init

src/core/mold_generator.py

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+# src/core/mold_generator.py
+from pathlib import Path
+from typing import Dict, List, Any, Tuple, Optional
+import numpy as np
+from OCC.Core.BRepOffsetAPI import BRepOffsetAPI_MakeThickSolid
+from OCC.Core.BRepAlgoAPI import BRepAlgoAPI_Cut, BRepAlgoAPI_Fuse
+from OCC.Core.BRepBuilderAPI import BRepBuilderAPI_MakeFace, BRepBuilderAPI_Transform
+from OCC.Core.Geom import Geom_Plane
+from OCC.Core.gp import gp_Pln, gp_Dir, gp_Pnt, gp_Vec, gp_Trsf
+from OCC.Core.TopTools import TopTools_ListOfShape
+from OCC.Core.TopoDS import TopoDS_Face, TopoDS_Shape
+from OCC.Core.BRep import BRep_Tool
+from OCC.Core.BRepMesh import BRepMesh_IncrementalMesh
+from OCC.Core.BRepExtrema import BRepExtrema_DistShapeShape
+from OCC.Core.GProp import GProp_GProps
+from OCC.Core.BRepGProp import brepgprop
+
+from models.schemas import create_mold_cavity_data, create_mold_key_info
+from utils.logger import get_logger
+
+logger = get_logger(__name__)
+
+
+class MoldCavityGenerator:
+    """模具型腔生成器 - 基于产品模型生成Cavity和Core"""
+
+    def __init__(self, shrinkage_rate: float = 0.005, draft_angle: float = 2.0):
+        """
+        初始化模具生成器
+
+        Args:
+            shrinkage_rate: 收缩率（默认0.5% for ABS）
+            draft_angle: 拔模角（默认2度）
+        """
+        self.shrinkage_rate = shrinkage_rate
+        self.draft_angle = draft_angle  # 度
+
+        # 分型面检测参数
+        self.parting_line_tolerance = 0.1
+        self.max_draft_angle = 5.0
+
+    def generate_mold_cavities(self, product_shape: Any) -> Dict[str, Any]:
+        """
+        从产品的3D模型生成型腔和型芯
+
+        Returns:
+            {
+                "cavity": cavity_shape,      # 型腔（产品外部）
+                "core": core_shape,          # 型芯（产品内部）
+                "parting_surface": parting_surface,  # 分型面
+                "parting_line": parting_line         # 分型线
+            }
+        """
+        logger.info("开始生成模具型腔...")
+
+        try:
+            # Step 1: 分析产品几何
+            analysis = self._analyze_product_geometry(product_shape)
+
+            # Step 2: 检测分型面和分型线
+            parting_surface, parting_line = self._detect_parting_surface(
+                product_shape, analysis
+            )
+
+            # Step 3: 应用收缩率补偿
+            scaled_shape = self._apply_shrinkage_compensation(product_shape)
+
+            # Step 4: 添加拔模角
+            drafted_shape = self._apply_draft_angles(scaled_shape, parting_surface)
+
+            # Step 5: 分离型腔和型芯
+            cavity, core = self._split_cavity_core(drafted_shape, parting_surface)
+
+            logger.info("模具型腔生成完成")
+
+            return {
+                "cavity": cavity,
+                "core": core,
+                "parting_surface": parting_surface,
+                "parting_line": parting_line,
+                "analysis": analysis
+            }
+
+        except Exception as e:
+            logger.error(f"模具型腔生成失败: {e}")
+            raise
+
+    def generate_detailed_cavity_json(self, cavity_data: Dict) -> Dict[str, Any]:
+        """
+        生成详细的型腔三维JSON数据
+
+        Returns:
+            包含完整几何信息的JSON结构
+        """
+        cavity = cavity_data["cavity"]
+        core = cavity_data["core"]
+        parting_surface = cavity_data["parting_surface"]
+        analysis = cavity_data["analysis"]
+
+        # 提取型腔几何数据
+        cavity_geometry = self._extract_shape_geometry(cavity, "cavity")
+        core_geometry = self._extract_shape_geometry(core, "core")
+
+        # 提取分型面数据
+        parting_geometry = self._extract_parting_surface_geometry(
+            parting_surface
+        )
+
+        detailed_json = {
+            "metadata": {
+                "version": "2.0",
+                "generated_at": str(np.datetime64('now')),
+                "shrinkage_rate": self.shrinkage_rate,
+                "draft_angle": self.draft_angle,
+                "unit": "mm"
+            },
+            "product_analysis": {
+                "bounding_box": analysis.get("bounding_box", {}),  # 使用get方法
+                "volume": analysis.get("volume", 0),               # 使用get方法
+                "surface_area": analysis.get("surface_area", 0),   # 使用get方法
+                "center_of_mass": analysis.get("center_of_mass", [0, 0, 0])  # 使用get方法
+            },
+            "mold_cavities": {
+                "cavity": cavity_geometry,
+                "core": core_geometry
+            },
+            "parting_surface": parting_geometry,
+            "manufacturing_info": {
