_rubber_seal_squeezes_as_mooney_rivlin_rubber() {
|
||
let [inner, outer, height] = SEAL;
|
||
let area = std::f64::consts::PI * (outer * outer - inner * inner);
|
||
let lambda: f64 = 1.0 - SEAL_SQUEEZE / height;
|
||
let (c01, c10) = (0.2, 6.0 / (2.0 * 1.49) / 2.0 - 0.2);
|
||
let closed = 2.0 * (lambda - lambda.powi(-2)) * (c10 + c01 / lambda) * area;
|
||
let squeeze = |s: &mut Session| -> f64 {
|
||
s.execute("solve.nonlinear", &json!({})).unwrap();
|
||
let r = s.execute("results.reactions", &json!({"step": "Squeeze", "sets": ["top"]})).unwrap();
|
||
r["sets"][0]["force"][2].as_f64().unwrap()
|
||
};
|
||
let mut s = open("rubber-seal");
|
||
let bonded = squeeze(&mut s);
|
||
let node = |s: &Session, xyz: [f64; 3]| -> u32 {
|
||
*s.model.nodes().iter().find(|(_, n)| (0..3).all(|k| (n.xyz[k] - xyz[k]).abs() < 1e-9)).unwrap().0
|
||
};
|
||
let held = [
|
||
("hold_y", [inner, 0.0, 0.0], [None, Some(0.0), None]),
|
||
("hold_x", [0.0, inner, 0.0], [Some(0.0), None, None]),
|
||
("hold_y2", [-inner, 0.0, 0.0], [None, Some(0.0), None]),
|
||
];
|
||
for (name, at, [ux, uy, _]) in held {
|
||
let n = node(&s, at);
|
||
s.execute("model.set.create", &json!({"name": name, "nodes": [n]})).unwrap();
|
||
s.execute(
|
||
"model.boundary_condition.create",
|
||
&json!({"name": name, "type": "displacement", "target": {"set": name}, "values": [ux, uy, null, null, null, null]}),
|
||
)
|
||
.unwrap();
|
||
}
|
||
s.execute(
|
||
"model.boundary_condition.edit",
|
||
&json!({"name": "Base", "type": "displacement", "target": {"set": "bottom"}, "values": [null, null, 0, null, null, null]}),
|
||
)
|
||
.unwrap();
|
||
s.execute(
|
||
"model.boundary_condition.edit",
|
||
&json!({"name": "Press", "type": "displacement", "target": {"set": "top"}, "values": [null, null, -SEAL_SQUEEZE, null, null, null]}),
|
||
)
|
||
.unwrap();
|
||
s.execute("model.step.edit", &json!({"name": "Squeeze", "boundary_conditions": ["Base", "Press", "hold_y", "hold_x", "hold_y2"]})).unwrap();
|
||
let free = squeeze(&mut s);
|
||
assert!((free - closed).abs() < 0.03 * closed.abs(), "frictionless {free} N against {closed} N");
|
||
let stiffer = bonded / free;
|
||
assert!(stiffer > 1.05 && stiffer < 2.5, "bonded {bonded} N, frictionless {free} N");
|
||
}
|
||
|
||
#[test]
|
||
fn the_flow_sample_opens_ready_to_solve() {
|
||
let s = open("flow-past");
|
||
assert_eq!(s.model.fluid_domains().len(), 1);
|
||
}
|
||
|
||
/// The drag on the bracket, as a coefficient on the upright's frontal area (40 × 50 mm), is
|
||
/// that of a bluff plate standing on a wall at a Reynolds number of 83, raised by the 17 %
|
||
/// blockage of the box: between 1 and 3.5 (a flat plate broadside to the flow is about 1.2 at
|
||
/// high Reynolds number and rises as it falls). The lattice conserves mass.
|
||
#[test]
|
||
#[ignore = "heavy: cargo xtask test --heavy (CI heavy job)"]
|
||
fn the_flow_past_the_bracket_has_a_bluff_body_drag() {
|
||
let mut s = open("flow-past");
|
||
let r = s.execute("solve.run", &json!({})).unwrap();
|
||
let r = &r["steps"][0]["summary"];
|
||
let drag: f64 = r["forces"].as_array().unwrap().iter().filter(|f| f["body"] == "Bracket").map(|f| f["mean"][0].as_f64().unwrap()).sum();
|
||
let [density, _] = AIR;
|
||
let cd = drag / (0.5 * density * FLOW_SPEED * FLOW_SPEED * 40.0 * 50.0);
|
||
assert!(cd > 1.0 && cd < 3.5, "Cd {cd}: {r}");
|
||
assert!(r["mass"]["relative_change"].as_f64().unwrap().abs() < 0.01, "{r}");
|
||
}
|
||
|
||
/// The heated bracket's temperatures lie between the air's and the heater's, falling along
|
||
/// the bracket away from the heater. Its thermal expansion: with the air at the heater's
|
||
/// temperature the bracket warms evenly by ΔT, and held at the foot's hole alone (at x = 40)
|
||
/// it grows freely, so a point moves α ΔT times its distance from the hole's axis along x:
|
||
/// the upright's top by −0.0432 mm (within 3 %), the foot's end by +0.024 mm (within 6 %).
