589 lines
22 KiB
Python
589 lines
22 KiB
Python
# src/core/mold_generator.py
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from pathlib import Path
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from typing import Dict, List, Any, Tuple, Optional
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import numpy as np
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from OCC.Core.BRepOffsetAPI import BRepOffsetAPI_MakeThickSolid
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from OCC.Core.BRepAlgoAPI import BRepAlgoAPI_Cut, BRepAlgoAPI_Fuse
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from OCC.Core.BRepBuilderAPI import BRepBuilderAPI_MakeFace, BRepBuilderAPI_Transform
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from OCC.Core.BRepPrimAPI import BRepPrimAPI_MakeBox
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from OCC.Core.Geom import Geom_Plane
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from OCC.Core.gp import gp_Pln, gp_Dir, gp_Pnt, gp_Vec, gp_Trsf
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from OCC.Core.TopTools import TopTools_ListOfShape
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from OCC.Core.TopoDS import TopoDS_Face, TopoDS_Shape
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from OCC.Core.BRep import BRep_Tool
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from OCC.Core.BRepMesh import BRepMesh_IncrementalMesh
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from OCC.Core.BRepExtrema import BRepExtrema_DistShapeShape
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from OCC.Core.GProp import GProp_GProps
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from OCC.Core.BRepGProp import brepgprop
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from models.schemas import create_mold_cavity_data, create_mold_key_info
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from utils.logger import get_logger
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logger = get_logger(__name__)
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class MoldCavityGenerator:
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"""模具型腔生成器 - 基于产品模型生成Cavity和Core"""
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def __init__(self, shrinkage_rate: float = 0.005, draft_angle: float = 2.0,
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material_density: float = 1.05):
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"""
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初始化模具生成器
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Args:
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shrinkage_rate: 收缩率（默认0.5% for ABS）
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draft_angle: 拔模角（默认2度）
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material_density: 材料密度 g/cm³（默认1.05 for ABS）
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"""
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self.shrinkage_rate = shrinkage_rate
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self.draft_angle = draft_angle # 度
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self.material_density = material_density # g/cm³
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# 常用塑料材料密度（g/cm³）
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self.material_densities = {
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"ABS": 1.05,
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"PP": 0.90,
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"PC": 1.20,
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"PE": 0.95,
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"PS": 1.05,
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"PA": 1.14,
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"POM": 1.42,
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"PMMA": 1.18
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}
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# 分型面检测参数
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self.parting_line_tolerance = 0.1
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self.max_draft_angle = 5.0
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def set_material(self, material: str):
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"""设置产品材料"""
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if material in self.material_densities:
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self.material_density = self.material_densities[material]
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logger.info(f"材料设置为 {material}, 密度: {self.material_density} g/cm³")
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else:
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logger.warning(f"未知材料 {material}, 使用默认密度 {self.material_density} g/cm³")
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def generate_mold_cavities(self, product_shape: Any) -> Dict[str, Any]:
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"""
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从产品的3D模型生成型腔和型芯
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Returns:
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{
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"cavity": cavity_shape, # 型腔（产品外部）
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"core": core_shape, # 型芯（产品内部）
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"parting_surface": parting_surface, # 分型面
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"parting_line": parting_line # 分型线
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}
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"""
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logger.info("开始生成模具型腔...")
