diff --git a/src/api/routes.py b/src/api/routes.py index d9fe501..dc4b07c 100644 --- a/src/api/routes.py +++ b/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） - clamping_force_ton = int(projected_area_cm2 * 600 / 1000) + # 计算最优型腔数量 + # 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） - mold_length = max(bbox_dims[0] if len(bbox_dims) > 0 else 120, 120) + 40 - mold_width = max(bbox_dims[1] if len(bbox_dims) > 1 else 100, 100) + 40 - mold_height = max(bbox_dims[2] if len(bbox_dims) > 2 else 60, 60) + 50 + # 计算模具尺寸（基于型腔布局） + # 单型腔：产品尺寸 + 边距 + # 多型腔：需要考虑型腔排列 + 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 - injection_time = max(5, volume_cm3 / 50) # 注塑时间 - cycle_time = cooling_time + injection_time + 8 # 开合模约8秒 + cooling_time = (wall_thickness_max ** 2) * 4 # 冷却时间与壁厚平方成正比 + injection_time = max(3, volume_cm3 / 100) # 注塑时间 + 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, - "draft_angle": 2.0 + "shrinkage_rate": shrinkage_rate, + "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_hardness": "HB 150-170", + "mold_material": "铝合金7075" if clamping_force_ton < 200 else "P20钢材", + "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", - "sink_mark_areas": "thick_sections", - "warpage_risk": "low" + "potential_weld_lines": "center" if cavity_count > 1 else "minimal", + "sink_mark_areas": "thick_sections" if wall_thickness_max > 4 else "minimal", + "warpage_risk": "medium" if wall_thickness_max > 5 else "low" } } }