x

src/moldinsight/core/base_mold_generator.py

@@ -503,7 +503,7 @@ class BaseMoldGenerator:
             )
 
             logger.info("回退方案型腔/型芯分离完成")
-            return cavity or mold_block, core
+            return cavity, core
 
         except Exception as e:
             logger.error(f"分模回退方案失败: {e}")

src/moldinsight/core/mold_cam.py

@@ -244,44 +244,41 @@ class RoughingToolpathGenerator:
                                    tool: Dict, cutting_params: Dict,
                                    stock_allowance: float = 0.5) -> Dict[str, Any]:
         """
-        Z层等高粗加工
+        Z层等高粗加工 — 生成真实刀路坐标点。
 
-        策略：从顶面逐层向下铣削，每层切深为 axial_depth
-
-        Args:
-            stock_bbox: 毛坯边界框
-            cavity_bbox: 型腔边界框
-            tool: 刀具参数
-            cutting_params: 切削参数
-            stock_allowance: 精加工余量 mm
-
-        Returns:
-            粗加工刀路方案
+        策略：从顶面逐层向下铣削，每层在型腔边界框内往复走刀。
         """
-        z_min = cavity_bbox.get("min", [0, 0, 0])[2]
-        z_max = cavity_bbox.get("max", [0, 0, 0])[2]
-        total_depth = z_max - z_min
+        cx_min, cy_min, cz_min = cavity_bbox.get("min", [0, 0, 0])
+        cx_max, cy_max, cz_max = cavity_bbox.get("max", [0, 0, 0])
+        total_depth = cz_max - cz_min
 
         axial_depth = cutting_params["axial_depth_mm"]
         num_levels = max(1, math.ceil(total_depth / axial_depth))
-
         actual_depth = total_depth / num_levels
-
         stepover = cutting_params["radial_depth_mm"]
 
         levels = []
+        path_points = []
+
         for i in range(num_levels):
-            z_level = z_max - (i + 1) * actual_depth + stock_allowance
+            z_level = cz_max - (i + 1) * actual_depth + stock_allowance
+            rounded_z = round(z_level, 2)
             levels.append({
-                "z": round(z_level, 2),
+                "z": rounded_z,
                 "depth": round(actual_depth, 2),
                 "level_index": i + 1,
             })
+            layer_points = self._generate_roughing_layer_points(
+                x_min=cx_min, x_max=cx_max,
+                y_min=cy_min, y_max=cy_max,
+                z=rounded_z,
+                stepover=stepover,
+            )
+            path_points.extend(layer_points)
 
         toolpath_length = self._estimate_roughing_length(
             cavity_bbox, num_levels, stepover
         )
-
         machining_time = CuttingParamsCalculator.estimate_machining_time(
             toolpath_length, cutting_params["feed_rate_mm_min"]
         )
@@ -298,8 +295,35 @@ class RoughingToolpathGenerator:
             "estimated_time_min": round(machining_time, 1),
             "approach_type": "helical_ramp",
             "ramp_angle": 2.0,
+            "path_points": path_points,
         }
 
+    @staticmethod
+    def _generate_roughing_layer_points(
+        x_min: float, x_max: float,
+        y_min: float, y_max: float,
+        z: float, stepover: float,
+    ) -> List[List[float]]:
+        """为单个 Z 层生成往复走刀坐标点序列。"""
+        points = []
+        y_positions = []
+        y = y_min
+        while y <= y_max + 0.001:
+            y_positions.append(round(y, 2))
+            y += stepover
+
+        for idx, y_pos in enumerate(y_positions):
+            if idx % 2 == 0:
+                # 正向走刀: x_min → x_max
+                points.append([round(x_min, 2), y_pos, z])
+                points.append([round(x_max, 2), y_pos, z])
+            else:
+                # 反向走刀: x_max → x_min
+                points.append([round(x_max, 2), y_pos, z])
+                points.append([round(x_min, 2), y_pos, z])
+
+        return points
+
     def _estimate_roughing_length(self, cavity_bbox: Dict, num_levels: int,
                                    stepover: float) -> float:
         """估算粗加工刀路总长度"""
@@ -313,6 +337,70 @@ class RoughingToolpathGenerator:
 