|
||
/// The clamped bore cannot grow, which holds both points back a little; how much depends on
|
||
/// the tet mesh, which differs between platforms (#115): 2.1 % at the top on the Linux CI.
|
||
#[test]
|
||
#[ignore = "heavy: cargo xtask test --heavy (CI heavy job)"]
|
||
fn the_heated_bracket_warms_and_expands_as_steel() {
|
||
let mut s = open("heated-bracket");
|
||
let r = s.execute("solve.run", &json!({})).unwrap();
|
||
let r = &r["steps"][0]["summary"];
|
||
assert!((r["max_temperature"]["value"].as_f64().unwrap() - HEATER).abs() < 1e-9, "{r}");
|
||
let probe = |s: &mut Session| s.execute("solve.probe", &json!({"step": "Heat", "at": [[4.0, 50.0, 20.0], [60.0, 4.0, 20.0]]})).unwrap();
|
||
let p = probe(&mut s);
|
||
let (upright, foot) = (p["nodes"][0]["temperature"].as_f64().unwrap(), p["nodes"][1]["temperature"].as_f64().unwrap());
|
||
assert!(upright > foot && foot > AMBIENT && upright <= HEATER, "{upright} {foot}");
|
||
let foot_hole = json!([{"body": "Bracket", "face": "F4:bore:side:0"}, {"body": "Bracket", "face": "F4:bore:side:1"}]);
|
||
s.execute("model.set.create", &json!({"name": "foot_hole", "geometry": foot_hole})).unwrap();
|
||
s.execute("model.boundary_condition.edit", &json!({"name": "Clamp", "type": "fixed", "target": {"set": "foot_hole"}})).unwrap();
|
||
s.execute("model.load.edit", &json!({"name": "Air", "type": "convection", "set": "skin", "film": 0.01, "sink": HEATER})).unwrap();
|
||
s.execute("solve.static", &json!({})).unwrap();
|
||
let p = probe(&mut s);
|
||
let grow = STEEL_EXPANSION * (HEATER - AMBIENT);
|
||
// The bore itself cannot grow, which holds back the foot's end, 16 mm from its edge, a
|
||
// little more than the upright's top, 32 mm away.
|
||
for (i, tolerance) in [(0, 0.03), (1, 0.06)] {
|
||
let node = &p["nodes"][i];
|
||
let (ux, expected) = (node["displacement"][0].as_f64().unwrap(), grow * (node["xyz"][0].as_f64().unwrap() - 40.0));
|
||
assert!((ux - expected).abs() < tolerance * expected.abs(), "{node}: {ux} against {expected}");
|
||
}
|
||
}
|
||
|
||
/// The hex20 bracket's tip deflection agrees with a fine tet10 solution of the unpartitioned
|
||
/// part (0.5093 mm, crates/testkit/tests/bracket_blocks.rs) within 1 %, its mesh conforms
|
||
/// across all 30 cells, and the load reaches the clamp.
|
||
#[test]
|
||
#[ignore = "heavy: cargo xtask test --heavy (CI heavy job)"]
|
||
fn the_hex_bracket_bends_like_the_fine_tet_solution() {
|
||
let mut s = open("bracket-hex");
|
||
let elements = s.model.elements().values().filter(|e| e.kind == fieldcraft_model::ElementKind::Hex20).count();
|
||
assert_eq!(elements, s.model.elements().len());
|
||
let r = s.execute("solve.run", &json!({})).unwrap();
|
||
let r = &r["steps"][0]["summary"];
|
||
let probe = s.execute("solve.probe", &json!({"step": "Load", "at": [[60.0, 4.0, 20.0]]})).unwrap();
|
||
let tip = probe["nodes"][0]["displacement"][1].as_f64().unwrap();
|
||
assert!((tip + 0.5093).abs() < 0.01 * 0.5093, "{tip}");
|
||
let reaction = s.execute("results.reactions", &json!({"step": "Load", "sets": ["top"]})).unwrap();
|
||
assert!((reaction["sets"][0]["force"][1].as_f64().unwrap() - 1000.0).abs() < 1e-6, "{reaction}");
|
||
assert!(r["max_von_mises"]["value"].as_f64().unwrap() > 200.0, "{r}");
|
||
}
|
||
|
||
/// The crank opens as one conforming structured hex20 mesh: the
|
||
/// half's seven cells, every cut merged node for node (no ties), the half and its mirror
|
||
/// image alike and joined on the symmetry plane, the spindle and pedal faces found on both
|
||
/// halves (the image's faces carry the names of the half they are the image of), and the
|
||
/// quality floor: scaled Jacobian at least 0.3, edge ratio at most 10.
