修改分模逻辑为注塑模

src/core/base_mold_generator.py

@@ -226,13 +226,14 @@ class BaseMoldGenerator:
 
     def _split_cavity_core(self, shape: Any, parting_surface: Any, margin: int = 20) -> Tuple[Any, Any]:
         """
-        分离型腔和型芯
+        分离型腔和型芯 — 完全嵌入 + 突出贴合方式
 
-        正确流程：
-        1. 创建模具块（产品边界框 + 余量）
-        2. 用分型面将模具块切分为 A板（上模）和 B板（下模）
-        3. A板减去产品 → 型腔（凹模）
-        4. B板减去产品 → 型芯（凸模）
+        流程：
+        1. 创建完整模具块（产品包围盒 + 全方向余量）
+        2. 型腔（凹模）= 模具块 - 产品 → 产品完全嵌入型腔块中
+        3. 型芯（凸模）= 产品形状突出体 → 从芯块面突出贴合
+
+        不再使用分型面中间切开产品的方式。
         """
         try:
             bbox = Bnd_Box()
@@ -246,38 +247,69 @@ class BaseMoldGenerator:
             mold_ymax = ymax + margin
             mold_zmax = zmax + margin
 
-            mold_block = BRepPrimAPI_MakeBox(
+            cavity_block = BRepPrimAPI_MakeBox(
                 gp_Pnt(mold_xmin, mold_ymin, mold_zmin),
                 gp_Pnt(mold_xmax, mold_ymax, mold_zmax)
             ).Shape()
 
-            parting_plane = self._get_parting_plane(parting_surface, shape)
-            if parting_plane is None:
-                logger.warning("无法获取分型面平面，使用Z中面作为分型面")
-                center_z = (zmin + zmax) / 2
-                parting_plane = gp_Pln(gp_Pnt(0, 0, center_z), gp_Dir(0, 0, 1))
-
-            a_plate, b_plate = self._split_mold_block_by_plane(mold_block, parting_plane)
-
-            if a_plate is None or b_plate is None:
-                logger.warning("A/B板分离失败，回退到简化方法")
-                return self._split_cavity_core_fallback(shape, mold_block)
-
-            cavity = self._subtract_product_from_plate(a_plate, shape, "A板")
-            core = self._subtract_product_from_plate(b_plate, shape, "B板")
-
+            cavity = self._subtract_product_from_plate(cavity_block, shape, "型腔")
             if cavity is None:
-                cavity = a_plate
-            if core is None:
-                core = b_plate
+                logger.warning("型腔布尔减运算失败，使用原始模具块")
+                cavity = cavity_block
 
-            logger.info("型腔/型芯分离完成（基于分型面A/B板切分）")
+            core = self._build_protruding_core(
+                shape, cavity_block,
+                mold_xmin, mold_ymin, mold_zmin,
+                mold_xmax, mold_ymax, mold_zmax,
+                xmin, ymin, zmin, xmax, ymax, zmax
+            )
+
+            logger.info("型腔/型芯分离完成（完全嵌入+突出贴合）")
             return cavity, core
 
         except Exception as e:
             logger.error(f"型腔分离失败: {e}")
             return self._split_cavity_core_fallback(shape, None)
 
+    def _build_protruding_core(
+        self,
+        shape: Any,
+        cavity_block: Any,
+        mold_xmin: float, mold_ymin: float, mold_zmin: float,
+        mold_xmax: float, mold_ymax: float, mold_zmax: float,
+        xmin: float, ymin: float, zmin: float,
+        xmax: float, ymax: float, zmax: float,
+    ) -> Any:
+        """
+        构建突出贴合式型芯。
+
+        型芯 = 模具块 ∩ 产品形状 → 产品突出体。
+        从视觉上：型芯面突出产品形状，与型腔的凹入形状完美贴合。
+        """
+        try:
+            common_op = BRepAlgoAPI_Common(cavity_block, shape)
+            if common_op.IsDone():
+                core = common_op.Shape()
+                logger.info("型芯突出体构建成功（布尔交）")
+                return core
+        except Exception as e:
+            logger.warning(f"布尔交构建型芯失败: {e}")
+
+        try:
+            core_plate = BRepPrimAPI_MakeBox(
+                gp_Pnt(mold_xmin, mold_ymin, zmin - 5.0),
+                gp_Pnt(mold_xmax, mold_ymax, zmin)
+            ).Shape()
+            cut_op = BRepAlgoAPI_Cut(cavity_block, shape)
+            if cut_op.IsDone():
+                logger.info("型芯突出体构建成功（布尔减回退）")
+                return cut_op.Shape()
+        except Exception:
+            pass
+
+        logger.info("型芯回退为产品形状")
+        return shape
+
     def _get_parting_plane(self, parting_surface: Any, shape: Any) -> Optional[gp_Pln]:
         """从分型面提取平面方程"""
         try:
@@ -370,68 +402,52 @@ class BaseMoldGenerator:
     def _split_cavity_core_fallback(self, shape: Any,
                                      mold_block: Optional[Any] = None) -> Tuple[Any, Any]:
         """
-        分模回退方案：当分型面切分失败时使用
+        分模回退方案：完全嵌入+突出贴合，不切分模具块。
 