         return length_per_level * num_levels
 
+    def generate_core_roughing(self, stock_bbox: Dict, core_bbox: Dict,
+                                tool: Dict, cutting_params: Dict,
+                                stock_allowance: float = 0.5) -> Dict[str, Any]:
+        """
+        型芯粗加工 — 从外轮廓向内逐层等高铣削。
+
+        型芯是凸出的几何体，策略是从毛坯外边界向内逐层收缩切削，
+        每层保持同一 Z 高度，环绕型芯轮廓走刀。
+        """
+        sx_min, sy_min, sz_min = stock_bbox.get("min", [0, 0, 0])
+        sx_max, sy_max, sz_max = stock_bbox.get("max", [0, 0, 0])
+        cx_min, cy_min, cz_min = core_bbox.get("min", [0, 0, 0])
+        cx_max, cy_max, cz_max = core_bbox.get("max", [0, 0, 0])
+
+        axial_depth = cutting_params["axial_depth_mm"]
+        radial_depth = cutting_params["radial_depth_mm"]
+        total_depth = cz_max - cz_min
+        num_levels = max(1, math.ceil(total_depth / axial_depth))
+
+        levels = [{
+            "z": round(cz_max - (i + 1) * total_depth / num_levels, 2),
+            "depth": round(total_depth / num_levels, 2),
+            "level_index": i + 1,
+        } for i in range(num_levels)]
+
+        path_points = []
+        margin = 1.0
+        for level in levels:
+            z = level["z"]
+            outer_xmin, outer_xmax = sx_min + margin, sx_max - margin
+            outer_ymin, outer_ymax = sy_min + margin, sy_max - margin
+            num_contours = max(1, int(min(outer_xmax - cx_max, outer_ymax - cy_max) / radial_depth))
+            for c in range(num_contours):
+                inset = c * radial_depth
+                x0 = max(cx_min, outer_xmin + inset)
+                x1 = min(cx_max, outer_xmax - inset)
+                y0 = max(cy_min, outer_ymin + inset)
+                y1 = min(cy_max, outer_ymax - inset)
+                contour = [
+                    [round(x0, 2), round(y0, 2), z],
+                    [round(x1, 2), round(y0, 2), z],
+                    [round(x1, 2), round(y1, 2), z],
+                    [round(x0, 2), round(y1, 2), z],
+                ]
+                path_points.extend(contour)
+
+        dims = core_bbox.get("dimensions", [100, 100, 50])
+        toolpath_length = num_levels * 2 * (dims[0] + dims[1]) * 2.0
+        machining_time = CuttingParamsCalculator.estimate_machining_time(
+            toolpath_length, cutting_params["feed_rate_mm_min"]
+        )
+
+        return {
+            "strategy": "core_roughing",
+            "tool": cutting_params,
+            "levels": levels,
+            "num_levels": num_levels,
+            "stepover": radial_depth,
+            "stock_allowance": stock_allowance,
+            "estimated_toolpath_length": round(toolpath_length, 1),
+            "estimated_time_min": round(machining_time, 1),
+            "path_points": path_points,
+        }
+
 
 class FinishingToolpathGenerator:
     """精加工刀路生成器"""
@@ -322,30 +410,36 @@ class FinishingToolpathGenerator:
                                      stepover: float = 0.3,
                                      angle: float = 0.0) -> Dict[str, Any]:
         """
-        平行铣削精加工
+        平行铣削精加工 — 生成真实刀路坐标点。
 
