cyclecad 3.10.4 → 3.12.0

package/app/js/modules/ai-engineer.js

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+/* AI Engineering Analyst v1.0 — engineering analysis with cited methodology.
+ *
+ * v1 scope: bolted-joint analysis (VDI 2230 / Shigley methodology).
+ * Verified against MecAgent demo problem (4×M12/10.9, 18kN shear, 18kN axial, 420Nm moment,
+ * μ=0.16, preload 39kN/bolt, BCD 96mm, K_s=1.5) — expected F_friction=24960N,
+ * F_max_tensile=6687.5N, σ_vm=558MPa.
+ *
+ * Future scope (tasks #11 + #12): gears (AGMA), shafts (Goodman/Soderberg), bearings (L10),
+ * welds (throat stress), plus RAG citations.
+ *
+ * Architecture:
+ *   - Pure-JS analytical core (0 deps) — deterministic, unit-tested.
+ *   - Natural-language parser extracts structured parameters from free-text.
+ *   - Form UI with live recompute + LaTeX render (KaTeX, loaded on demand from CDN).
+ *   - LLM layer (optional v1.1) calls the analytical core for every number — never fabricates results.
+ */
+(function(){
+  'use strict';
+  window.CycleCAD = window.CycleCAD || {};
+
+  // ===================================================================
+  // REFERENCE DATA — ISO 898-1 mechanical property classes for carbon steel bolts
+  // Values: {nominalTensile R_m, proofStress R_p0.2, yieldStrength R_el} all in MPa
+  // ===================================================================
+  const STEEL_GRADES = Object.freeze({
+    '4.6':  { R_m: 400,  R_p02: 225,  R_el: 240,  label: '4.6 (low-carbon steel, mild)' },
+    '4.8':  { R_m: 400,  R_p02: 310,  R_el: 320,  label: '4.8 (low-carbon)' },
+    '5.6':  { R_m: 500,  R_p02: 300,  R_el: 300,  label: '5.6 (medium-carbon)' },
+    '5.8':  { R_m: 500,  R_p02: 380,  R_el: 400,  label: '5.8 (medium-carbon)' },
+    '6.8':  { R_m: 600,  R_p02: 440,  R_el: 480,  label: '6.8 (medium-carbon)' },
+    '8.8':  { R_m: 800,  R_p02: 580,  R_el: 640,  label: '8.8 (quenched & tempered, most common)' },
+    '10.9': { R_m: 1000, R_p02: 830,  R_el: 900,  label: '10.9 (alloy, quenched & tempered)' },
+    '12.9': { R_m: 1200, R_p02: 970,  R_el: 1080, label: '12.9 (alloy, Q&T high-strength)' }
+  });
+
+  // DIN 13 stress cross-section area A_s in mm² for standard metric coarse threads.
+  // A_s = π/4 · ((d_2 + d_3) / 2)² where d_2 is pitch dia, d_3 is minor dia (nut thread root).
+  const BOLT_STRESS_AREA = Object.freeze({
+    M3: 5.03, M3_5: 6.78, M4: 8.78, M5: 14.2, M6: 20.1, M7: 28.9,
+    M8: 36.6, M10: 58.0, M12: 84.3, M14: 115, M16: 157, M18: 192,
+    M20: 245, M22: 303, M24: 353, M27: 459, M30: 561,
+    M33: 694, M36: 817, M39: 976, M42: 1120, M45: 1300, M48: 1470,
+    M52: 1760, M56: 2030
+  });
+
+  // Nominal (major) diameter in mm for standard metric coarse threads.
+  const BOLT_MAJOR_DIA = Object.freeze({
+    M3: 3, M4: 4, M5: 5, M6: 6, M8: 8, M10: 10, M12: 12, M14: 14, M16: 16,
+    M18: 18, M20: 20, M22: 22, M24: 24, M27: 27, M30: 30, M33: 33, M36: 36,
+    M39: 39, M42: 42, M45: 45, M48: 48, M52: 52, M56: 56
+  });
+
+  // Typical friction coefficients for clamped-joint faying surfaces (from VDI 2230 Table A6).
+  const FRICTION_PRESETS = Object.freeze({
+    'dry_steel_steel': 0.16,
+    'oiled_steel_steel': 0.12,
+    'aluminum_aluminum': 0.18,
+    'zinc_coated': 0.14,
+    'hot_dip_galvanized': 0.36,
+    'phosphated': 0.16,
+    'blasted_clean': 0.45
+  });
+
+  // ===================================================================
+  // ANALYTICAL CORE — bolted-joint slip + tension + combined stress
+  // ===================================================================
+
+  /**
+   * Bolted joint safety analysis (VDI 2230 + Shigley approach).
+   *
+   * @param {object} p Input parameters.
+   * @param {number} p.boltCount Number of bolts z (≥1).
+   * @param {string} p.grade Steel grade, e.g. '10.9'.
+   * @param {string} p.thread Thread designation, e.g. 'M12'.
+   * @param {number} p.preload Per-bolt preload F_V [N].
+   * @param {number} p.shearForce External transverse/shear force F_Q [N].
+   * @param {number} p.axialForce External axial/separating force F_A [N].
+   * @param {number} p.moment In-plane moment M [N·mm].
+   * @param {number} p.bcd Bolt-circle diameter [mm].
+   * @param {number} p.friction Faying-surface coefficient μ.
+   * @param {number} p.safetyFactor Required slip safety factor K_s.
+   * @param {number} [p.frictionInterfaces=1] Number of friction-bearing interfaces n.
+   * @returns {object} Structured result with inputs, slip/tension/stress checks, verdict.
+   */
+  function boltedJointAnalysis(p) {
+    // Input normalisation
+    const z             = Math.max(1, Math.round(Number(p.boltCount) || 4));
+    const grade         = STEEL_GRADES[p.grade] ? p.grade : '8.8';
+    const thread        = BOLT_STRESS_AREA[p.thread] ? p.thread : 'M12';
+    const F_preload     = Math.max(0, Number(p.preload) || 0);
+    const F_shear       = Math.max(0, Number(p.shearForce) || 0);
+    const F_axial       = Math.max(0, Number(p.axialForce) || 0);
+    const M             = Math.max(0, Number(p.moment) || 0);
+    const bcd           = Math.max(0, Number(p.bcd) || 0);
+    const mu            = Math.max(0.01, Number(p.friction) || 0.15);
+    const K_s           = Math.max(1, Number(p.safetyFactor) || 1.5);
+    const n_interfaces  = Math.max(1, Math.round(Number(p.frictionInterfaces) || 1));
+
+    const A_s = BOLT_STRESS_AREA[thread];
+    const d = BOLT_MAJOR_DIA[thread];
+    const spec = STEEL_GRADES[grade];
+    const R_p02 = spec.R_p02;
+    const R_m = spec.R_m;
+    const r = bcd / 2;
+
+    // --- CHECK 1: Slip resistance ----------------------------------------------
+    // Friction capacity:   F_friction = μ · n · z · F_V
+    const F_friction = mu * n_interfaces * z * F_preload;
+
+    // Per-bolt tangential force from in-plane moment (at BCD):
+    //   F_M_tangential,i = M · r_i / Σr_j²  → for a uniform circle: M / (z · r)
+    const F_moment_tangential_per_bolt = (r > 0) ? M / (z * r) : 0;
+
+    // Worst-case per-bolt tangential force (shear/z plus moment contribution, aligned):
+    const F_bolt_tangential_max = F_shear / z + F_moment_tangential_per_bolt;
+
+    // Aggregate tangential resultant that the joint must resist (sum of worst-case bolt forces):
+    const F_shear_total = z * F_bolt_tangential_max;
+    const F_required_slip = K_s * F_shear_total;
+    const slipSafe = F_friction >= F_required_slip;
+    const slipMargin = F_required_slip > 0 ? F_friction / F_required_slip : Infinity;
+
+    // --- CHECK 2: Bolt tension (worst-loaded bolt) ------------------------------
+    // External tension per bolt: F_A/z + contribution from moment at worst position
+    //   (axial moment component adds on the tension side of the BCD)
+    const F_axial_per_bolt = F_axial / z;
+    const F_moment_axial_per_bolt = (r > 0) ? M / (z * r) : 0;
+    const F_max_external = F_axial_per_bolt + F_moment_axial_per_bolt;
+
+    // Simplified: assume load factor Φ = 1 (rigid joint). In reality 0.1-0.3 for gasketed.
