When Simulation Lies: A Sim-to-Real Benchmark and Domain-Randomized RL Recipe for Tool-Use Agents

Tool-use language agents are evaluated on benchmarks that assume clean inputs, unambiguous tool registries, and reliable APIs. Real deployments violate all these assumptions: user typos propagate into hallucinated tool names, a misconfigured request timeout can stall an agent indefinitely, and duplicate tool names across servers can freeze an SDK. We study these failures as a sim-to-real gap in the tool-use partially observable Markov decision process (POMDP), where deployment noise enters through the observation, action space, reward-relevant metadata, or transition dynamics. We introduce RobustBench-TC, a benchmark with 22 perturbation types organized by these four POMDP components, each grounded in a verified GitHub issue or documented tool-calling failure. Across 21 models from 1.5B to 32B parameters (including the closed-source o4-mini), the robustness profile is sharply uneven: observation perturbations reduce accuracy by less than 5%, while reward-relevant and transition perturbations reduce accuracy by roughly 40% and 30%, respectively; scale alone does not close these gaps. We then propose ToolRL-DR, a domain-randomization reinforcement learning (RL) recipe that trains a tool-use agent on perturbation-augmented trajectories spanning the three statically encodable POMDP components. On a 3B backbone, ToolRL-DR-Full retains roughly three-quarters of clean accuracy and reaches an aggregate perturbed accuracy comparable to open-source 14B function-calling baselines while substantially narrowing the gap to o4-mini. It closes approximately 27% of the Transition gap despite never seeing transition perturbations in training, suggesting that RL on adversarial static tool-use inputs induces a more persistent retry policy that transfers to unseen runtime failures.