Are the two mass groups of the 2 mm laser-cut bracket search two separate basins?

What it found

A small diagnostic (stylised, preliminary). The lighter and heavier groups of gauge-2 search results differ in web width (about 14.3–14.9 against 15.2–15.6 mm), not in fillet radius. A coarse grid shows one connected feasible region, but a 0.1 mm scan shows the feasible set is ragged in width: isolated feasible pockets lie below a contiguous region, and the lighter group matches those pockets. This is consistent with a coarse-mesh stress artefact rather than two broad basins, a mechanism not tested here. Twenty seeds, one process, one mesh; nothing was built.

Paper, code and results

• README and method
• Experiments and results
• Code
• Tests

More in Simulation-first design

• Do the isolated feasible pockets of the 2 mm laser-cut bracket survive mesh refinement?The isolated feasible pockets of the gauge-2 bracket scan (web width below 15.4 mm) vanish when the mesh is refined from 2.5 to 1.5 mm and the smallest feasible width rises by about 1 mm; stylised, preliminary.
• Does the feasible boundary of the 2 mm laser-cut bracket converge when the mesh is refined to 0.5 mm?On meshes of 1.0 and 0.5 mm no width in the usable 15.0–16.0 mm window of the gauge-2 bracket scan is feasible (one point at 0.75 mm), and the lowest peak stress rises 11–14% from 1.5 to 0.5 mm; negative, stylised, preliminary.
• Does the 1.5 mm bracket clear buckling when the whole L is one 3D body with a flexible corner?The whole 1.5 mm L-bracket as one 3D body clears the buckling floor under the design load (factor 4.01 vs closed-form 3.47) but not with the load reversed (2.25, below 3); sharp corner, ideal sheet, preliminary.
• How wide must the 1.5 mm L-bracket be to clear the buckling floor when the load is reversed?Widening the 1.5 mm L-bracket web from 18.4 to about 22.6 mm lifts the reversed-load buckling factor from 2.27 to the floor of 3, at +5.9 g (+19%) plate mass; buckling only, sharp corner, ideal sheet, preliminary.
• Do the reversed-load buckling widths of the L-bracket change with more element layers through the thickness?More element layers through the thickness (1 to 4) move the L-bracket's reversed-load buckling factor by at most 1.2% and the width needed for the floor of 3 by at most 0.07 mm at 1.5 to 3.0 mm gauges, so the thicker-sheet designs of simdesign-revgauge stand; coarse in-plane mesh, sharp corner, ideal sheet, preliminary.
• Do the reversed-load buckling-limited L-bracket designs also pass the forward-load buckling, stress and deflection checks?Under the forward 100 N load the four reversed-load buckling-limited L-brackets all clear buckling (factor 4.7 to 5.6), but only the 1.5 mm design also meets the 100 MPa and 4 mm limits; the 2.5 and 3.0 mm designs fail by 2 to 8 times, and the 2.0 mm design passes only on the coarse mesh (95.7 vs 144.9 MPa finer). Stylised.

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Produced with AI assistance (Claude). Results are from the code in this repository and are simulated or stylised unless the abstract says otherwise; nothing here implies affiliation with or endorsement by any lab, researcher or company cited. MIT licensed.