+    // Full VDI 2230 uses F_S_max = F_V + Φ · F_A_ext. For v1, conservative (Φ=1):
+    const F_bolt_total = F_preload + F_max_external;
+
+    // --- CHECK 3: Combined stress (Von Mises) -----------------------------------
+    // σ = F_bolt_total / A_s     (tensile)
+    // τ = F_bolt_tangential_max / A_s   (shear from transverse loads + moment)
+    // σ_vm = √(σ² + 3τ²)         (von Mises for uniaxial tension + shear)
+    const sigma = F_bolt_total / A_s;
+    const tau   = F_bolt_tangential_max / A_s;
+    const sigma_vm = Math.sqrt(sigma * sigma + 3 * tau * tau);
+    const stressUtilization = R_p02 > 0 ? sigma_vm / R_p02 : Infinity;
+    const stressSafe = sigma_vm < R_p02;
+
+    // --- VERDICT ----------------------------------------------------------------
+    // Classification: joint is SAFE if both slip and stress checks pass.
+    // If stress passes but slip fails, joint is a BEARING-TYPE joint — bolts transmit shear
+    // directly. Still safe if stress is within proof strength.
+    let verdict, verdictClass, notes = [];
+    if (slipSafe && stressSafe) {
+      verdict = 'SAFE';
+      verdictClass = 'pass';
+      notes.push('Preload prevents slip; bolt stress stays below proof strength.');
+    } else if (!slipSafe && stressSafe) {
+      verdict = 'SAFE (bearing-type)';
+      verdictClass = 'warn';
+      notes.push('Slip resistance marginal — joint relies on bolt shank shear.');
+      notes.push('Consider increasing preload (higher Q_F) or adding friction (higher μ) to restore friction-type safety.');
+    } else {
+      verdict = 'UNSAFE';
+      verdictClass = 'fail';
+      if (!stressSafe) notes.push('Combined stress σ_vm = ' + sigma_vm.toFixed(1) + ' MPa exceeds proof strength ' + R_p02 + ' MPa.');
+      if (!slipSafe)  notes.push('Insufficient friction capacity — bolts must also resist direct shear.');
+    }
+
+    return {
+      inputs: { z, grade, thread, d, A_s, F_preload, F_shear, F_axial, M, bcd, r, mu, K_s, n_interfaces, R_p02, R_m, gradeLabel: spec.label },
+      slipResistance: {
+        F_friction, F_moment_tangential_per_bolt, F_bolt_tangential_max,
+        F_shear_total, F_required: F_required_slip, margin: slipMargin, safe: slipSafe
+      },
+      tensionCheck: {
+        F_axial_per_bolt, F_moment_axial_per_bolt, F_max_external,
+        F_preload, F_bolt_total
+      },
+      combinedStress: {
+        sigma, tau, sigma_vm, R_p02, utilization: stressUtilization, safe: stressSafe
+      },
+      verdict, verdictClass, notes
+    };
+  }
+
+  // ===================================================================
+  // GEAR MATERIAL DATA — AGMA Grade 1 steel allowables (Shigley Table 14-3 / 14-6)
+  // Keys: hardness in HB (Brinell). Values: {S_t, S_c} in MPa (converted from psi).
+  // S_t: allowable bending stress. S_c: allowable contact (surface) stress.
+  // Formulas for through-hardened steel (AGMA 2001):
+  //   S_t = 77 * HB + 12,800 psi        (Grade 1 bending)
+  //   S_c = 322 * HB + 29,100 psi       (Grade 1 contact)
+  // 1 psi = 0.00689476 MPa.
+  // ===================================================================
+  /**
+   * Allowable bending stress for Grade 1 through-hardened gear steel (AGMA 2001).
+   * @param {number} HB Brinell hardness (180–400 typical).
+   * @returns {number} S_t in MPa.
+   */
+  function gearAllowableBending(HB) {
+    return (77 * HB + 12800) * 0.00689476;
+  }
+  /**
+   * Allowable contact stress for Grade 1 through-hardened gear steel (AGMA 2001).
+   * @param {number} HB Brinell hardness.
+   * @returns {number} S_c in MPa.
+   */
+  function gearAllowableContact(HB) {
+    return (322 * HB + 29100) * 0.00689476;
+  }
+
+  // AGMA geometry factor J (bending) — approximated from Shigley Fig. 14-6
+  // for external spur gears at 20° pressure angle. Interpolated by number of teeth.
+  const J_TABLE = [
+    [12, 0.245], [14, 0.265], [17, 0.295], [20, 0.32], [25, 0.345],
+    [30, 0.365], [35, 0.38], [40, 0.39], [50, 0.41], [75, 0.435], [100, 0.45]
+  ];
+  function gearGeometryJ(teeth) {
+    const z = Math.max(J_TABLE[0][0], Math.min(J_TABLE[J_TABLE.length-1][0], teeth));
+    for (let i = 0; i < J_TABLE.length - 1; i++) {
+      const [z1, j1] = J_TABLE[i], [z2, j2] = J_TABLE[i+1];
+      if (z >= z1 && z <= z2) return j1 + (j2 - j1) * (z - z1) / (z2 - z1);
+    }
+    return 0.4;
+  }
+
+  // AGMA geometry factor I (pitting) — external gear pair, 20° pressure angle.
+  // Approximated from Shigley Eq. 14-23 with m_N = 1 for spur gears.
+  function gearGeometryI(pinionTeeth, gearTeeth, pressureAngle) {
+    const phi = (pressureAngle || 20) * Math.PI / 180;
+    const mG = gearTeeth / pinionTeeth;
+    return (Math.cos(phi) * Math.sin(phi) / 2) * (mG / (mG + 1));
+  }
+
+  /**
+   * Spur gear AGMA bending + pitting analysis (Shigley Ch. 14).
+   *
+   * Uses the fundamental AGMA 2001 stress equations with sensible default modifying factors.
+   * For safety-critical applications, confirm each K-factor per AGMA 908-B89.
+   *
+   * @param {object} p
+   * @param {number} p.pinionTeeth  z_P — pinion tooth count.
+   * @param {number} p.gearTeeth    z_G — gear tooth count.
+   * @param {number} p.module       m — in mm.
+   * @param {number} p.faceWidth    F — in mm.
+   * @param {number} p.torque       T_P — torque on pinion in N·m.
+   * @param {number} p.pinionHB     HB_P — Brinell hardness of pinion.
+   * @param {number} p.gearHB       HB_G — Brinell hardness of gear.
+   * @param {number} [p.overload=1.0]       K_o — 1.0 uniform / 1.25 moderate / 1.5 heavy shock.
+   * @param {number} [p.dynamic=1.1]        K_v — dynamic factor (≈1.0 precision, 1.1–1.3 typical).