|
||
#[test]
|
||
fn the_crank_opens_as_one_structured_mesh_of_two_alike_halves() {
|
||
let (arm, mirror) = (find("crank-arm").unwrap(), find("crank-mirror").unwrap());
|
||
let prepared = |x: &Sample| x.prepare.map(|f| f());
|
||
assert!(
|
||
arm.design == mirror.design && prepared(arm) == prepared(mirror) && (arm.script)(&[]) == (mirror.script)(&[]),
|
||
"one model under two names"
|
||
);
|
||
{
|
||
let name = "crank-arm";
|
||
let mut s = open(name);
|
||
let bodies: Vec<String> = s.design.as_ref().unwrap().bodies.iter().map(|b| b.name.clone()).collect();
|
||
let mut cells: Vec<String> = CRANK_CELLS.iter().map(|c| c.to_string()).collect();
|
||
cells.push("CrankArm/b".into());
|
||
assert_eq!(bodies, cells);
|
||
assert!(s.model.ties().is_empty(), "every cut merged");
|
||
let elements = s.model.elements().values().filter(|e| e.kind == fieldcraft_model::ElementKind::Hex20).count();
|
||
assert_eq!(elements, s.model.elements().len());
|
||
let mut set = |name: &str, bodies: &[&str]| {
|
||
s.execute("model.set.create", &json!({"name": name, "geometry": bodies.iter().map(|b| json!({"body": b})).collect::<Vec<_>>()}))
|
||
.unwrap();
|
||
s.model.resolve_set(name).unwrap()
|
||
};
|
||
let (a, b) = (set("half_a", &CRANK_CELLS), set("half_b", &["CrankArm/b"]));
|
||
assert_eq!(a.elements.len(), b.elements.len());
|
||
assert_eq!(a.elements.len() + b.elements.len(), elements);
|
||
assert_eq!(a.faces.len(), b.faces.len(), "the halves' skins are alike");
|
||
let shared = a.nodes.iter().filter(|n| b.nodes.binary_search(n).is_ok()).count();
|
||
assert!(shared > 100, "{shared}");
|
||
assert_eq!(a.nodes.len() + b.nodes.len() - shared, s.model.nodes().len());
|
||
let q = s.execute("mesh.quality", &json!({})).unwrap();
|
||
assert_eq!(q["valid"].as_u64().unwrap() as usize, elements, "{q}");
|
||
let metric = |m: &str, k: &str| q["metrics"][m][k].as_f64().unwrap();
|
||
assert!(metric("scaled_jacobian", "min") >= 0.3, "{q}");
|
||
assert!(metric("edge_ratio", "max") <= 10.0, "{q}");
|
||
let members = |set: &str| s.model.sets().get(set).map_or(Vec::new(), |x| x.geometry.iter().map(|g| g.body.clone()).collect::<Vec<_>>());
|
||
for set in ["spindle", "pedal"] {
|
||
let bodies = members(set);
|
||
assert!(bodies.iter().any(|b| b.starts_with("CrankArm/a/")) && bodies.iter().any(|b| b == "CrankArm/b"), "{set}: {bodies:?}");
|
||
assert!(!s.model.resolve_set(set).unwrap().faces.is_empty(), "{set}");
|
||
}
|
||
let faces = |set: &str| s.model.sets().get(set).map_or(0, |x| x.geometry.len());
|
||
assert_eq!((faces("spindle"), faces("pedal")), (10, 4), "{name}");
|
||
}
|
||
}
|
||
|
||
/// Solved, the crank's root bends as a beam: σxx on the arm's sides at x = 29 mm (35.6 mm
|
||
/// wide, 16 thick, 141 mm from the pedal) within 3 % of M/Z = 1500 · 141 / (16 · 35.6² / 6) =
|
||
/// 62.6 MPa, equal and opposite on the two mirror-image sides, and the spindle carries the
|
||
/// whole load.