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try:
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# Step 1: 分析产品几何
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analysis = self._analyze_product_geometry(product_shape)
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# Step 2: 检测分型面和分型线
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parting_surface, parting_line = self._detect_parting_surface(
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product_shape, analysis
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)
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# Step 3: 应用收缩率补偿
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scaled_shape = self._apply_shrinkage_compensation(product_shape)
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# Step 4: 添加拔模角
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drafted_shape = self._apply_draft_angles(scaled_shape, parting_surface)
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# Step 5: 分离型腔和型芯
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cavity, core = self._split_cavity_core(drafted_shape, parting_surface)
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logger.info("模具型腔生成完成")
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return {
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"cavity": cavity,
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"core": core,
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"parting_surface": parting_surface,
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"parting_line": parting_line,
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"analysis": analysis
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}
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except Exception as e:
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logger.error(f"模具型腔生成失败: {e}")
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raise
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def generate_detailed_cavity_json(self, cavity_data: Dict) -> Dict[str, Any]:
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"""
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生成详细的型腔三维JSON数据
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Returns:
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包含完整几何信息的JSON结构
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"""
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cavity = cavity_data["cavity"]
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core = cavity_data["core"]
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parting_surface = cavity_data["parting_surface"]
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analysis = cavity_data["analysis"]
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# 提取型腔几何数据
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cavity_geometry = self._extract_shape_geometry(cavity, "cavity")
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core_geometry = self._extract_shape_geometry(core, "core")
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# 提取分型面数据
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parting_geometry = self._extract_parting_surface_geometry(
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parting_surface
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)
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detailed_json = {
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"metadata": {
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"version": "2.0",
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"generated_at": str(np.datetime64('now')),
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"shrinkage_rate": self.shrinkage_rate,
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"draft_angle": self.draft_angle,
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"unit": "mm"
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},
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"product_analysis": {
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"bounding_box": analysis.get("bounding_box", {}), # 使用get方法
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"volume": analysis.get("volume", 0), # 使用get方法
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"surface_area": analysis.get("surface_area", 0), # 使用get方法
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"center_of_mass": analysis.get("center_of_mass", [0, 0, 0]) # 使用get方法
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},
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"mold_cavities": {
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"cavity": cavity_geometry,
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"core": core_geometry
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},
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"parting_surface": parting_geometry,
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"manufacturing_info": {
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"estimated_mold_size": self._calculate_mold_size(analysis),
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"estimated_clamping_force": self._calculate_clamping_force(analysis),
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"recommended_material": self._get_recommended_material()
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}
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}
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return detailed_json
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def generate_cavity_key_info(self, cavity_data: Dict) -> Dict[str, Any]:
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"""
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生成模具型腔的关键信息
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Returns:
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关键参数摘要
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"""
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analysis = cavity_data["analysis"]
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key_info = {
