x

src/core/base_mold_generator.py

@@ -2,7 +2,7 @@ from typing import Dict, List, Any, Tuple, Optional
 import math
 import numpy as np
 from OCC.Core.BRepOffsetAPI import BRepOffsetAPI_DraftAngle
-from OCC.Core.BRepAlgoAPI import BRepAlgoAPI_Cut, BRepAlgoAPI_Section, BRepAlgoAPI_Common
+from OCC.Core.BRepAlgoAPI import BRepAlgoAPI_Cut, BRepAlgoAPI_Section, BRepAlgoAPI_Common, BRepAlgoAPI_Fuse
 from OCC.Core.BRepBuilderAPI import BRepBuilderAPI_MakeFace, BRepBuilderAPI_Transform
 from OCC.Core.BRepPrimAPI import BRepPrimAPI_MakeBox, BRepPrimAPI_MakeHalfSpace
 from OCC.Core.gp import gp_Pln, gp_Dir, gp_Pnt, gp_Trsf, gp_Ax2
@@ -226,14 +226,12 @@ class BaseMoldGenerator:
 
     def _split_cavity_core(self, shape: Any, parting_surface: Any, margin: int = 20) -> Tuple[Any, Any]:
         """
-        用分型面将模具块切分为A板（上模/型腔）和B板（下模/型芯），
-        然后从每个板中减去产品形状的对应部分。
+        分离型腔和型芯 — 完全嵌入 + 突出贴合方式。
 
-        流程：
-        1. 创建完整模具块（产品包围盒 + 全方向余量）
-        2. 用分型面将模具块切分为 A板 和 B板
-        3. A板 - 产品 = 型腔（凹模）
-        4. B板 - 产品 = 型芯（凸模）
+        型腔（凹模）= 完整模具块 - 产品 → 产品形状完全嵌入型腔块中
+        型芯（凸模）= 底座平板 + 产品融合 → 产品从底座面突出，与型腔凹入完美贴合
+
+        不再将模具块沿分型面一分为二。
         """
         try:
             bbox = Bnd_Box()
@@ -254,33 +252,109 @@ class BaseMoldGenerator:
 
             parting_plane = self._get_parting_plane(parting_surface, shape)
             if parting_plane is None:
-                logger.warning("无法提取分型面平面，使用回退方案")
                 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)
+            cavity = self._subtract_product_from_plate(mold_block, shape, "型腔")
+            if cavity is None:
+                cavity = mold_block
 
-            if a_plate is not None and b_plate is not None:
-                cavity = self._subtract_product_from_plate(a_plate, shape, "型腔(A板)")
-                core = self._subtract_product_from_plate(b_plate, shape, "型芯(B板)")
+            core = self._build_core_with_base(
+                shape, mold_block, parting_plane,
+                mold_xmin, mold_ymin, mold_zmin,
+                mold_xmax, mold_ymax, mold_zmax,
+                xmin, ymin, zmin, xmax, ymax, zmax
+            )
 
-                if cavity is not None and core is not None:
-                    logger.info("型腔/型芯分离完成（分型面切分+布尔减）")
-                    return cavity, core
-                elif cavity is not None:
-                    logger.warning("型芯生成失败，使用产品形状")
-                    return cavity, shape
-                elif core is not None:
-                    logger.warning("型腔生成失败，使用模具块")
-                    return mold_block, core
-
-            logger.warning("A/B板切分不完全，回退到原方案")
-            return self._split_cavity_core_fallback(shape, mold_block)
+            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)
 
