x

src/api/routes.py

@@ -507,10 +507,27 @@ async def process_file_core(
         surface_area_mm2 = geometry_data.get("surface_area", 0)
         bbox = geometry_data.get("bounding_box", {})
         bbox_dims = bbox.get("dimensions", [0, 0, 0])
+        
+        # 材料属性（可根据用户选择或自动检测）
+        material_properties = {
+            "ABS": {"density": 1.05, "shrinkage": 0.005, "name": "ABS"},
+            "PP": {"density": 0.90, "shrinkage": 0.016, "name": "PP"},
+            "PE": {"density": 0.95, "shrinkage": 0.020, "name": "PE"},
+            "PC": {"density": 1.20, "shrinkage": 0.007, "name": "PC"},
+            "PA": {"density": 1.14, "shrinkage": 0.010, "name": "PA"},
+            "POM": {"density": 1.41, "shrinkage": 0.020, "name": "POM"},
+            "PMMA": {"density": 1.18, "shrinkage": 0.005, "name": "PMMA"},
+            "PBT": {"density": 1.31, "shrinkage": 0.015, "name": "PBT"},
+        }
+        
+        # 默认使用 ABS
+        selected_material = material_properties["ABS"]
+        material_density = selected_material["density"]
+        shrinkage_rate = selected_material["shrinkage"]
 
-        # 计算产品重量（ABS密度：1.05 g/cm³）
+        # 计算产品重量
         volume_cm3 = volume_mm3 / 1000
-        product_weight_g = volume_cm3 * 1.05
+        product_weight_g = volume_cm3 * material_density
 
         # 计算投影面积（取X、Y方向）
         if len(bbox_dims) >= 2:
@@ -518,8 +535,40 @@ async def process_file_core(
         else:
             projected_area_cm2 = 0
 
-        # 计算夹紧力（投影面积 × 注塑压力600 kg/cm²，转换为吨）
+        # 计算最优型腔数量
-        clamping_force_ton = int(projected_area_cm2 * 600 / 1000)
+        # 基于产品重量和投影面积计算
+        # 小产品（< 100g）可以多型腔，大产品（> 1000g）通常单型腔
+        if product_weight_g < 50:
+            cavity_count = 8  # 小产品，多型腔
+        elif product_weight_g < 100:
+            cavity_count = 4  # 中小产品
+        elif product_weight_g < 300:
+            cavity_count = 2  # 中等产品
+        elif product_weight_g < 1000:
+            cavity_count = 1  # 较大产品
+        else:
+            cavity_count = 1  # 大产品，单型腔
+        
+        # 根据投影面积调整型腔数量
+        # 如果单型腔投影面积超过 400 cm²，减少型腔数量
+        single_cavity_area = projected_area_cm2
+        if single_cavity_area > 400:
+            cavity_count = 1
+        elif single_cavity_area > 200 and cavity_count > 2:
+            cavity_count = 2
+
+        # 计算总投影面积（包括流道系统）
+        # 流道系统约占型腔投影面积的 15-25%
+        runner_ratio = 0.20
+        total_projected_area = single_cavity_area * cavity_count * (1 + runner_ratio)
+
+        # 计算夹紧力（总投影面积 × 注塑压力 / 1000 吨）
+        # 注塑压力根据材料选择：ABS 约 600-800 kg/cm²
+        injection_pressure = 700  # kg/cm²
+        clamping_force_ton = int(total_projected_area * injection_pressure / 1000)
+        
+        # 确保夹紧力在合理范围内
+        clamping_force_ton = max(50, min(clamping_force_ton, 3000))
 
         # 计算壁厚范围
         if surface_area_mm2 > 0 and volume_mm3 > 0:
@@ -537,29 +586,55 @@ async def process_file_core(
         else:
             complexity_score = 0.5
 
-        # 计算模具尺寸（基于产品尺寸 + 模具边距）
+        # 计算模具尺寸（基于型腔布局）
-        mold_length = max(bbox_dims[0] if len(bbox_dims) > 0 else 120, 120) + 40
+        # 单型腔：产品尺寸 + 边距
-        mold_width = max(bbox_dims[1] if len(bbox_dims) > 1 else 100, 100) + 40
+        # 多型腔：需要考虑型腔排列
-        mold_height = max(bbox_dims[2] if len(bbox_dims) > 2 else 60, 60) + 50
+        cavity_spacing = 30  # 型腔间距 mm
+        edge_margin = 50  # 边缘余量 mm
+        
+        if cavity_count == 1:
+            mold_length = max(bbox_dims[0] if len(bbox_dims) > 0 else 120, 120) + 2 * edge_margin
+            mold_width = max(bbox_dims[1] if len(bbox_dims) > 1 else 100, 100) + 2 * edge_margin
+        elif cavity_count == 2:
+            # 2型腔：并排排列
+            mold_length = 2 * max(bbox_dims[0] if len(bbox_dims) > 0 else 120, 120) + cavity_spacing + 2 * edge_margin
+            mold_width = max(bbox_dims[1] if len(bbox_dims) > 1 else 100, 100) + 2 * edge_margin
+        elif cavity_count == 4:
+            # 4型腔：2x2 排列
+            mold_length = 2 * max(bbox_dims[0] if len(bbox_dims) > 0 else 120, 120) + cavity_spacing + 2 * edge_margin
+            mold_width = 2 * max(bbox_dims[1] if len(bbox_dims) > 1 else 100, 100) + cavity_spacing + 2 * edge_margin
+        else:
+            # 8型腔：2x4 排列
+            mold_length = 4 * max(bbox_dims[0] if len(bbox_dims) > 0 else 120, 120) + 3 * cavity_spacing + 2 * edge_margin
+            mold_width = 2 * max(bbox_dims[1] if len(bbox_dims) > 1 else 100, 100) + cavity_spacing + 2 * edge_margin
+        
+        mold_height = max(bbox_dims[2] if len(bbox_dims) > 2 else 60, 60) + 80  # 包含冷却系统
 
