x

src/core/base_mold_generator.py

@@ -6,8 +6,8 @@ from OCC.Core.BRepAlgoAPI import BRepAlgoAPI_Cut, BRepAlgoAPI_Section, BRepAlgoA
 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
-from OCC.Core.TopoDS import TopoDS_Face, topods
-from OCC.Core.BRep import BRep_Tool
+from OCC.Core.TopoDS import TopoDS_Face, TopoDS_Compound, topods
+from OCC.Core.BRep import BRep_Tool, BRep_Builder
 from OCC.Core.BRepMesh import BRepMesh_IncrementalMesh
 from OCC.Core.GProp import GProp_GProps
 from OCC.Core.BRepGProp import brepgprop
@@ -297,27 +297,25 @@ class BaseMoldGenerator:
         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。
+        构建带底座的型芯。
 
-        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。
+        核心逻辑：底座平板沿分型方向覆盖模具半空间，
+        与产品形状做布尔融合，形成"底座+产品突出体"。
+        融合失败时用 TopoDS_Compound 兜底，确保底座永不会丢失。
         """
         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)
+        prod_span = max((xmax - xmin), (ymax - ymin), (zmax - zmin))
+        overlap = max(prod_span * 0.15, 8.0)
 
         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],
-        )):
+        for i in range(3):
+            n = [nx, ny, nz][i]
+            o = [float(origin.X()), float(origin.Y()), float(origin.Z())][i]
             if abs(n) < 0.001:
                 continue
             if n > 0:
@@ -325,12 +323,13 @@ class BaseMoldGenerator:
             else:
                 base_p1[i] = o - overlap
 
+        base_plate = None
         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")
+            logger.info(f"型芯底座构建: 重叠量={overlap:.1f}mm")
         except Exception as e:
             logger.warning(f"底座构建失败: {e}")
             return shape
@@ -339,21 +338,33 @@ class BaseMoldGenerator:
             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
+                explorer = TopExp_Explorer(core, TopAbs_FACE)
+                face_count = 0
+                while explorer.More():
+                    face_count += 1
+                    explorer.Next()
+                if face_count > 0:
+                    logger.info(f"型芯融合成功 (面数={face_count})")
+                    return core
+                logger.warning("Fuse 结果无几何，尝试备用方案")
         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
+        return self._build_core_compound(base_plate, shape)
 
-        logger.info("型芯回退为产品形状")
-        return shape
+    @staticmethod
+    def _build_core_compound(base_plate: Any, shape: Any) -> Any:
+        """
+        兜底方案：构建 TopoDS_Compound 包含底座平板 + 产品。
+        即使布尔融合失败，底座也绝不会丢失。
+        """
+        compound = TopoDS_Compound()
+        builder = BRep_Builder()
+        builder.MakeCompound(compound)
+        builder.Add(compound, base_plate)
+        builder.Add(compound, shape)
+        logger.info("型芯 Compound 兜底构建 (底座+产品)")
+        return compound
 
     def _get_parting_plane(self, parting_surface: Any, shape: Any) -> Optional[gp_Pln]:
         """从分型面提取平面方程"""