Deriving structural bracket geometry and aerodynamic camber profiles from first-principles load equations at sub-100ms latencies, validated against destructive workshop press trials at PSG College of Engineering Coimbatore.
FIGURE 01 // ARCHITECTURAL SCHEMATIC // 01
01QUESTION
Can first-principles mechanical derivation (Shigley Eq 6-2) coupled to PicoGK B-Rep volumetric kernel and Tet10 FEA solve bracket geometry and airfoil camber within <15% variance under physical load-to-failure testing?
02HYPOTHESIS
Separating ambiguity interpretation (LLaMA 3.2 3B) from deterministic mathematical derivation (Shigley fatigue math) and automated Gmsh Tet10 / CalculiX FEA eliminates manual CAD re-spins while guaranteeing FOS >= 2.0.
03SETUP
Analytical derivation pipeline coupled to PicoGK volumetric kernel, automated Gmsh Tet10 meshing, CalculiX static FEA, and destructive hydraulic press load-cell rig at PSG College of Engineering Coimbatore workshop. Public FAILURES.md tracking.
05OBSERVATIONS
CalculiX FEA convergence reached in 11.2s; Von Mises stress peaks of 184 MPa matched analytical prediction within 3.2%. Destructive load test on Al 6061-T6 bracket yielded at 5,820 N against 5,200 N target (11.9% variance, safely within <15% error margin).
06FAILURES / LIMITATIONS
FEA mesh singularities occurred at sharp interior bracket fillet transitions (R < 1.5mm) under high shear sweep angles (>18°). Weld-adjacent micro-buckling observed before predicted tensile yield on physical test piece.