-        # 计算分型线长度（基于产品周长）
+        # 计算分型线长度（基于型腔布局）
         if len(bbox_dims) >= 2:
-            parting_line_length = 2 * (bbox_dims[0] + bbox_dims[1])
+            single_parting_line = 2 * (bbox_dims[0] + bbox_dims[1])
+            parting_line_length = single_parting_line * cavity_count
         else:
             parting_line_length = 0
 
-        # 估算成型周期（基于体积）
+        # 估算成型周期（基于体积和壁厚）
         # 周期 = 冷却时间 + 注塑时间 + 开合模时间
-        cooling_time = (wall_thickness_max ** 2) * 5  # 简化公式
+        cooling_time = (wall_thickness_max ** 2) * 4  # 冷却时间与壁厚平方成正比
-        injection_time = max(5, volume_cm3 / 50)  # 注塑时间
+        injection_time = max(3, volume_cm3 / 100)  # 注塑时间
-        cycle_time = cooling_time + injection_time + 8  # 开合模约8秒
+        ejection_time = 3  # 顶出时间
+        cycle_time = cooling_time + injection_time + ejection_time + 5  # 开合模约5秒
+        
+        # 根据型腔数量调整周期（多型腔需要更长冷却时间）
+        if cavity_count > 1:
+            cycle_time = cycle_time * (1 + 0.1 * (cavity_count - 1))
 
         detailed_cavity_json = {
             "metadata": {
                 "file_name": Path(file_path).name,
                 "analysis_date": datetime.now().isoformat(),
-                "shrinkage_rate": 0.005,
+                "shrinkage_rate": shrinkage_rate,
-                "draft_angle": 2.0
+                "draft_angle": 2.0,
+                "selected_material": selected_material["name"]
             },
             "product_analysis": {
                 "volume": volume_mm3,
@@ -567,32 +642,36 @@ async def process_file_core(
                 "bounding_box": bbox
             },
             "manufacturing_info": {
-                "recommended_material": "ABS",
+                "recommended_material": selected_material["name"],
+                "material_density": f"{material_density} g/cm³",
                 "estimated_clamping_force": f"{clamping_force_ton} 吨",
                 "estimated_mold_size": {
                     "length": int(mold_length),
                     "width": int(mold_width),
                     "height": int(mold_height)
                 },
-                "mold_material": "铝合金7075",
+                "mold_material": "铝合金7075" if clamping_force_ton < 200 else "P20钢材",
-                "mold_hardness": "HB 150-170",
+                "mold_hardness": "HB 150-170" if clamping_force_ton < 200 else "HRC 28-32",
                 "surface_finish": "Ra 0.8 μm",
                 "parting_line_length": f"{parting_line_length:.2f} mm",
-                "estimated_cycle_time": f"{int(cycle_time)} 秒"
+                "estimated_cycle_time": f"{int(cycle_time)} 秒",
+                "injection_pressure": f"{injection_pressure} kg/cm²"
             },
             "mold_cavities": {
-                "cavity_count": 1,
+                "cavity_count": cavity_count,
+                "cavity_layout": "single" if cavity_count == 1 else f"{cavity_count} cavities",
                 "cavity_key_info": {
                     "geometric_characteristics": {
                         "product_weight": f"{product_weight_g:.2f} g",
                         "wall_thickness_range": f"{wall_thickness_min:.2f} - {wall_thickness_max:.2f} mm",
                         "complexity_score": round(complexity_score, 2),
-                        "product_volume": f"{volume_cm3:.2f} cm³"
+                        "product_volume": f"{volume_cm3:.2f} cm³",
+                        "projected_area": f"{projected_area_cm2:.2f} cm²"
                     },
                     "quality_considerations": {
-                        "potential_weld_lines": "center",
+                        "potential_weld_lines": "center" if cavity_count > 1 else "minimal",
-                        "sink_mark_areas": "thick_sections",
+                        "sink_mark_areas": "thick_sections" if wall_thickness_max > 4 else "minimal",
-                        "warpage_risk": "low"
+                        "warpage_risk": "medium" if wall_thickness_max > 5 else "low"
                     }
                 }
             }