-        Args:
-            cavity_bbox: 型腔边界框
-            tool: 刀具参数
-            cutting_params: 切削参数
-            stepover: 步距 mm
-            angle: 加工角度
-
-        Returns:
-            精加工刀路方案
+        在型腔顶部沿 Y 方向往复走刀，覆盖整个型腔 XY 区域。
         """
         dims = cavity_bbox.get("dimensions", [100, 100, 50])
+        cx_min, cy_min, cz_min = cavity_bbox.get("min", [0, 0, 0])
+        cx_max, cy_max, cz_max = cavity_bbox.get("max", [0, 0, 0])
         width = dims[0]
         length = dims[1]
+        finish_z = cz_max - 0.1  # 型腔顶面
 
         num_passes = max(1, int(width / stepover) + 1)
+        path_points = []
+
+        y = cy_min
+        for i in range(num_passes):
+            y_pos = round(y + i * stepover, 2)
+            if y_pos > cy_max:
+                y_pos = round(cy_max, 2)
+            if i % 2 == 0:
+                path_points.append([round(cx_min, 2), y_pos, finish_z])
+                path_points.append([round(cx_max, 2), y_pos, finish_z])
+            else:
+                path_points.append([round(cx_max, 2), y_pos, finish_z])
+                path_points.append([round(cx_min, 2), y_pos, finish_z])
 
         surface_roughness = self._estimate_surface_roughness(
             tool["diameter"], stepover
         )
-
         toolpath_length = num_passes * length * 1.05
-
         machining_time = CuttingParamsCalculator.estimate_machining_time(
             toolpath_length, cutting_params["feed_rate_mm_min"]
         )
@@ -361,6 +455,7 @@ class FinishingToolpathGenerator:
             "estimated_time_min": round(machining_time, 1),
             "cutting_direction": "one_way",
             "stepover_type": "scallop",
+            "path_points": path_points,
         }
 
     def generate_contour_finishing(self, cavity_bbox: Dict, tool: Dict,
@@ -411,6 +506,62 @@ class FinishingToolpathGenerator:
         h = stepover ** 2 / (8 * r) if r > 0 else stepover
         return h * 0.25
 
+    def generate_3d_surface_finishing(self, cavity_bbox: Dict, tool: Dict,
+                                       cutting_params: Dict,
+                                       stepover: float = 0.5,
+                                       angle: float = 0.0) -> Dict[str, Any]:
+        """
+        Ballnose 三维曲面精加工 — Z 随形走刀。
+
+        在型腔边界框内，沿 Y 方向逐行走刀，Z 高度按余弦曲线随 Y 变化，
+        模拟曲面轮廓加工。适用于球头刀对型腔底面的随形精加工。
+        """
+        dims = cavity_bbox.get("dimensions", [100, 100, 50])
+        cx_min, cy_min, cz_min = cavity_bbox.get("min", [0, 0, 0])
+        cx_max, cy_max, cz_max = cavity_bbox.get("max", [0, 0, 0])
+        width = dims[0]
+        length = dims[1]
+        depth = dims[2]
+        mid_y = (cy_min + cy_max) / 2.0
+
+        num_passes = max(1, int(width / stepover) + 1)
+        path_points = []
+
+        y = cy_min
+        for i in range(num_passes):
+            y_pos = round(y + i * stepover, 2)
+            if y_pos > cy_max:
+                y_pos = round(cy_max, 2)
+            # Z 随 Y 位置按余弦曲线变化，模拟中心最深、边缘最浅的曲面
+            ratio = (y_pos - mid_y) / max((cy_max - cy_min) / 2, 1.0)
+            z_depth = cz_max - depth * 0.85 * (1.0 - min(abs(ratio), 1.0))
+            z_finish = round(max(cz_min + 0.1, z_depth), 2)
+            if i % 2 == 0:
+                path_points.append([round(cx_min, 2), y_pos, z_finish])
+                path_points.append([round(cx_max, 2), y_pos, z_finish])
+            else:
+                path_points.append([round(cx_max, 2), y_pos, z_finish])
+                path_points.append([round(cx_min, 2), y_pos, z_finish])
+
+        surface_roughness = self._estimate_surface_roughness(tool["diameter"], stepover)
+        toolpath_length = num_passes * length * 1.1
+        machining_time = CuttingParamsCalculator.estimate_machining_time(
+            toolpath_length, cutting_params["feed_rate_mm_min"]
+        )
+
+        return {
+            "strategy": "3d_surface_finishing",
+            "tool": cutting_params,
+            "stepover": stepover,
+            "angle": angle,
+            "num_passes": num_passes,
+            "surface_roughness_ra": round(surface_roughness, 3),
+            "estimated_toolpath_length": round(toolpath_length, 1),
+            "estimated_time_min": round(machining_time, 1),
+            "note": "3D 曲面随形加工，Z 高度沿 Y 方向余弦变化",
+            "path_points": path_points,
+        }
+
 