+    @staticmethod
+    def _extract_parting_normal(parting_surface: Any) -> List[float]:
+        """从分型面提取法向量"""
+        try:
+            surface = BRepAdaptor_Surface(parting_surface)
+            if surface.GetType() == 0:
+                plane = surface.Plane()
+                n = plane.Axis().Direction()
+                return [float(n.X()), float(n.Y()), float(n.Z())]
+        except Exception:
+            pass
+        return [0.0, 0.0, 1.0]
+
+    def _build_core_with_base(
+        self,
+        shape: Any,
+        mold_block: Any,
+        parting_plane: gp_Pln,
+        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:
+        """
+        构建带底座的型芯：底座平板 + 产品突出体融合。
+
+        底座从模具边界延伸到分型面（沿分型方向），
+        并略微伸入产品体积以确保布尔融合成功。
+        """
+        normal = parting_plane.Axis().Direction()
+        origin = parting_plane.Location()
+        nx, ny, nz = float(normal.X()), float(normal.Y()), float(normal.Z())
+
+        prod_extent = (xmax - xmin) + (ymax - ymin) + (zmax - zmin)
+        overlap = max(prod_extent * 0.01, 0.5)
+
+        base_p1 = [mold_xmin, mold_ymin, mold_zmin]
+        base_p2 = [mold_xmax, mold_ymax, mold_zmax]
+
+        for i, (n, o, lo, hi) in enumerate(zip(
+            [nx, ny, nz],
+            [float(origin.X()), float(origin.Y()), float(origin.Z())],
+            [mold_xmin, mold_ymin, mold_zmin],
+            [mold_xmax, mold_ymax, mold_zmax],
+        )):
+            if abs(n) < 0.001:
+                continue
+            if n > 0:
+                base_p2[i] = o + overlap
+            else:
+                base_p1[i] = o - overlap
+
+        try:
+            base_plate = BRepPrimAPI_MakeBox(
+                gp_Pnt(base_p1[0], base_p1[1], base_p1[2]),
+                gp_Pnt(base_p2[0], base_p2[1], base_p2[2])
+            ).Shape()
+            logger.info("型芯底座平板构建完成")
+        except Exception as e:
+            logger.warning(f"底座构建失败: {e}")
+            return shape
+
+        try:
+            fuse_op = BRepAlgoAPI_Fuse(base_plate, shape)
+            if fuse_op.IsDone():
+                core = fuse_op.Shape()
+                logger.info("型芯（底座+产品突出体）融合成功")
+                return core
+        except Exception as e:
+            logger.warning(f"底座融合失败: {e}")
+
+        try:
+            cut_op = BRepAlgoAPI_Cut(mold_block, shape)
+            if cut_op.IsDone():
+                logger.info("型芯通过布尔减回退构建")
+                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:
@@ -373,9 +447,9 @@ class BaseMoldGenerator:
     def _split_cavity_core_fallback(self, shape: Any,
                                      mold_block: Optional[Any] = None) -> Tuple[Any, Any]:
         """
-        分模回退方案：用边界框中心面作为分型面切分模具块。
+        分模回退方案：完全嵌入 + 突出贴合，用 Z 中心面做分型基准。
         """
-        logger.warning("使用分模回退方案")
+        logger.warning("使用分模回退方案（完全嵌入 + 突出贴合）")
 
         try:
             bbox = Bnd_Box()
@@ -389,19 +463,22 @@ class BaseMoldGenerator:
                     gp_Pnt(xmax + margin, ymax + margin, zmax + margin)
                 ).Shape()
 
+            cavity = self._subtract_product_from_plate(mold_block, shape, "型腔(回退)")
+            if cavity is None:
+                cavity = mold_block
+
             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 not None and b_plate is not None:
-                cavity = self._subtract_product_from_plate(a_plate, shape, "型腔(回退)")
-                core = self._subtract_product_from_plate(b_plate, shape, "型芯(回退)")
-                if cavity is not None and core is not None:
-                    logger.info("回退方案型腔/型芯分离完成")
-                    return cavity, core
+            core = self._build_core_with_base(
+                shape, mold_block, parting_plane,
+                xmin - margin, ymin - margin, zmin - margin,
+                xmax + margin, ymax + margin, zmax + margin,
+                xmin, ymin, zmin, xmax, ymax, zmax
+            )
 
-            cavity = self._subtract_product_from_plate(mold_block, shape, "型腔(兜底)")
-            return cavity or mold_block, shape
+            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}")