+   * @param {number} [p.loadDist=1.3]       K_m — load distribution (1.3 good alignment).
+   * @param {number} [p.reliability=1.0]    K_R — 1.0 @ 99% reliability, 1.25 @ 99.9%.
+   * @param {number} [p.pressureAngle=20]   φ — pressure angle in degrees.
+   * @param {number} [p.Z_E=190]            Elastic coefficient for steel-steel (MPa^0.5).
+   * @returns {object} {inputs, pinion:{…}, gear:{…}, verdict, …}
+   */
+  function spurGearAnalysis(p) {
+    const z_P = Math.max(12, Math.round(Number(p.pinionTeeth) || 20));
+    const z_G = Math.max(12, Math.round(Number(p.gearTeeth) || 40));
+    const m   = Math.max(0.5, Number(p.module) || 2);
+    const F   = Math.max(3, Number(p.faceWidth) || 25);
+    const T_P = Math.max(0, Number(p.torque) || 0);
+    const HB_P = Math.max(150, Number(p.pinionHB) || 240);
+    const HB_G = Math.max(150, Number(p.gearHB)   || HB_P);
+    const K_o = Math.max(1, Number(p.overload) || 1.0);
+    const K_v = Math.max(1, Number(p.dynamic)  || 1.1);
+    const K_m = Math.max(1, Number(p.loadDist) || 1.3);
+    const K_R = Math.max(1, Number(p.reliability) || 1.0);
+    const phi = Number(p.pressureAngle) || 20;
+    const Z_E = Number(p.Z_E) || 190;
+    const K_s = 1.0;   // size factor — ignore for typical sizes
+    const K_B = 1.0;   // rim thickness — solid blank
+    const C_f = 1.0;   // surface condition — clean-cut
+    const Y_N = 1.0, Z_N = 1.0, C_H = 1.0, K_T = 1.0; // nominal life factors
+    const mG = z_G / z_P;
+
+    // Pitch diameters and tangential load
+    const d_P = m * z_P;                    // pinion pitch dia in mm
+    const d_G = m * z_G;                    // gear pitch dia
+    const T_Pnmm = T_P * 1000;              // convert N·m → N·mm
+    const W_t = (d_P > 0) ? (2 * T_Pnmm) / d_P : 0;  // tangential load N
+
+    // Geometry factors
+    const J_P = gearGeometryJ(z_P);
+    const J_G = gearGeometryJ(z_G);
+    const I   = gearGeometryI(z_P, z_G, phi);
+
+    // AGMA bending stress (both gears see same W_t but different J)
+    const sigma_b_P = (W_t * K_o * K_v * K_s * K_m * K_B) / (F * m * J_P);
+    const sigma_b_G = (W_t * K_o * K_v * K_s * K_m * K_B) / (F * m * J_G);
+
+    // AGMA contact stress (same magnitude for both meshing teeth)
+    const sigma_c = (W_t > 0 && d_P > 0 && I > 0)
+      ? Z_E * Math.sqrt((W_t * K_o * K_v * K_s * K_m * C_f) / (d_P * F * I))
+      : 0;
+
+    // Allowable stresses (material)
+    const St_P = gearAllowableBending(HB_P);
+    const St_G = gearAllowableBending(HB_G);
+    const Sc_P = gearAllowableContact(HB_P);
+    const Sc_G = gearAllowableContact(HB_G);
+
+    // Factors of safety — Shigley Eq. 14-41 / 14-42 simplified
+    const SF_bending_P = St_P * Y_N / (sigma_b_P * K_T * K_R);
+    const SF_bending_G = St_G * Y_N / (sigma_b_G * K_T * K_R);
+    const SF_contact_P = (Sc_P * Z_N * C_H) / (sigma_c * K_T * K_R);
+    const SF_contact_G = (Sc_G * Z_N * C_H) / (sigma_c * K_T * K_R);
+
+    const SF_min = Math.min(SF_bending_P, SF_bending_G, SF_contact_P, SF_contact_G);
+    const safe = SF_min >= 1.0;
+    const verdict = SF_min >= 2.0 ? 'SAFE (margin ≥ 2)' :
+                    SF_min >= 1.5 ? 'SAFE (margin ≥ 1.5 — industry typical)' :
+                    SF_min >= 1.0 ? 'MARGINAL (factor < 1.5 — review assumptions)' :
+                                    'UNSAFE (factor < 1.0 — tooth will fail)';
+    const verdictClass = SF_min >= 1.5 ? 'pass' : SF_min >= 1.0 ? 'warn' : 'fail';
+    const notes = [];
+    if (SF_bending_P < SF_bending_G) notes.push('Pinion is the weaker gear in bending (lower J factor) — as expected.');
+    if (SF_contact_P < SF_bending_P) notes.push('Contact stress governs over bending — consider surface hardening (carburizing/induction) for higher S_c.');
+    if (SF_min < 1.5) notes.push('Margin below industry-typical 1.5 — increase module, face width, or hardness.');
+
+    return {
+      inputs: { z_P, z_G, m, F, T_P, HB_P, HB_G, K_o, K_v, K_m, K_R, phi, Z_E,
+                d_P, d_G, mG, W_t, J_P, J_G, I, St_P, St_G, Sc_P, Sc_G },
+      pinion: { SF_bending: SF_bending_P, SF_contact: SF_contact_P,
+                sigma_b: sigma_b_P, sigma_c, S_t: St_P, S_c: Sc_P, J: J_P },
+      gear:   { SF_bending: SF_bending_G, SF_contact: SF_contact_G,
+                sigma_b: sigma_b_G, sigma_c, S_t: St_G, S_c: Sc_G, J: J_G },
+      SF_min, safe, verdict, verdictClass, notes
+    };
+  }
+
+  // ===================================================================
+  // SHAFT FATIGUE — Goodman / Soderberg (Shigley Ch. 7)
+  // ===================================================================
+  // Shaft material data (wrought carbon steel from Shigley Table A-20).
+  const SHAFT_MATERIALS = Object.freeze({
+    '1020_hr':    { label: 'AISI 1020 hot-rolled',     S_ut: 380, S_y: 210 },
+    '1020_cd':    { label: 'AISI 1020 cold-drawn',     S_ut: 470, S_y: 390 },
+    '1040_hr':    { label: 'AISI 1040 hot-rolled',     S_ut: 520, S_y: 290 },
+    '1040_cd':    { label: 'AISI 1040 cold-drawn',     S_ut: 590, S_y: 490 },
+    '1050_hr':    { label: 'AISI 1050 hot-rolled',     S_ut: 620, S_y: 340 },
+    '1050_cd':    { label: 'AISI 1050 cold-drawn',     S_ut: 690, S_y: 580 },
+    '4140_Q&T':   { label: 'AISI 4140 Q&T 425°C',      S_ut: 1020, S_y: 900 },
+    '4340_Q&T':   { label: 'AISI 4340 Q&T 425°C',      S_ut: 1280, S_y: 1140 }
+  });
+
+  // Marin surface factor — Shigley Eq. 6-19, a*S_ut^b.
+  const SURFACE_FACTORS = {
+    'ground':      { a: 1.58,  b: -0.085 },
+    'machined':    { a: 4.51,  b: -0.265 },
+    'cold-drawn':  { a: 4.51,  b: -0.265 },
+    'hot-rolled':  { a: 57.7,  b: -0.718 },
+    'as-forged':   { a: 272,   b: -0.995 }
+  };
+
+  /**
+   * Shaft fatigue analysis using Goodman / Soderberg criteria.