-        使用Z中面将模具块简单切分为上下两半
+        1. 创建完整模具块 → 型腔 = 模具块 - 产品（产品完全嵌入）
+        2. 型芯 = 产品形状突出体（突出贴合）
         """
-        logger.warning("使用分模回退方案（Z中面切分）")
+        logger.warning("使用分模回退方案（完全嵌入+突出贴合）")
 
         try:
             bbox = Bnd_Box()
             brepbndlib.Add(shape, bbox)
             xmin, ymin, zmin, xmax, ymax, zmax = bbox.Get()
 
+            margin = 20
             if mold_block is None:
-                margin = 20
                 mold_block = BRepPrimAPI_MakeBox(
                     gp_Pnt(xmin - margin, ymin - margin, zmin - margin),
                     gp_Pnt(xmax + margin, ymax + margin, zmax + margin)
                 ).Shape()
 
-            center_z = (zmin + zmax) / 2
-            parting_plane = gp_Pln(gp_Pnt(0, 0, center_z), gp_Dir(0, 0, 1))
+            cavity = self._subtract_product_from_plate(mold_block, shape, "型腔(回退)")
+            if cavity is None:
+                cavity = mold_block
 
-            a_plate, b_plate = self._split_mold_block_by_plane(mold_block, parting_plane)
+            core = self._build_protruding_core(
+                shape, mold_block,
+                xmin - margin, ymin - margin, zmin - margin,
+                xmax + margin, ymax + margin, zmax + margin,
+                xmin, ymin, zmin, xmax, ymax, zmax
+            )
 
-            if a_plate is not None and b_plate is not None:
-                cavity = self._subtract_product_from_plate(a_plate, shape, "A板(回退)")
-                core = self._subtract_product_from_plate(b_plate, shape, "B板(回退)")
-                return cavity or a_plate, core or b_plate
-
-            logger.warning("回退方案也失败，使用最简A/B板切分（避免返回产品本体）")
-            center_z = (zmin + zmax) / 2
-            margin = 20
-            a_plate = BRepPrimAPI_MakeBox(
-                gp_Pnt(xmin - margin, ymin - margin, center_z),
-                gp_Pnt(xmax + margin, ymax + margin, zmax + margin)
-            ).Shape()
-            b_plate = BRepPrimAPI_MakeBox(
-                gp_Pnt(xmin - margin, ymin - margin, zmin - margin),
-                gp_Pnt(xmax + margin, ymax + margin, center_z)
-            ).Shape()
-
-            cavity = self._subtract_product_from_plate(a_plate, shape, "A板(最简)")
-            core = self._subtract_product_from_plate(b_plate, shape, "B板(最简)")
-            return cavity or a_plate, core or b_plate
+            logger.info("回退方案型腔/型芯分离完成")
+            return cavity or mold_block, core
 
         except Exception as e:
             logger.error(f"分模回退方案失败: {e}")
-            # 最后兜底也返回模具半板，而不是产品本体，避免预览出现“三份产品”
             try:
                 bbox = Bnd_Box()
                 brepbndlib.Add(shape, bbox)
                 xmin, ymin, zmin, xmax, ymax, zmax = bbox.Get()
-                center_z = (zmin + zmax) / 2
                 margin = 20
-                a_plate = BRepPrimAPI_MakeBox(
-                    gp_Pnt(xmin - margin, ymin - margin, center_z),
+                cavity_block = BRepPrimAPI_MakeBox(
+                    gp_Pnt(xmin - margin, ymin - margin, zmin - margin),
                     gp_Pnt(xmax + margin, ymax + margin, zmax + margin)
                 ).Shape()
-                b_plate = BRepPrimAPI_MakeBox(
-                    gp_Pnt(xmin - margin, ymin - margin, zmin - margin),
-                    gp_Pnt(xmax + margin, ymax + margin, center_z)
-                ).Shape()
-                return a_plate, b_plate
+                cavity = self._subtract_product_from_plate(cavity_block, shape, "型腔(兜底)")
+                return cavity or cavity_block, shape
             except Exception:
                 return shape, shape