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"mold_parameters": {
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"shrinkage_rate": f"{self.shrinkage_rate * 100:.2f}%",
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"draft_angle": f"{self.draft_angle}°",
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"parting_line_length": self._calculate_parting_line_length(
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cavity_data["parting_line"]
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),
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"cavity_depth": analysis.get("bounding_box", {}).get("dimensions", [0, 0, 0])[2]
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},
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"geometric_characteristics": {
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"product_volume": f"{analysis.get('volume', 0) / 1000:.2f} cm³",
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"product_weight": self._calculate_product_weight(analysis),
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"wall_thickness_range": self._estimate_wall_thickness(analysis),
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"complexity_score": self._calculate_complexity_score(analysis)
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},
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"manufacturing_requirements": {
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"cavity_material": "Aluminum Alloy 7075",
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"hardness": "HRC 30-35",
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"surface_finish": "SPI A2",
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"estimated_cycle_time": self._estimate_cycle_time(analysis),
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"recommended_injection_pressure": "80-120 MPa"
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},
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"quality_considerations": {
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"potential_weld_lines": self._identify_weld_line_risk(analysis),
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"sink_mark_areas": self._identify_sink_mark_risk(analysis),
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"warpage_risk": self._assess_warpage_risk(analysis)
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}
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}
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return key_info
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# ==================== 内部方法 ====================
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def _analyze_product_geometry(self, shape: Any) -> Dict[str, Any]:
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"""分析产品几何属性"""
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# 计算体积属性
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volume_props = GProp_GProps()
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brepgprop.VolumeProperties(shape, volume_props)
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# 计算表面积属性
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surface_props = GProp_GProps()
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brepgprop.SurfaceProperties(shape, surface_props)
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# 计算边界框
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from OCC.Core.Bnd import Bnd_Box
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from OCC.Core.BRepBndLib import brepbndlib
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bbox = Bnd_Box()
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brepbndlib.Add(shape, bbox)
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xmin, ymin, zmin, xmax, ymax, zmax = bbox.Get()
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return {
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"volume": volume_props.Mass(),
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"surface_area": surface_props.Mass(),
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"center_of_mass": [
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volume_props.CentreOfMass().X(),
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volume_props.CentreOfMass().Y(),
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volume_props.CentreOfMass().Z()
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],
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"bounding_box": {
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"min": [xmin, ymin, zmin],
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"max": [xmax, ymax, zmax],
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"dimensions": [xmax - xmin, ymax - ymin, zmax - zmin],
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"center": [(xmin + xmax) / 2, (ymin + ymax) / 2, (zmin + zmax) / 2]
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},
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"inertia_matrix": self._get_inertia_matrix(volume_props)
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}
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def _detect_parting_surface(self, shape: Any, analysis: Dict) -> Tuple[Any, List]:
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"""检测分型面和分型线"""
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# 简化的分型面检测：基于Z方向的最高点和最低点
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bbox = analysis["bounding_box"]
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center_z = bbox["center"][2]
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# 创建分型面（XY平面）
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parting_plane = gp_Pln(
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gp_Pnt(0, 0, center_z),
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gp_Dir(0, 0, 1)
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)
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parting_surface = BRepBuilderAPI_MakeFace(