|
||
#[test]
|
||
#[ignore = "heavy: cargo xtask test --heavy (CI heavy job)"]
|
||
fn the_crank_arm_root_bends_as_the_beam_formula_says() {
|
||
let mut s = open("crank-arm");
|
||
s.execute("solve.run", &json!({})).unwrap();
|
||
let half_width: f64 = 19.0 - 7.0 * 29.0 / 170.0;
|
||
let probe = s.execute("solve.probe", &json!({"step": "Pedal", "at": [[29.0, -half_width, 8.0], [29.0, half_width, 8.0]]})).unwrap();
|
||
let sxx = |i: usize| probe["nodes"][i]["stress"][0].as_f64().unwrap();
|
||
let hand = PEDAL_LOAD * (170.0 - 29.0) / (16.0 * (2.0 * half_width).powi(2) / 6.0);
|
||
for (i, sign) in [(0, -1.0), (1, 1.0)] {
|
||
assert!((sign * sxx(i) - hand).abs() < 0.03 * hand, "{} against {hand} MPa: {probe}", sxx(i));
|
||
}
|
||
assert!((sxx(0) + sxx(1)).abs() < 0.01 * hand, "{probe}");
|
||
let reaction = s.execute("results.reactions", &json!({"step": "Pedal", "sets": ["spindle"]})).unwrap();
|
||
assert!((reaction["sets"][0]["force"][1].as_f64().unwrap() - PEDAL_LOAD).abs() < 1e-6, "{reaction}");
|
||
}
|
||
|
||
/// The conformity of `s`'s mesh ([`fieldcraft_mesh::quality::conformity`]).
|
||
fn conformity(s: &Session) -> fieldcraft_mesh::quality::Conformity {
|
||
let nodes: Vec<(u32, [f64; 3])> = s.model.nodes().iter().map(|(l, n)| (*l, n.xyz)).collect();
|
||
let elements = s.model.elements().iter().map(|(l, e)| (*l, e.kind, e.nodes.as_slice()));
|
||
fieldcraft_mesh::quality::conformity(&nodes, elements, 1e-6).unwrap()
|
||
}
|
||
|
||
/// The crank arm's hex20 mesh has no crack (#260): its free faces close up across the cells
|
||
/// and the mirror plane, no two nodes coincide and every element edge has one mid-side node.
|
||
#[test]
|
||
fn the_crank_arm_hex20_mesh_is_conforming() {
|
||
let s = open("crank-arm");
|
||
let c = conformity(&s);
|
||
assert!(c.is_conforming(), "{:?} {:?} {:?}", c.open_edges.first(), c.coincident.first(), c.midside_mismatches.first());
|
||
}
|
||
|
||
#[test]
|
||
fn the_drop_test_opens_ready_to_solve() {
|
||
let s = open("drop-test");
|
||
assert!(s.model.elements().len() > 1000);
|
||
}
|
||
|
||
/// The bracket's mass is ρ V (V: foot, upright and the fillet's corner, 36 − 9π mm² by 40 mm),
|
||
/// it meets the floor at √(2 g h) with ½ m v² of kinetic energy and conserves energy; by the
|
||
/// end the floor has taken half its downward momentum and turned kinetic energy into
|
||
/// vibration.
|
||
#[test]
|
||
#[ignore = "heavy: cargo xtask test --heavy (CI heavy job)"]
|
||
fn the_drop_test_lands_at_the_free_fall_speed_and_bounces() {
|
||
let mut s = open("drop-test");
|
||
let r = s.execute("solve.run", &json!({})).unwrap();
|
||
let r = &r["steps"][0]["summary"];
|
||
let volume = 60.0 * 8.0 * 40.0 + 8.0 * 42.0 * 40.0 + (36.0 - 9.0 * std::f64::consts::PI) * 40.0;
|
||
let mass = 2.7e-9 * volume;
|
||
let close = |a: f64, b: f64, rel: f64| (a - b).abs() <= rel * b.abs();
|
||
assert!(close(r["total_mass"].as_f64().unwrap(), mass, 0.005), "{r}");
|
||
assert!(r["completed"].as_bool() == Some(true) && r["energy_balance"].as_f64().unwrap() < 0.01, "{r}");
|
||
let h = s.execute("solve.history", &json!({"step": "Drop"})).unwrap();
|
||
let speed = (2.0 * GRAVITY * DROP_HEIGHT).sqrt();
|
||
let pz = |i: usize| h["momentum"][i][2].as_f64().unwrap();
|
||
let kinetic = |i: usize| h["energies"][i]["kinetic"].as_f64().unwrap();
|
||
assert!(close(pz(0), -mass * speed, 0.005), "{}", pz(0));
|
||
assert!(close(kinetic(0), 0.5 * mass * speed * speed, 0.01), "{}", kinetic(0));
|
||
let last = h["time"].as_array().unwrap().len() - 1;
|
||
let kept = pz(last) / pz(0);
|
||
assert!(kept > 0.4 && kept < 0.6 && kinetic(last) < kinetic(0), "{} {}", pz(last), kinetic(last));
|
||
}
|
||
}
|