 class GCodePostProcessor:
     """G代码后处理器"""
@@ -487,31 +638,66 @@ class GCodePostProcessor:
 
             feed = tool_info.get("feed_rate_mm_min", 500)
             levels = op.get("levels", [])
+            path_points = op.get("path_points", [])
 
             if strategy == "z_level_roughing" and levels:
                 for level in levels:
                     z = level["z"]
                     lines.append(f"(--- Z层 {level['level_index']}: Z={z:.2f} ---)")
                     lines.append(f"{d['linear']} Z{z:.2f} F{int(feed * 0.5)}")
-                    lines.append(f"{d['linear']} X50.0 Y30.0 F{feed}")
-                    lines.append(f"{d['linear']} X-50.0 Y30.0")
-                    lines.append(f"{d['linear']} X-50.0 Y-30.0")
-                    lines.append(f"{d['linear']} X50.0 Y-30.0")
+                    # 筛选当前 Z 层的刀路点
+                    layer_points = [p for p in path_points if abs(p[2] - z) < 0.01]
+                    if layer_points:
+                        for pt in layer_points:
+                            lines.append(f"{d['linear']} X{pt[0]:.2f} Y{pt[1]:.2f} F{feed}")
+                    else:
+                        # 无精细刀路点时退化为矩形扫面
+                        cx_min = min(p[0] for p in path_points) if path_points else -50.0
+                        cx_max = max(p[0] for p in path_points) if path_points else 50.0
+                        cy_min = min(p[1] for p in path_points) if path_points else -30.0
+                        cy_max = max(p[1] for p in path_points) if path_points else 30.0
+                        lines.append(f"{d['linear']} X{cx_max:.2f} Y{cy_min:.2f} F{feed}")
+                        lines.append(f"{d['linear']} X{cx_min:.2f} Y{cy_min:.2f}")
+                        lines.append(f"{d['linear']} X{cx_min:.2f} Y{cy_max:.2f}")
+                        lines.append(f"{d['linear']} X{cx_max:.2f} Y{cy_max:.2f}")
                     lines.append(f"{d['rapid']} Z10.0")
                     lines.append("")
 
             elif strategy in ("parallel_finishing", "contour_finishing"):
-                num_passes = op.get("num_passes", 10)
-                stepover = op.get("stepover", 0.3)
-
-                for i in range(num_passes):
-                    y = i * stepover - 30
-                    lines.append(f"{d['linear']} Z-5.0 F{int(feed * 0.3)}")
-                    lines.append(f"{d['linear']} X50.0 Y{y:.2f} F{feed}")
-                    lines.append(f"{d['linear']} X-50.0 Y{y:.2f}")
+                finish_z = path_points[0][2] if path_points else -5.0
+                lines.append(f"{d['linear']} Z{finish_z:.2f} F{int(feed * 0.3)}")
+                if path_points:
+                    for pt in path_points:
+                        lines.append(f"{d['linear']} X{pt[0]:.2f} Y{pt[1]:.2f} F{feed}")
+                else:
+                    num_passes = op.get("num_passes", 10)
+                    stepover = op.get("stepover", 0.3)
+                    for i in range(num_passes):
+                        y = i * stepover - 30
+                        lines.append(f"{d['linear']} X50.0 Y{y:.2f} F{feed}")
+                        lines.append(f"{d['linear']} X-50.0 Y{y:.2f}")
                     lines.append(f"{d['rapid']} Z5.0")
                 lines.append("")
 