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parting_plane,
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bbox["min"][0] - 10, bbox["max"][0] + 10,
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bbox["min"][1] - 10, bbox["max"][1] + 10
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).Face()
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# 分型线（简化）
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parting_line = [
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[bbox["min"][0], bbox["min"][1], center_z],
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[bbox["max"][0], bbox["min"][1], center_z],
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[bbox["max"][0], bbox["max"][1], center_z],
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[bbox["min"][0], bbox["max"][1], center_z],
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[bbox["min"][0], bbox["min"][1], center_z]
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]
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return parting_surface, parting_line
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def _apply_shrinkage_compensation(self, shape: Any) -> Any:
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"""应用收缩率补偿（放大模型）"""
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scale_factor = 1.0 + self.shrinkage_rate
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# 创建缩放变换
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trsf = gp_Trsf()
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trsf.SetScale(gp_Pnt(0, 0, 0), scale_factor)
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from OCC.Core.BRepBuilderAPI import BRepBuilderAPI_Transform
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scaled_shape = BRepBuilderAPI_Transform(shape, trsf, True).Shape()
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return scaled_shape
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def _apply_draft_angles(self, shape: Any, parting_surface: Any) -> Any:
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"""添加拔模角（简化实现）"""
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# 实际实现需要复杂的拔模面处理
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# 这里返回原始形状（假设已在CAD中处理）
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logger.warning("拔模角处理为简化实现，建议在设计阶段处理")
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return shape
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def _split_cavity_core(self, shape: Any, parting_surface: Any) -> Tuple[Any, Any]:
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"""分离型腔和型芯
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型腔(Cavity): 模具中形成产品外表面的部分，是产品形状的负形
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型芯(Core): 模具中形成产品内表面的部分，是产品形状的正形
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"""
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try:
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from OCC.Core.BRepPrimAPI import BRepPrimAPI_MakeBox
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from OCC.Core.BRepAlgoAPI import BRepAlgoAPI_Cut
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from OCC.Core.TopExp import TopExp_Explorer
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from OCC.Core.TopAbs import TopAbs_SOLID
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# 获取产品边界框
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from OCC.Core.Bnd import Bnd_Box
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from OCC.Core.BRepBndLib import brepbndlib
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bbox = Bnd_Box()
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brepbndlib.Add(shape, bbox)
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xmin, ymin, zmin, xmax, ymax, zmax = bbox.Get()
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# 计算模具块尺寸（比产品大一定余量）
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margin = 20 # mm
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mold_xmin = xmin - margin
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mold_ymin = ymin - margin
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mold_zmin = zmin - margin
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mold_xmax = xmax + margin
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mold_ymax = ymax + margin
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mold_zmax = zmax + margin
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# 创建模具块
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mold_block = BRepPrimAPI_MakeBox(
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gp_Pnt(mold_xmin, mold_ymin, mold_zmin),
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gp_Pnt(mold_xmax, mold_ymax, mold_zmax)
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).Shape()
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# 型腔 = 模具块 - 产品（布尔减法）
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cavity_operation = BRepAlgoAPI_Cut(mold_block, shape)
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if cavity_operation.IsDone():
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cavity = cavity_operation.Shape()
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logger.info("型腔生成成功（模具块减去产品）")
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else:
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logger.warning("型腔布尔运算失败，使用原始形状")
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cavity = mold_block
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# 型芯 = 产品形状本身（收缩补偿后）
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core = shape
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logger.info("型芯 = 产品形状")
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return cavity, core
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except Exception as e:
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logger.error(f"型腔分离失败: {e}")
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return shape, shape
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def _extract_shape_geometry(self, shape: Any, shape_type: str) -> Dict[str, Any]:
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"""提取形状几何数据为JSON格式"""
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try:
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# 网格化
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mesh = BRepMesh_IncrementalMesh(shape, 0.1)
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mesh.Perform()
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# 提取顶点和面
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from OCC.Core.TopExp import TopExp_Explorer
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from OCC.Core.TopAbs import TopAbs_FACE
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from OCC.Core.BRep import BRep_Tool
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from OCC.Core.Poly import Poly_Triangulation
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from OCC.Core.TopLoc import TopLoc_Location
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vertices = []
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faces = []
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explorer = TopExp_Explorer(shape, TopAbs_FACE)
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vertex_index = 0
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while explorer.More():
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# 使用 explorer.Current() 直接获取面
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face = explorer.Current()
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location = TopLoc_Location()
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triangulation = BRep_Tool.Triangulation(face, location)
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if triangulation:
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# 提取顶点
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nb_nodes = triangulation.NbNodes()
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for i in range(1, nb_nodes + 1):
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node = triangulation.Node(i)
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# 应用位置变换
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transformed = node.Transformed(location.Transformation())
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vertices.extend([
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float(transformed.X()),
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float(transformed.Y()),
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float(transformed.Z())
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])
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# 提取三角形面
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nb_triangles = triangulation.NbTriangles()
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for i in range(1, nb_triangles + 1):
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triangle = triangulation.Triangle(i)
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# 三角形顶点索引需要加上之前的顶点数量
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idx1 = triangle.Value(1) + vertex_index - 1
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idx2 = triangle.Value(2) + vertex_index - 1
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idx3 = triangle.Value(3) + vertex_index - 1
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faces.extend([int(idx1), int(idx2), int(idx3)])
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vertex_index += nb_nodes
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explorer.Next()
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vertex_count = len(vertices) // 3
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face_count = len(faces) // 3
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return {
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"type": shape_type,
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"vertices": vertices,
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"faces": faces,
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"vertex_count": vertex_count,
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"face_count": face_count,
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"triangulation": "BRepMesh三角化"
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}
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except Exception as e:
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logger.error(f"{shape_type}几何提取失败: {e}")
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return {
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"type": shape_type,
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"vertices": [],
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"faces": [],
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"vertex_count": 0,
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"face_count": 0,
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"triangulation": f"提取失败: {str(e)}"
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}
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def _extract_parting_surface_geometry(self, surface: Any) -> Dict[str, Any]:
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"""提取分型面几何数据"""
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# 尝试从surface获取边界信息，失败则使用默认值
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try:
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from OCC.Core.BRepAdaptor import BRepAdaptor_Surface
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adaptor = BRepAdaptor_Surface(surface)
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u_min, u_max = adaptor.FirstUParameter(), adaptor.LastUParameter()
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v_min, v_max = adaptor.FirstVParameter(), adaptor.LastVParameter()
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bounds = {
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"u_range": [float(u_min), float(u_max)],
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"v_range": [float(v_min), float(v_max)]
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}
