x

src/core/aluminum_foam_mold.py

@@ -247,9 +247,12 @@ class AluminumFoamMoldGenerator:
             "manufacturing_info": {
                 "estimated_mold_size": self._calculate_mold_size(analysis),
                 "estimated_clamping_force": self._calculate_clamping_force(analysis),
+                "clamping_force_formula": "投影面积(cm²) × 0.3 (泡沫材料系数)",
                 "recommended_material": material_info.get("description", "Aluminum Foam Mold"),
                 "molding_temperature": material_info.get("molding_temp", 380),
-                "expansion_ratio": material_info.get("expansion_ratio", 2.5)
+                "expansion_ratio": material_info.get("expansion_ratio", 2.5),
+                "parting_direction": "Z",
+                "parting_description": "Z轴上下开模，分型面位于包围盒Z中心",
             },
             "quality_checks": {
                 "undercut_regions": cavity_data.get("undercut_regions", []),
@@ -436,7 +439,11 @@ class AluminumFoamMoldGenerator:
     
     def _detect_parting_surfaces(self, shape: Any, analysis: Dict) -> Dict[str, Any]:
         """
-        检测分型面（支持多分型面）
+        检测分型面（泡沫模具专用）
+
+        规则：
+        1. 优先选择 Z 轴方向分型（上下开模）
+        2. 分型面位置选在产品的最大轮廓处，即包围盒的 Z 方向中心
         """
         # 1. 尝试 AI 模型
         if self.ai_parting_detector is not None:
@@ -446,58 +453,37 @@ class AluminumFoamMoldGenerator:
                     return self._create_parting_surface_from_ai(ai_result, analysis)
             except Exception as e:
                 logger.warning(f"AI 分型面检测失败: {e}")
-        
-        # 2. 法向量分析确定主方向
-        normal_stats = analysis.get("normal_statistics", {})
-        primary_direction = normal_stats.get("primary_direction", [0, 0, 1])
-        
-        # 3. 创建主分型面
+
+        # 2. 泡沫模具强制 Z 轴方向分型（上下开模）
         bbox = analysis["bounding_box"]
         center = bbox["center"]
-        
-        # 沿主方向创建分型面
-        dir_obj = gp_Dir(primary_direction[0], primary_direction[1], primary_direction[2])
-        parting_plane = gp_Pln(gp_Pnt(center[0], center[1], center[2]), dir_obj)
-        
+        primary_direction = [0, 0, 1]  # Z 轴方向
+
+        # 分型面位于包围盒 Z 方向中心（最大轮廓处）
+        parting_z = center[2]
+        parting_plane = gp_Pln(gp_Pnt(center[0], center[1], parting_z), gp_Dir(0, 0, 1))
+
         try:
             parting_surface = BRepBuilderAPI_MakeFace(parting_plane).Face()
         except Exception:
             # 回退到默认平面
-            parting_plane = gp_Pln(gp_Pnt(0, 0, center[2]), gp_Dir(0, 0, 1))
+            parting_plane = gp_Pln(gp_Pnt(0, 0, parting_z), gp_Dir(0, 0, 1))
             parting_surface = BRepBuilderAPI_MakeFace(parting_plane).Face()
-        
-        # 4. 计算分型线
+
+        logger.info(f"泡沫模具 Z 轴分型面: Z={parting_z:.2f} mm (包围盒中心)")
+
+        # 3. 计算分型线
         parting_line = self._calculate_parting_line(shape, parting_surface)
-        
-        # 5. 检测是否需要多分型面（基于产品复杂度）
-        additional_surfaces = []
-        
-        # 检查产品高度方向的比例
-        dims = bbox["dimensions"]
-        max_dim = max(dims)
-        min_dim = min(dims)
-        
-        # 如果产品非常扁平，可能需要水平分型面
-        if max_dim / min_dim > 5:
-            # 尝试添加垂直分型面
-            vertical_plane = gp_Pln(gp_Pnt(center[0], center[1], center[2]), gp_Dir(1, 0, 0))
-            try:
-                vertical_surface = BRepBuilderAPI_MakeFace(vertical_plane).Face()
-                additional_surfaces.append({
-                    "surface": vertical_surface,
-                    "direction": [1, 0, 0],
-                    "reason": "产品扁平，需要垂直分型"
-                })
-            except Exception:
-                pass
-        
+
         return {
             "primary_surface": parting_surface,
             "primary_line": parting_line,
             "primary_direction": primary_direction,
-            "confidence": normal_stats.get("confidence", 0.5),
-            "additional_surfaces": additional_surfaces,
-            "surface_count": 1 + len(additional_surfaces)
+            "confidence": 0.95,  # Z 轴分型置信度高
+            "additional_surfaces": [],
+            "surface_count": 1,
+            "parting_direction": "Z",
+            "parting_position_z": parting_z,
         }
     
     def _detect_undercut_regions(self, shape: Any, parting_surface: Any) -> List[Dict]:
@@ -904,17 +890,23 @@ class AluminumFoamMoldGenerator:
         }
     
     def _calculate_clamping_force(self, analysis: Dict) -> str:
-        """估算锁模力"""
-        volume_cm3 = analysis.get("volume", 0) / 1000
-        
-        if volume_cm3 < 10:
-            return "30-50 吨"
-        elif volume_cm3 < 50:
-            return "50-100 吨"
-        elif volume_cm3 < 200:
-            return "100-200 吨"
-        else:
-            return "200+ 吨"
+        """
+        估算锁模力（泡沫模具专用）
+
+        公式: 锁模力(吨) = 投影面积(cm²) × 0.3 (泡沫材料系数)
+        投影面积 = 长度 × 宽度 (Z轴开模)
+        """
+        bbox = analysis.get("bounding_box", {})
+        dims = bbox.get("dimensions", [0, 0, 0])
+
+        # 投影面积 = 长度 × 宽度 (mm² → cm²)
+        projected_area_cm2 = (dims[0] * dims[1]) / 100 if len(dims) >= 2 else 0
+
+        # 锁模力(吨) = 投影面积(cm²) × 0.3
+        clamping_force_ton = int(projected_area_cm2 * 0.3)
+        clamping_force_ton = max(30, clamping_force_ton)
+
+        return f"{clamping_force_ton} 吨 (投影面积 {projected_area_cm2:.1f} cm² × 0.3)"
     
     def _calculate_product_weight(self, analysis: Dict) -> str:
         """计算产品重量"""