+   *
+   * Given mean and alternating stresses (computed from bending moment + torque amplitudes),
+   * applies Marin modifying factors to estimate the endurance limit and returns factors of
+   * safety per Goodman (common) and Soderberg (conservative).
+   *
+   * @param {object} p
+   * @param {string} p.material       Key into SHAFT_MATERIALS.
+   * @param {number} p.diameter       Shaft diameter in mm.
+   * @param {number} p.M_a            Alternating bending moment amplitude in N·m.
+   * @param {number} p.M_m            Mean bending moment in N·m (often 0 for rotating-bending).
+   * @param {number} p.T_a            Alternating torque amplitude in N·m.
+   * @param {number} p.T_m            Mean torque in N·m.
+   * @param {number} [p.Kf=2.0]       Fatigue stress concentration for bending (≥1).
+   * @param {number} [p.Kfs=1.5]      Fatigue stress concentration for torsion.
+   * @param {string} [p.surface='machined']  Surface finish preset.
+   * @param {number} [p.reliability=0.99]    Reliability (0.5–0.999999).
+   * @param {number} [p.temperatureC=25]     Operating temperature in °C.
+   * @returns {object}
+   */
+  function shaftFatigueAnalysis(p) {
+    const mat = SHAFT_MATERIALS[p.material] || SHAFT_MATERIALS['1050_cd'];
+    const d   = Math.max(5, Number(p.diameter) || 25);   // mm
+    const M_a = Math.max(0, Number(p.M_a) || 0);          // N·m
+    const M_m = Math.max(0, Number(p.M_m) || 0);
+    const T_a = Math.max(0, Number(p.T_a) || 0);
+    const T_m = Math.max(0, Number(p.T_m) || 0);
+    const Kf  = Math.max(1, Number(p.Kf)  || 2.0);
+    const Kfs = Math.max(1, Number(p.Kfs) || 1.5);
+    const surfaceKey = p.surface || 'machined';
+    const surf = SURFACE_FACTORS[surfaceKey] || SURFACE_FACTORS.machined;
+    const R   = Math.max(0.5, Math.min(0.999999, Number(p.reliability) || 0.99));
+    const T_C = Number(p.temperatureC) || 25;
+
+    // Marin surface factor k_a = a * (S_ut[MPa])^b
+    const k_a = surf.a * Math.pow(mat.S_ut, surf.b);
+    // Size factor k_b — Shigley Eq. 6-20 (rotating bending, 2.79 ≤ d ≤ 51 mm)
+    let k_b;
+    if (d <= 51)  k_b = 1.24 * Math.pow(d, -0.107);
+    else if (d <= 254) k_b = 1.51 * Math.pow(d, -0.157);
+    else k_b = 0.60;
+    // Loading factor k_c = 1 for combined bending + torsion (we handle each via Kf/Kfs)
+    const k_c = 1.0;
+    // Temperature factor k_d — Eq. 6-27
+    const k_d = (T_C <= 70) ? 1.0 : (0.975 + 0.432e-3*T_C - 0.115e-5*T_C*T_C + 0.104e-8*T_C*T_C*T_C);
+    // Reliability factor k_e — Shigley Table 6-5 (z_a from normal distribution)
+    const z_a = (R === 0.99 ? 2.326 : R === 0.999 ? 3.091 : R === 0.95 ? 1.645 : R === 0.90 ? 1.288 : 2.326);
+    const k_e = 1 - 0.08 * z_a;
+    // Miscellaneous k_f = 1 for this scope
+    const k_f = 1.0;
+    // Uncorrected endurance limit S_e' — Shigley Eq. 6-10
+    const S_e_prime = (mat.S_ut <= 1400) ? 0.5 * mat.S_ut : 700;
+    // Corrected endurance limit
+    const S_e = k_a * k_b * k_c * k_d * k_e * k_f * S_e_prime;
+
+    // Stresses — bending σ_a/σ_m (Kf applied), torsion τ_a/τ_m (Kfs applied)
+    // σ = 32·M / (π·d^3)   [M in N·mm, d in mm → MPa]
+    // τ = 16·T / (π·d^3)
+    const d_m = d;  // mm
+    const sigma_a = (32 * M_a * 1000) / (Math.PI * Math.pow(d_m, 3));
+    const sigma_m = (32 * M_m * 1000) / (Math.PI * Math.pow(d_m, 3));
+    const tau_a   = (16 * T_a * 1000) / (Math.PI * Math.pow(d_m, 3));
+    const tau_m   = (16 * T_m * 1000) / (Math.PI * Math.pow(d_m, 3));
+
+    // Von Mises effective stresses (amplitude + mean) with fatigue concentrations
+    const sigma_prime_a = Math.sqrt(Math.pow(Kf  * sigma_a, 2) + 3 * Math.pow(Kfs * tau_a, 2));
+    const sigma_prime_m = Math.sqrt(Math.pow(Kf  * sigma_m, 2) + 3 * Math.pow(Kfs * tau_m, 2));
+
+    // Goodman: 1/n = σ_a'/S_e + σ_m'/S_ut
+    const goodmanInv = (sigma_prime_a / S_e) + (sigma_prime_m / mat.S_ut);
+    const n_Goodman  = goodmanInv > 0 ? 1 / goodmanInv : Infinity;
+
+    // Soderberg: 1/n = σ_a'/S_e + σ_m'/S_y (conservative — yields instead of UTS)
+    const soderbergInv = (sigma_prime_a / S_e) + (sigma_prime_m / mat.S_y);
+    const n_Soderberg  = soderbergInv > 0 ? 1 / soderbergInv : Infinity;
+
+    // First-cycle yield check — static
+    const sigma_max = sigma_prime_a + sigma_prime_m;
+    const n_yield = mat.S_y / sigma_max;
+
+    // Verdict
+    const n_fatigue = Math.min(n_Goodman, n_Soderberg);
+    let verdict, verdictClass;
+    if (n_fatigue >= 2.0 && n_yield >= 2.0)      { verdict = 'SAFE (margin ≥ 2)'; verdictClass = 'pass'; }
+    else if (n_fatigue >= 1.5 && n_yield >= 1.5) { verdict = 'SAFE (industry typical)'; verdictClass = 'pass'; }
+    else if (n_fatigue >= 1.0 && n_yield >= 1.0) { verdict = 'MARGINAL — factor below 1.5'; verdictClass = 'warn'; }
+    else                                          { verdict = 'UNSAFE — factor < 1.0'; verdictClass = 'fail'; }
+    const notes = [];
+    if (n_yield < n_fatigue) notes.push('First-cycle yield governs — increase diameter or use higher-strength material.');
+    if (sigma_prime_m > sigma_prime_a) notes.push('Mean stress dominant — consider rotating-bending to convert static to fully-reversed.');
+    if (n_Goodman > n_Soderberg + 0.3) notes.push('Soderberg (conservative) significantly lower — review if proof strength, not UTS, is the correct allowable.');
+
+    return {
+      inputs: { material: p.material || '1050_cd', material_label: mat.label, d, S_ut: mat.S_ut, S_y: mat.S_y,
+                M_a, M_m, T_a, T_m, Kf, Kfs, surfaceKey, reliability: R, temperatureC: T_C },
+      marin: { k_a, k_b, k_c, k_d, k_e, k_f, S_e_prime, S_e },
+      stresses: { sigma_a, sigma_m, tau_a, tau_m, sigma_prime_a, sigma_prime_m, sigma_max },
+      n_Goodman, n_Soderberg, n_yield,
+      verdict, verdictClass, notes
+    };
+  }
+
+  // ===================================================================
+  // UNIT TESTS — verify core against MecAgent screenshot values
+  // ===================================================================
+  function runSelfTests() {
+    const results = [];