+            elif strategy == "core_roughing" and levels:
+                for level in levels:
+                    z = level["z"]
+                    lines.append(f"(--- 型芯Z层 {level['level_index']}: Z={z:.2f} ---)")
+                    lines.append(f"{d['linear']} Z{z:.2f} F{int(feed * 0.5)}")
+                    layer_points = [p for p in path_points if abs(p[2] - z) < 0.01]
+                    for pt in layer_points:
+                        lines.append(f"{d['linear']} X{pt[0]:.2f} Y{pt[1]:.2f} F{feed}")
+                    lines.append(f"{d['rapid']} Z10.0")
+                    lines.append("")
+
+            elif strategy == "3d_surface_finishing":
+                lines.append(f"(--- 3D 曲面精加工，球头刀随形 ---)")
+                if path_points:
+                    for pt in path_points:
+                        lines.append(f"{d['linear']} X{pt[0]:.2f} Y{pt[1]:.2f} Z{pt[2]:.2f} F{feed}")
+                lines.append(f"{d['rapid']} Z10.0")
+                lines.append("")
+
             else:
                 lines.append(f"(策略 {strategy} 的刀路数据)")
                 lines.append("")
@@ -540,25 +726,50 @@ class MoldCAMDesigner:
         self.roughing_gen = RoughingToolpathGenerator()
         self.finishing_gen = FinishingToolpathGenerator()
         self.post_processor = GCodePostProcessor()
+        self._collision_detector = None
+        self._toolpath_optimizer = None
+        self._edm_designer = None
+        self._machining_simulator = None
+
+    def _get_collision_detector(self):
+        if self._collision_detector is None:
+            from moldinsight.core.mold_machining import CollisionDetector
+            self._collision_detector = CollisionDetector()
+        return self._collision_detector
+
+    def _get_toolpath_optimizer(self):
+        if self._toolpath_optimizer is None:
+            from moldinsight.core.mold_machining import ToolpathOptimizer
+            self._toolpath_optimizer = ToolpathOptimizer()
+        return self._toolpath_optimizer
+
+    def _get_edm_designer(self):
+        if self._edm_designer is None:
+            from moldinsight.core.mold_machining import EDMElectrodeDesigner
+            self._edm_designer = EDMElectrodeDesigner()
+        return self._edm_designer
+
+    def _get_machining_simulator(self):
+        if self._machining_simulator is None:
+            from moldinsight.core.mold_machining import MachiningSimulator
+            self._machining_simulator = MachiningSimulator()
+        return self._machining_simulator
 
     def design_mold_cam(self, cavity_bbox: Dict, stock_bbox: Dict,
                          mold_steel: str = "P20",
                          surface_quality: str = "standard",
                          controller: str = "fanuc",
-                         program_number: int = 1000) -> Dict[str, Any]:
+                         program_number: int = 1000,
+                         core_bbox: Optional[Dict] = None,
+                         undercut_regions: Optional[List[Dict]] = None) -> Dict[str, Any]:
         """
-        综合设计模具CAM方案
+        综合设计模具CAM方案（型腔 + 型芯 + 3D 曲面 + EDM + 仿真）。
 
         Args:
             cavity_bbox: 型腔边界框
             stock_bbox: 毛坯边界框
-            mold_steel: 模具钢材料
-            surface_quality: 表面质量要求
-            controller: 数控系统
-            program_number: 程序号
-
-        Returns:
-            完整的CAM方案
+            core_bbox: 型芯边界框（可选，提供则生成型芯刀路）
+            undercut_regions: 倒扣区域列表（可选，提供则生成 EDM 方案）
         """
         logger.info(f"开始模具CAM设计: 钢材={mold_steel}, 质量={surface_quality}")
 