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except Exception as e:
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logger.warning(f"分型面边界提取失败，使用默认值: {e}")
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bounds = {
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"u_range": [-200, 200],
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"v_range": [-200, 200]
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}
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# 分型面是水平面，法向量为 [0, 0, 1]，原点在 Z 轴中心
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return {
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"type": "plane",
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"normal": [0, 0, 1],
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"origin": [0, 0, 0],
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"bounds": bounds
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}
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return {
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"type": "plane",
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"normal": [0, 0, 1],
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"origin": [0, 0, 0],
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"bounds": bounds
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}
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def _calculate_mold_size(self, analysis: Dict) -> Dict[str, float]:
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"""估算模具尺寸"""
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product_bbox = analysis["bounding_box"]["dimensions"]
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# 模具通常比产品大20-50mm
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margin = 30 # mm
|
||
|
||
return {
|
||
"length": product_bbox[0] + 2 * margin,
|
||
"width": product_bbox[1] + 2 * margin,
|
||
"height": product_bbox[2] + 2 * margin + 100, # 增加100mm用于模架
|
||
"margin": margin
|
||
}
|
||
|
||
def _calculate_clamping_force(self, analysis: Dict) -> str:
|
||
"""估算锁模力"""
|
||
volume_cm3 = analysis.get("volume", 0) / 1000 # mm³ → cm³
|
||
|
||
# 经验公式: 锁模力 ≈ 投影面积 × 压力 × 安全系数
|
||
# 简化估算
|
||
if volume_cm3 < 10:
|
||
return "50-100 吨"
|
||
elif volume_cm3 < 100:
|
||
return "150-300 吨"
|
||
elif volume_cm3 < 500:
|
||
return "400-600 吨"
|
||
else:
|
||
return "800+ 吨"
|
||
|
||
def _get_recommended_material(self) -> str:
|
||
"""推荐模具材料"""
|
||
# 根据产品产量推荐模具材料
|
||
# 小批量 (<5000件): 铝合金
|
||
# 中批量 (5000-50000件): P20钢
|
||
# 大批量 (>50000件): H13钢
|
||
return "Aluminum Alloy 7075 (铝合金模具)"
|
||
|
||
def _calculate_product_weight(self, analysis: Dict) -> str:
|
||
"""计算产品重量（使用当前材料密度）"""
|
||
volume_cm3 = analysis.get("volume", 0) / 1000
|
||
weight_g = volume_cm3 * self.material_density
|
||
return f"{weight_g:.2f} g"
|
||
|
||
def _estimate_wall_thickness(self, analysis: Dict) -> str:
|
||
"""估算壁厚范围"""
|
||
volume = analysis.get("volume", 0)
|
||
surface_area = analysis.get("surface_area", 0)
|
||
|
||
if surface_area > 0 and volume > 0:
|
||
avg_thickness = (volume / surface_area) * 0.6
|
||
return f"{avg_thickness * 0.7:.2f} - {avg_thickness * 1.3:.2f} mm"
|
||
elif volume > 0:
|
||
# 如果没有surface_area，基于体积估算
|
||
bbox_dims = analysis.get("bounding_box", {}).get("dimensions", [1, 1, 1])
|
||
bbox_volume = bbox_dims[0] * bbox_dims[1] * bbox_dims[2]
|
||
if bbox_volume > 0:
|
||
efficiency = volume / bbox_volume
|
||
avg_thickness = (bbox_dims[0] + bbox_dims[1]) / 2 * efficiency
|
||
return f"{avg_thickness * 0.7:.2f} - {avg_thickness * 1.3:.2f} mm"
|
||
|
||
return "2.0 - 4.0 mm (默认)"
|
||
|
||
def _calculate_complexity_score(self, analysis: Dict) -> float:
|
||
"""计算复杂度评分（0-10）"""
|
||
# 基于体积、表面积比、边界框等
|
||
volume = analysis.get("volume", 0)
|
||
surface_area = analysis.get("surface_area", 0)
|
||
|
||
if surface_area > 0 and volume > 0:
|
||
thickness_ratio = (volume / surface_area) * 0.6
|
||
complexity = min(thickness_ratio / 5.0, 10.0)
|
||
return round(complexity, 1)
|
||
elif volume > 0:
|
||
# 如果没有surface_area，基于拓扑复杂度评分
|
||
bbox_dims = analysis.get("bounding_box", {}).get("dimensions", [100, 100, 100])
|
||
bbox_volume = bbox_dims[0] * bbox_dims[1] * bbox_dims[2]
|
||
if bbox_volume > 0:
|
||
volume_ratio = volume / bbox_volume
|
||
complexity = (1.0 - volume_ratio) * 10
|
||
return round(min(max(complexity, 0), 10), 1)
|
||
|
||
return 5.0
|
||
|
||
def _estimate_cycle_time(self, analysis: Dict) -> str:
|
||
"""估算成型周期"""
|
||
volume_cm3 = analysis.get("volume", 0) / 1000
|
||
|
||
if volume_cm3 < 10:
|
||
return "15-25 秒"
|
||
elif volume_cm3 < 50:
|
||
return "25-40 秒"
|
||
elif volume_cm3 < 200:
|
||
return "40-60 秒"
|
||
else:
|
||
return "60-90 秒"
|
||
|
||
def _identify_weld_line_risk(self, analysis: Dict) -> str:
|
||
"""识别熔接痕风险"""
|
||
# 基于几何复杂度判断
|
||
complexity = self._calculate_complexity_score(analysis)
|
||
|
||
if complexity > 7:
|
||
return "高 - 建议优化浇口位置"
|
||
elif complexity > 4:
|
||
return "中 - 需仿真验证"
|
||
else:
|
||
return "低"
|
||
|
||
def _identify_sink_mark_risk(self, analysis: Dict) -> str:
|
||
"""识别缩痕风险"""
|
||
thickness = self._estimate_wall_thickness(analysis)
|
||
# 简化的风险评估
|
||
return "中 - 建议壁厚均匀性检查"
|
||
|
||
def _assess_warpage_risk(self, analysis: Dict) -> str:
|
||
"""评估翘曲风险"""
|
||
bbox = analysis.get("bounding_box", {}).get("dimensions", [1, 1, 1])
|
||
aspect_ratio = max(bbox) / min(bbox)
|
||
|
||
if aspect_ratio > 5:
|
||
return "高 - 建议增加加强筋"
|
||
elif aspect_ratio > 3:
|
||
return "中 - 需优化冷却"
|
||
else:
|
||
return "低"
|
||
|
||
def _get_inertia_matrix(self, props: GProp_GProps) -> List[List[float]]:
|
||
"""获取惯性矩阵"""
|
||
inertia = props.MatrixOfInertia()
|
||
return [
|
||
[inertia.Value(1, 1), inertia.Value(1, 2), inertia.Value(1, 3)],
|
||
[inertia.Value(2, 1), inertia.Value(2, 2), inertia.Value(2, 3)],
|
||
[inertia.Value(3, 1), inertia.Value(3, 2), inertia.Value(3, 3)]
|
||
]
|
||
|
||
def _calculate_parting_line_length(self, parting_line: List) -> float:
|
||
"""计算分型线长度"""
|
||
# 简化的长度计算
|
||
return 250.0 # mm
|