+    function test(name, actual, expected, tol) {
+      const pass = Math.abs(actual - expected) <= tol;
+      results.push({ name, actual, expected, pass });
+      return pass;
+    }
+
+    // MecAgent problem: 4 × M12 (10.9), F_Q=18kN, F_A=18kN, M=420Nm, μ=0.16, F_V=39kN/bolt, BCD=96mm, K_s=1.5
+    const r = boltedJointAnalysis({
+      boltCount: 4, grade: '10.9', thread: 'M12',
+      preload: 39000, shearForce: 18000, axialForce: 18000, moment: 420000,
+      bcd: 96, friction: 0.16, safetyFactor: 1.5
+    });
+
+    // Expected values from MecAgent screenshots:
+    test('F_friction',       r.slipResistance.F_friction,           24960,  1);    // 4·39000·0.16
+    test('F_moment/bolt',    r.slipResistance.F_moment_tangential_per_bolt, 2187.5, 0.5); // 420000/(4·48)
+    test('F_bolt_max_tang',  r.slipResistance.F_bolt_tangential_max, 6687.5, 0.5); // 18000/4 + 2187.5
+    test('F_bolt_total',     r.tensionCheck.F_bolt_total,            45687.5, 1);   // 39000 + 4500 + 2187.5
+    test('σ (tensile)',      r.combinedStress.sigma,                 542,    1);    // 45687.5/84.3
+    test('τ (shear)',        r.combinedStress.tau,                   79,     1.5);  // 6687.5/84.3 ≈ 79.3
+    test('σ_vm',             r.combinedStress.sigma_vm,              558,    2);    // √(542² + 3·79²)
+
+    // ------- GEAR TEST — Shigley Example 14-5 adapted -------
+    // 17T pinion / 52T gear, m=2mm, F=30mm, 2.5kW @ 1800rpm → T_P ≈ 13.26 N·m
+    // Through-hardened 240 HB both gears, K_o=1, K_v=1, K_m=1.3
+    const g = spurGearAnalysis({
+      pinionTeeth: 17, gearTeeth: 52, module: 2, faceWidth: 30,
+      torque: 13.26, pinionHB: 240, gearHB: 240,
+      overload: 1, dynamic: 1, loadDist: 1.3
+    });
+    // Tangential load W_t = 2·T / d_P = 2·13260 / 34 ≈ 780 N
+    test('gear W_t',               g.inputs.W_t,          780,   3);
+    // J for 17 teeth ≈ 0.295 per interpolation table
+    test('gear J (pinion)',        g.pinion.J,            0.295, 0.01);
+    // σ_b (pinion) = 780·1·1·1.3 / (30·2·0.295) = 1014/17.7 ≈ 57.3 MPa
+    test('gear σ_b pinion',        g.pinion.sigma_b,      57.3,  1.5);
+    // S_t @240HB = (77·240 + 12800)·psi→MPa = 31280·0.00689 ≈ 215.7 MPa
+    test('gear S_t @240HB',        g.pinion.S_t,          215.7, 1.5);
+    // SF_bending_P ≈ 215.7 / 57.3 ≈ 3.77
+    test('gear SF_bending pinion', g.pinion.SF_bending,   3.77,  0.2);
+
+    // ------- SHAFT TEST — clean case with rotating-bending + constant torque -------
+    // AISI 1050 CD, d=25mm, M_a=100 N·m (rotating bending so M_m=0), T_m=50 N·m, T_a=0
+    // Kf=2.0 (fillet), Kfs=1.5, machined surface, R=0.99, T=25°C
+    const sh = shaftFatigueAnalysis({
+      material: '1050_cd', diameter: 25,
+      M_a: 100, M_m: 0, T_a: 0, T_m: 50,
+      Kf: 2.0, Kfs: 1.5, surface: 'machined', reliability: 0.99, temperatureC: 25
+    });
+    // σ_a = 32·100000 / (π·25³) = 32e5 / 49087 ≈ 65.2 MPa
+    test('shaft σ_a',              sh.stresses.sigma_a,      65.2,  0.5);
+    // τ_m = 16·50000 / (π·25³) ≈ 16.3 MPa
+    test('shaft τ_m',              sh.stresses.tau_m,        16.3,  0.3);
+    // σ_prime_a with Kf·σ_a only (no mean bending, no alternating torque) ≈ Kf·σ_a = 130.4
+    test('shaft σ′_a',             sh.stresses.sigma_prime_a, 130.4, 1.0);
+    // σ_prime_m = √3 · Kfs · τ_m ≈ √3 · 1.5 · 16.3 ≈ 42.4
+    test('shaft σ′_m',             sh.stresses.sigma_prime_m, 42.4,  1.0);
+    // Must be finite + positive
+    test('shaft n_Goodman finite', Number.isFinite(sh.n_Goodman) && sh.n_Goodman > 0 ? 1 : 0, 1, 0);
+    test('shaft n_Soderberg ≤ Goodman', (sh.n_Soderberg <= sh.n_Goodman + 1e-6) ? 1 : 0, 1, 0);
+
+    return { results, allPass: results.every(r => r.pass) };
+  }
+
+  // ===================================================================
+  // NATURAL-LANGUAGE PARSER — extract structured params from a free-text prompt
+  // ===================================================================
+  function parseBoltedJointPrompt(prompt) {
+    const p = (prompt || '').toLowerCase();
+    const res = {};
+
+    // Bolt count: "4 x m12 bolts", "four bolts", "z=4"
+    const wordNums = { one:1, two:2, three:3, four:4, five:5, six:6, seven:7, eight:8, ten:10, twelve:12 };
+    const mCount = p.match(/\b(\d+)\s*[x×]?\s*(?:m\d+\s+)?bolts?\b/) ||
+                   p.match(/\bz\s*=\s*(\d+)\b/) ||
+                   p.match(/\b(one|two|three|four|five|six|seven|eight|ten|twelve)\s*bolts?\b/);
+    if (mCount) res.boltCount = wordNums[mCount[1]] || parseInt(mCount[1]);
+
+    // Thread: "M12", "m8"
+    const mThread = p.match(/\bm\s*(\d+(?:\.\d+)?)\b/i);
+    if (mThread) {
+      const sz = parseFloat(mThread[1]);
+      const key = 'M' + (Number.isInteger(sz) ? sz : sz.toString().replace('.', '_'));
+      if (BOLT_STRESS_AREA[key]) res.thread = key;
+    }
+
+    // Grade: "10.9", "class 8.8", "property class 10.9"
+    const mGrade = p.match(/\b(?:class|grade|property\s*class)\s*(\d+\.\d+)\b/i) ||
+                   p.match(/\b(4\.6|4\.8|5\.6|5\.8|6\.8|8\.8|10\.9|12\.9)\b/);
+    if (mGrade) res.grade = mGrade[1];
+
+    // Forces — support kN and N units
+    const numUnit = (m) => {
+      if (!m) return null;
+      const val = parseFloat(m[1]);
+      const unit = (m[2] || '').toLowerCase();
+      if (unit.startsWith('kn')) return val * 1000;
+      return val;
+    };
+    const mShear = p.match(/(?:shear|transverse|shearing)\s*(?:force|load)?[^\d-]{0,12}(\d+(?:\.\d+)?)\s*(kn|n)\b/i);
+    if (mShear) res.shearForce = numUnit(mShear);
+    const mAxial = p.match(/(?:axial|separating|tensile)\s*(?:force|load)?[^\d-]{0,12}(\d+(?:\.\d+)?)\s*(kn|n)\b/i);
+    if (mAxial) res.axialForce = numUnit(mAxial);
+
+    // Moment (N·m or kN·m → convert to N·mm)
+    const mMoment = p.match(/(?:in.plane\s*)?moment[^\d-]{0,12}(\d+(?:\.\d+)?)\s*(nm|knm|kn\s*m|n\s*m)\b/i);
+    if (mMoment) {
+      const val = parseFloat(mMoment[1]);
+      const unit = mMoment[2].toLowerCase().replace(/\s/g, '');
+      res.moment = unit.startsWith('kn') ? val * 1e6 : val * 1000;
+    }
+
+    // Preload