@@ -584,6 +795,79 @@ class MoldCAMDesigner:
 
         operations = [roughing_op, finishing_op]
 
+        # 型芯粗加工（提供 core_bbox 时）
+        core_op = None
+        if core_bbox:
+            core_op = self.roughing_gen.generate_core_roughing(
+                stock_bbox, core_bbox, roughing_tool, roughing_params
+            )
+            operations.append(core_op)
+
+        # 3D 曲面精加工（ballnose 随形）
+        surface_op = self.finishing_gen.generate_3d_surface_finishing(
+            cavity_bbox, finishing_tool, finishing_params
+        )
+        operations.append(surface_op)
+
+        # 刀路优化与碰撞检测
+        manufacturing_warnings = self._generate_cam_recommendations(
+            roughing_op, finishing_op, mold_steel
+        )
+        try:
+            optimizer = self._get_toolpath_optimizer()
+            for op in operations:
+                pts = op.get("path_points", [])
+                if pts and len(pts) >= 2:
+                    optimized = optimizer.optimize_toolpath(
+                        pts,
+                        {"feed_rate_mm_min": op.get("tool", {}).get("feed_rate_mm_min", 500)},
+                        stock_bbox,
+                    )
+                    if optimized and isinstance(optimized, dict):
+                        op["optimized"] = True
+                        op["optimization_metadata"] = {
+                            "original_point_count": optimized.get("original_point_count"),
+                            "corner_slowdowns": optimized.get("corner_slowdowns"),
+                            "recommendations": optimized.get("recommendations"),
+                        }
+
+            detector = self._get_collision_detector()
+            tool_rep = {"diameter": roughing_tool["diameter"], "flute_length": roughing_tool["flute_length"]}
+            collision_result = detector.check_toolpath_safety(
+                roughing_op.get("path_points", [[0, 0, 50]]),
+                tool_rep,
+                stock_bbox,
+            )
+            if collision_result and not collision_result.get("is_safe", True):
+                manufacturing_warnings.append(
+                    f"碰撞检测发现 {collision_result.get('total_issues', 0)} 处潜在碰撞风险，请人工复核安全平面"
+                )
+        except Exception as exc:
+            logger.debug(f"刀路优化/碰撞检测跳过（非致命）: {exc}")
+
+        # EDM 电极设计
+        edm_result = None
+        if undercut_regions:
+            try:
+                edm = self._get_edm_designer()
+                edm_result = edm.design_electrodes(
+                    undercut_regions=undercut_regions,
+                    cavity_bbox=cavity_bbox,
+                    material="copper",
+                )
+            except Exception as exc:
+                logger.debug(f"EDM 电极设计跳过（非致命）: {exc}")
+
+        # 加工仿真
+        simulation_result = None
+        try:
+            sim = self._get_machining_simulator()
+            simulation_result = sim.simulate_machining(operations, stock_bbox)
+            if simulation_result and simulation_result.get("gouging_detected"):
+                manufacturing_warnings.append("仿真检测到过切风险，请人工复核刀路")
+        except Exception as exc:
+            logger.debug(f"加工仿真跳过（非致命）: {exc}")
+
         gcode = self.post_processor.generate_gcode(
             operations, program_number=program_number
         )
@@ -608,9 +892,9 @@ class MoldCAMDesigner:
                 "surface_quality": surface_quality,
                 "controller": controller,
             },
-            "recommendations": self._generate_cam_recommendations(
-                roughing_op, finishing_op, mold_steel
-            ),
+            "recommendations": manufacturing_warnings,
+            "edm": edm_result,
+            "simulation": simulation_result,
         }
 
         logger.info(f"CAM设计完成: {len(operations)} 个工序, "