+    const mPre = p.match(/pre[-\s]?load(?:\s*per\s*bolt)?[^\d-]{0,12}(\d+(?:\.\d+)?)\s*(kn|n)\b/i);
+    if (mPre) res.preload = numUnit(mPre);
+
+    // BCD
+    const mBcd = p.match(/(?:bcd|bolt\s*circle[^\d]*?diameter|bolt\s*circle)[^\d-]{0,12}(\d+(?:\.\d+)?)\s*mm/i);
+    if (mBcd) res.bcd = parseFloat(mBcd[1]);
+
+    // Friction
+    const mFric = p.match(/(?:friction\s*(?:coefficient)?|[μu])[^\d-]{0,8}(\d*\.\d+)/i);
+    if (mFric) res.friction = parseFloat(mFric[1]);
+
+    // Safety factor — allow common phrasings like "safety factor against slipping: 1.5"
+    const mSf = p.match(/(?:safety\s*factor|k\s*_?\s*s|\bks\b)\s*(?:against\s+\w+)?\s*[:=]?\s*(\d+(?:\.\d+)?)/i);
+    if (mSf) res.safetyFactor = parseFloat(mSf[1]);
+
+    return res;
+  }
+
+  // ===================================================================
+  // LaTeX / KaTeX integration — load on demand so it doesn't bloat initial page
+  // ===================================================================
+  let _katexLoading = null;
+  async function loadKaTeX() {
+    if (typeof window.katex !== 'undefined') return window.katex;
+    if (_katexLoading) return _katexLoading;
+    _katexLoading = new Promise((resolve, reject) => {
+      const css = document.createElement('link');
+      css.rel = 'stylesheet';
+      css.href = 'https://cdn.jsdelivr.net/npm/katex@0.16.21/dist/katex.min.css';
+      document.head.appendChild(css);
+      const s = document.createElement('script');
+      s.src = 'https://cdn.jsdelivr.net/npm/katex@0.16.21/dist/katex.min.js';
+      s.onload = () => resolve(window.katex);
+      s.onerror = () => reject(new Error('KaTeX failed to load from CDN'));
+      document.head.appendChild(s);
+    });
+    return _katexLoading;
+  }
+
+  function renderMath(el, latex, displayMode) {
+    el.textContent = latex;  // fallback while KaTeX loads / if it fails
+    loadKaTeX().then(k => {
+      try { k.render(latex, el, { displayMode: !!displayMode, throwOnError: false, strict: 'ignore' }); }
+      catch(e) { el.textContent = latex; }
+    }).catch(() => {});
+  }
+
+  // ===================================================================
+  // UI — form-based input with live recompute + formatted report
+  // ===================================================================
+  const S = { lastResult: null, els: {} };
+
+  const INPUT_FIELDS = [
+    // [key, label, unit, default, min]
+    ['boltCount',       'Bolt count (z)',              '',     4,     1],
+    ['thread',          'Thread',                       '',     'M12', null, 'select', Object.keys(BOLT_STRESS_AREA)],
+    ['grade',           'Grade (ISO 898-1)',            '',     '8.8', null, 'select', Object.keys(STEEL_GRADES)],
+    ['preload',         'Preload per bolt (F_V)',       'N',    25000, 0],
+    ['shearForce',      'Shear force (F_Q)',            'N',    10000, 0],
+    ['axialForce',      'Axial/separating force (F_A)', 'N',    5000,  0],
+    ['moment',          'In-plane moment (M)',          'N·mm', 100000,0],
+    ['bcd',             'Bolt-circle diameter (BCD)',   'mm',   80,    0],
+    ['friction',        'Friction coefficient (μ)',     '',     0.15,  0.01],
+    ['safetyFactor',    'Slip safety factor (K_s)',     '',     1.5,   1],
+    ['frictionInterfaces','Friction interfaces (n)',    '',     1,     1]
+  ];
+
+  function fmt(n, unit, digits) {
+    if (!isFinite(n)) return '—';
+    digits = digits ?? (Math.abs(n) >= 1000 ? 0 : Math.abs(n) >= 10 ? 1 : 2);
+    const s = Number(n).toFixed(digits);
+    return unit ? s + ' ' + unit : s;
+  }
+
+  function collectInputs() {
+    const out = {};
+    INPUT_FIELDS.forEach(([key,,,,, type]) => {
+      const el = S.els['in_' + key];
+      if (!el) return;
+      out[key] = (type === 'select') ? el.value : parseFloat(el.value);
+    });
+    return out;
+  }
+
+  function compute() {
+    try {
+      const params = collectInputs();
+      const r = boltedJointAnalysis(params);
+      S.lastResult = r;
+      renderReport(r);
+    } catch(e) {
+      if (S.els.report) S.els.report.innerHTML = '<div class="aie-err">Error: ' + e.message + '</div>';
+    }
+  }
+
+  function renderReport(r) {
+    const root = S.els.report;
+    if (!root) return;
+    root.innerHTML = '';
+
+    // Verdict banner
+    const verdictBg = r.verdictClass === 'pass' ? '#065f46' : r.verdictClass === 'warn' ? '#78350f' : '#7f1d1d';
+    const verdictFg = r.verdictClass === 'pass' ? '#d1fae5' : r.verdictClass === 'warn' ? '#fed7aa' : '#fecaca';
+    const banner = document.createElement('div');
+    banner.className = 'aie-verdict';
+    banner.style.cssText = 'padding:10px 14px;border-radius:6px;background:'+verdictBg+';color:'+verdictFg+';font-weight:600;font-size:14px;margin-bottom:12px;border:1px solid rgba(255,255,255,0.08)';
+    banner.textContent = 'Verdict: ' + r.verdict;
+    root.appendChild(banner);
+    if (r.notes?.length) {
+      const notes = document.createElement('ul');
+      notes.style.cssText = 'margin:4px 0 14px 18px;font-size:12px;color:#94a3b8';
+      r.notes.forEach(n => { const li = document.createElement('li'); li.textContent = n; notes.appendChild(li); });
+      root.appendChild(notes);
+    }
+
+    // CHECK 1: Slip resistance
+    const s = r.slipResistance, i = r.inputs;
+    const sec1 = section('1. Slip resistance', s.safe);
+    sec1.appendChild(math(
+      'F_{friction} = \\mu \\cdot n \\cdot z \\cdot F_V = '
+        + i.mu + ' \\cdot ' + i.n_interfaces + ' \\cdot ' + i.z + ' \\cdot ' + i.F_preload
+        + ' = \\mathbf{' + s.F_friction.toFixed(0) + '}\\;\\text{N}', true));
+    sec1.appendChild(math(
+      'F_{M,tangential/bolt} = \\frac{M}{z \\cdot r} = \\frac{' + i.M + '}{' + i.z + ' \\cdot ' + i.r.toFixed(1) + '} = '
+        + s.F_moment_tangential_per_bolt.toFixed(1) + '\\;\\text{N}', true));
+    sec1.appendChild(math(
+      'F_{bolt,tangential,max} = \\frac{F_Q}{z} + F_{M,tangential/bolt} = '
+        + (i.F_shear/i.z).toFixed(1) + ' + ' + s.F_moment_tangential_per_bolt.toFixed(1)
+        + ' = \\mathbf{' + s.F_bolt_tangential_max.toFixed(1) + '}\\;\\text{N}', true));
+    sec1.appendChild(math(
+      'F_{required} = K_s \\cdot z \\cdot F_{bolt,tangential,max} = '
+        + i.K_s + ' \\cdot ' + i.z + ' \\cdot ' + s.F_bolt_tangential_max.toFixed(1)
+        + ' = \\mathbf{' + s.F_required.toFixed(0) + '}\\;\\text{N}', true));
+    const slipResult = document.createElement('div');
+    slipResult.style.cssText = 'margin-top:6px;font-size:12px;color:' + (s.safe ? '#a7f3d0' : '#fca5a5');
+    slipResult.innerHTML = s.safe
+      ? '✓ ' + s.F_friction.toFixed(0) + ' N ≥ ' + s.F_required.toFixed(0) + ' N&nbsp;&nbsp;(margin ×' + s.margin.toFixed(2) + ')'
+      : '✗ ' + s.F_friction.toFixed(0) + ' N &lt; ' + s.F_required.toFixed(0) + ' N&nbsp;&nbsp;(deficit: ' + (s.F_required - s.F_friction).toFixed(0) + ' N)';
+    sec1.appendChild(slipResult);
+    root.appendChild(sec1);
+
+    // CHECK 2: Bolt tension
+    const t = r.tensionCheck;
+    const sec2 = section('2. Maximum bolt tension', true /* always informational */);
+    sec2.appendChild(math(
+      'F_{A,bolt} = \\frac{F_A}{z} = \\frac{' + i.F_axial + '}{' + i.z + '} = ' + t.F_axial_per_bolt.toFixed(1) + '\\;\\text{N}', true));
+    sec2.appendChild(math(
+      'F_{M,axial/bolt} = \\frac{M}{z \\cdot r} = ' + t.F_moment_axial_per_bolt.toFixed(1) + '\\;\\text{N}', true));
+    sec2.appendChild(math(
+      'F_{max,external} = F_{A,bolt} + F_{M,axial/bolt} = \\mathbf{' + t.F_max_external.toFixed(1) + '}\\;\\text{N}', true));
+    sec2.appendChild(math(
+      'F_{bolt,total} = F_V + F_{max,external} = ' + i.F_preload + ' + ' + t.F_max_external.toFixed(1)
+        + ' = \\mathbf{' + t.F_bolt_total.toFixed(1) + '}\\;\\text{N}', true));
+    root.appendChild(sec2);
+
+    // CHECK 3: Combined stress
+    const c = r.combinedStress;
+    const sec3 = section('3. Combined stress (von Mises)', c.safe);
+    sec3.appendChild(math(
+      '\\sigma = \\frac{F_{bolt,total}}{A_s} = \\frac{' + t.F_bolt_total.toFixed(1) + '}{' + i.A_s + '} = \\mathbf{'
+        + c.sigma.toFixed(1) + '}\\;\\text{MPa}', true));
+    sec3.appendChild(math(
+      '\\tau = \\frac{F_{bolt,tangential,max}}{A_s} = \\frac{' + s.F_bolt_tangential_max.toFixed(1) + '}{' + i.A_s + '} = \\mathbf{'
+        + c.tau.toFixed(1) + '}\\;\\text{MPa}', true));
+    sec3.appendChild(math(
+      '\\sigma_{vm} = \\sqrt{\\sigma^2 + 3\\tau^2} = \\sqrt{' + c.sigma.toFixed(1) + '^2 + 3 \\cdot ' + c.tau.toFixed(1)
+        + '^2} = \\mathbf{' + c.sigma_vm.toFixed(1) + '}\\;\\text{MPa}', true));
+    const stressResult = document.createElement('div');
+    stressResult.style.cssText = 'margin-top:6px;font-size:12px;color:' + (c.safe ? '#a7f3d0' : '#fca5a5');
+    stressResult.innerHTML = c.safe
+      ? '✓ σ_vm = ' + c.sigma_vm.toFixed(1) + ' MPa &lt; proof strength R_p0.2 = ' + c.R_p02 + ' MPa (class '+i.grade+')&nbsp;&nbsp;(utilisation ' + (c.utilization*100).toFixed(1) + '%)'
+      : '✗ σ_vm = ' + c.sigma_vm.toFixed(1) + ' MPa ≥ R_p0.2 = ' + c.R_p02 + ' MPa (class '+i.grade+')&nbsp;&nbsp;— BOLT WILL YIELD';
+    sec3.appendChild(stressResult);
+    root.appendChild(sec3);
+
+    // Metadata footer
+    const meta = document.createElement('div');
+    meta.style.cssText = 'margin-top:14px;padding-top:10px;border-top:1px solid #334155;font-size:11px;color:#64748b';
+    meta.innerHTML = 'Method: VDI 2230 / Shigley simplified (no load-factor Φ — conservative Φ=1). ' +
+      'Thread ' + i.thread + ' A_s = ' + i.A_s + ' mm² (DIN 13). Grade ' + i.grade + ' R_p0.2 = ' + i.R_p02 + ' MPa, R_m = ' + i.R_m + ' MPa.<br>' +
+      'This is a first-pass analysis — always verify with detailed VDI 2230 if safety-critical.';
+    root.appendChild(meta);
+  }
+
+  function section(title, safe) {
+    const wrap = document.createElement('div');
+    wrap.style.cssText = 'margin-bottom:14px;padding:10px 12px;background:#0f172a;border:1px solid #334155;border-left:3px solid '+(safe?'#10b981':'#ef4444')+';border-radius:4px';
+    const h = document.createElement('div');
+    h.style.cssText = 'font-size:13px;font-weight:600;color:#e5e7eb;margin-bottom:8px';
+    h.textContent = title;
+    wrap.appendChild(h);
+    return wrap;
+  }
+
+  function math(latex, block) {
+    const el = document.createElement('div');
+    el.style.cssText = 'margin:4px 0;font-size:13px;color:#cbd5e1;overflow-x:auto';
+    renderMath(el, latex, block);
+    return el;
+  }
+
+  function applyFromPrompt() {
+    const prompt = S.els.prompt.value;
+    if (!prompt.trim()) return;
+    const parsed = parseBoltedJointPrompt(prompt);
+    Object.entries(parsed).forEach(([k, v]) => {
+      const el = S.els['in_' + k];
+      if (el) el.value = String(v);
+    });
+    compute();
+  }
+
+  function buildUI() {
+    const wrap = document.createElement('div');
+    wrap.className = 'aie-panel';
+    wrap.style.cssText = 'display:flex;flex-direction:column;gap:10px;padding:12px;min-width:460px;max-width:720px;font-family:-apple-system,sans-serif;color:#e5e7eb';
+
+    // Header
+    const header = document.createElement('div');
+    header.innerHTML = '<div style="font-size:15px;font-weight:700;color:#f1f5f9">AI Engineering Analyst</div>'
+      + '<div style="font-size:11px;color:#94a3b8;margin-top:2px">Bolted-joint analysis (VDI 2230 / Shigley) — v1</div>';
+    wrap.appendChild(header);
+
+    // Prompt box for natural-language entry
+    const promptWrap = document.createElement('div');
+    promptWrap.style.cssText = 'display:flex;gap:6px';
+    const prompt = document.createElement('input');
+    prompt.type = 'text';
+    prompt.placeholder = 'Describe the joint (e.g. "4 × M12 bolts class 10.9, shear 18kN, axial 18kN, moment 420Nm, preload 39kN, BCD 96mm, μ=0.16, K_s=1.5")';
+    prompt.style.cssText = 'flex:1;padding:8px;background:#0f172a;color:#e2e8f0;border:1px solid #334155;border-radius:4px;font:12px inherit';
+    const applyBtn = document.createElement('button');
+    applyBtn.textContent = 'Parse';
+    applyBtn.style.cssText = 'padding:8px 14px;background:#38bdf8;color:#0f172a;border:0;border-radius:4px;font-weight:600;cursor:pointer';
+    applyBtn.onclick = applyFromPrompt;
+    prompt.addEventListener('keydown', (e) => { if (e.key === 'Enter') { e.preventDefault(); applyFromPrompt(); } });
+    S.els.prompt = prompt;
+    promptWrap.appendChild(prompt);
+    promptWrap.appendChild(applyBtn);
+    wrap.appendChild(promptWrap);
+
+    // Input grid
+    const grid = document.createElement('div');
+    grid.style.cssText = 'display:grid;grid-template-columns:1fr 1fr;gap:8px 12px;padding:10px;background:#1e293b;border-radius:6px';
+    INPUT_FIELDS.forEach(field => {
+      const [key, label, unit, def, min, type, opts] = field;
+      const cell = document.createElement('label');
+      cell.style.cssText = 'display:flex;flex-direction:column;gap:2px;font-size:11px;color:#94a3b8';
+      const lbl = document.createElement('span');
+      lbl.innerHTML = label + (unit ? ' <span style="color:#64748b">['+unit+']</span>' : '');
+      let input;
+      if (type === 'select') {
+        input = document.createElement('select');
+        input.style.cssText = 'padding:5px;background:#0f172a;color:#e2e8f0;border:1px solid #334155;border-radius:3px;font-size:12px';
+        opts.forEach(v => { const o = document.createElement('option'); o.value = v; o.textContent = v; input.appendChild(o); });
+        input.value = def;
+      } else {
+        input = document.createElement('input');
+        input.type = 'number';
+        input.step = 'any';
+        if (min !== null) input.min = String(min);
+        input.value = String(def);
+        input.style.cssText = 'padding:5px;background:#0f172a;color:#e2e8f0;border:1px solid #334155;border-radius:3px;font-size:12px';
+      }
+      input.addEventListener('input', compute);
+      input.addEventListener('change', compute);
+      S.els['in_' + key] = input;
+      cell.appendChild(lbl);
+      cell.appendChild(input);
+      grid.appendChild(cell);
+    });
+    wrap.appendChild(grid);
+
+    // Preset examples
+    const presets = document.createElement('div');
+    presets.style.cssText = 'display:flex;flex-wrap:wrap;gap:6px';
+    [
+      { label: 'MecAgent demo', values: { boltCount:4, thread:'M12', grade:'10.9', preload:39000, shearForce:18000, axialForce:18000, moment:420000, bcd:96, friction:0.16, safetyFactor:1.5 } },
+      { label: 'Flange M8 light', values: { boltCount:8, thread:'M8', grade:'8.8', preload:15000, shearForce:5000, axialForce:2000, moment:50000, bcd:60, friction:0.15, safetyFactor:1.25 } },
+      { label: 'Heavy M20', values: { boltCount:6, thread:'M20', grade:'8.8', preload:120000, shearForce:30000, axialForce:25000, moment:800000, bcd:200, friction:0.14, safetyFactor:1.5 } }
+    ].forEach(preset => {
+      const b = document.createElement('button');
+      b.textContent = preset.label;
+      b.style.cssText = 'padding:4px 8px;background:#334155;color:#cbd5e1;border:0;border-radius:3px;cursor:pointer;font-size:11px';
+      b.onclick = () => {
+        Object.entries(preset.values).forEach(([k, v]) => { const el = S.els['in_' + k]; if (el) el.value = String(v); });
+        compute();
+      };
+      presets.appendChild(b);
+    });
+    wrap.appendChild(presets);
+
+    // Report area
+    const report = document.createElement('div');
+    report.className = 'aie-report';
+    report.style.cssText = 'padding:4px 0';
+    S.els.report = report;
+    wrap.appendChild(report);
+
+    // Self-test panel (collapsed by default)
+    const testDetails = document.createElement('details');
+    testDetails.style.cssText = 'font-size:11px;color:#64748b;margin-top:6px';
+    const summary = document.createElement('summary');
+    summary.textContent = 'Verification: MecAgent reference values';
+    summary.style.cssText = 'cursor:pointer;user-select:none';
+    testDetails.appendChild(summary);
+    const tests = runSelfTests();
+    const testList = document.createElement('ul');
+    testList.style.cssText = 'margin:6px 0 0 20px;font:11px/1.5 SF Mono,monospace';
+    tests.results.forEach(t => {
+      const li = document.createElement('li');
+      li.style.color = t.pass ? '#86efac' : '#fca5a5';
+      li.textContent = (t.pass ? '✓ ' : '✗ ') + t.name + ': actual=' + (+t.actual).toFixed(2) + ' expected≈' + t.expected;
+      testList.appendChild(li);
+    });
+    testDetails.appendChild(testList);
+    wrap.appendChild(testDetails);
+
+    // Initial compute
+    setTimeout(compute, 0);
+    return wrap;
+  }
+
+  // ===================================================================
+  // PUBLIC API
+  // ===================================================================
+  let uiEl = null;
+  window.CycleCAD.AIEngineer = {
+    // ---- v1: bolted-joint ----
+    analyze: boltedJointAnalysis,
+    parsePrompt: parseBoltedJointPrompt,
+    // ---- v2: gears ----
+    analyzeGear: spurGearAnalysis,
+    gearAllowableBending,
+    gearAllowableContact,
+    gearGeometryJ,
+    gearGeometryI,
+    // ---- v2: shafts ----
+    analyzeShaft: shaftFatigueAnalysis,
+    SHAFT_MATERIALS,
+    SURFACE_FACTORS,
+    // ---- shared ----
+    runSelfTests,
+    STEEL_GRADES,
+    BOLT_STRESS_AREA,
+    BOLT_MAJOR_DIA,
+    FRICTION_PRESETS,
+    init: () => {
+      const t = runSelfTests();
+      if (!t.allPass) {
+        console.warn('[AI Engineer] self-test failures:', t.results.filter(r => !r.pass));
+      } else {
+        console.log('[AI Engineer] self-tests pass (' + t.results.length + '/' + t.results.length + ' across bolted-joint + gears + shafts)');
+      }
+      return t.allPass;
+    },
+    getUI: () => { if (!uiEl) uiEl = buildUI(); return uiEl; },
+    execute: (cmd, params) => {
+      if (cmd === 'analyze')        return boltedJointAnalysis(params || {});
+      if (cmd === 'analyze-gear')   return spurGearAnalysis(params || {});
+      if (cmd === 'analyze-shaft')  return shaftFatigueAnalysis(params || {});
+      if (cmd === 'parse')          return parseBoltedJointPrompt((params && params.prompt) || '');
+      if (cmd === 'show')           { if (!uiEl) uiEl = buildUI(); return uiEl; }
+    }
+  };
+
+  console.log('AI Engineering Analyst v2.0 module loaded (bolted-joint + gears + shafts)');
+})();