+                "estimated_mold_size": self._calculate_mold_size(analysis),
+                "estimated_clamping_force": self._calculate_clamping_force(analysis),
+                "recommended_material": self._get_recommended_material()
+            }
+        }
+
+        return detailed_json
+
+    def generate_cavity_key_info(self, cavity_data: Dict) -> Dict[str, Any]:
+        """
+        生成模具型腔的关键信息
+
+        Returns:
+            关键参数摘要
+        """
+        analysis = cavity_data["analysis"]
+
+        key_info = {
+            "mold_parameters": {
+                "shrinkage_rate": f"{self.shrinkage_rate * 100:.2f}%",
+                "draft_angle": f"{self.draft_angle}°",
+                "parting_line_length": self._calculate_parting_line_length(
+                    cavity_data["parting_line"]
+                ),
+                "cavity_depth": analysis.get("bounding_box", {}).get("dimensions", [0, 0, 0])[2]
+            },
+            "geometric_characteristics": {
+                "product_volume": f"{analysis.get('volume', 0) / 1000:.2f} cm³",
+                "product_weight": self._calculate_product_weight(analysis),
+                "wall_thickness_range": self._estimate_wall_thickness(analysis),
+                "complexity_score": self._calculate_complexity_score(analysis)
+            },
+            "manufacturing_requirements": {
+                "cavity_material": "Aluminum Alloy 7075",
+                "hardness": "HRC 30-35",
+                "surface_finish": "SPI A2",
+                "estimated_cycle_time": self._estimate_cycle_time(analysis),
+                "recommended_injection_pressure": "80-120 MPa"
+            },
+            "quality_considerations": {
+                "potential_weld_lines": self._identify_weld_line_risk(analysis),
+                "sink_mark_areas": self._identify_sink_mark_risk(analysis),
+                "warpage_risk": self._assess_warpage_risk(analysis)
+            }
+        }
+
+        return key_info
+
+    # ==================== 内部方法 ====================
+
+    def _analyze_product_geometry(self, shape: Any) -> Dict[str, Any]:
+        """分析产品几何属性"""
+        # 计算体积属性
+        volume_props = GProp_GProps()
+        brepgprop.VolumeProperties(shape, volume_props)
+
+        # 计算表面积属性
+        surface_props = GProp_GProps()
+        brepgprop.SurfaceProperties(shape, surface_props)
+
+        # 计算边界框
+        from OCC.Core.Bnd import Bnd_Box
+        from OCC.Core.BRepBndLib import brepbndlib
+
+        bbox = Bnd_Box()
+        brepbndlib.Add(shape, bbox)
+        xmin, ymin, zmin, xmax, ymax, zmax = bbox.Get()
+
+        return {
+            "volume": volume_props.Mass(),
+            "surface_area": surface_props.Mass(),
+            "center_of_mass": [
+                volume_props.CentreOfMass().X(),
+                volume_props.CentreOfMass().Y(),
+                volume_props.CentreOfMass().Z()
+            ],
+            "bounding_box": {
+                "min": [xmin, ymin, zmin],
+                "max": [xmax, ymax, zmax],
+                "dimensions": [xmax - xmin, ymax - ymin, zmax - zmin],
+                "center": [(xmin + xmax) / 2, (ymin + ymax) / 2, (zmin + zmax) / 2]
+            },
+            "inertia_matrix": self._get_inertia_matrix(volume_props)
+        }
+
+    def _detect_parting_surface(self, shape: Any, analysis: Dict) -> Tuple[Any, List]:
+        """检测分型面和分型线"""
+        # 简化的分型面检测：基于Z方向的最高点和最低点
+        bbox = analysis["bounding_box"]
+        center_z = bbox["center"][2]
+
+        # 创建分型面（XY平面）
+        parting_plane = gp_Pln(
+            gp_Pnt(0, 0, center_z),
+            gp_Dir(0, 0, 1)
+        )
+        parting_surface = BRepBuilderAPI_MakeFace(
+            parting_plane,
+            bbox["min"][0] - 10, bbox["max"][0] + 10,
+            bbox["min"][1] - 10, bbox["max"][1] + 10
+        ).Face()
+
+        # 分型线（简化）
+        parting_line = [
+            [bbox["min"][0], bbox["min"][1], center_z],
+            [bbox["max"][0], bbox["min"][1], center_z],
+            [bbox["max"][0], bbox["max"][1], center_z],
+            [bbox["min"][0], bbox["max"][1], center_z],
+            [bbox["min"][0], bbox["min"][1], center_z]
+        ]
+
+        return parting_surface, parting_line
+
+    def _apply_shrinkage_compensation(self, shape: Any) -> Any:
+        """应用收缩率补偿（放大模型）"""
+        scale_factor = 1.0 + self.shrinkage_rate
+
+        # 创建缩放变换
+        trsf = gp_Trsf()
+        trsf.SetScale(gp_Pnt(0, 0, 0), scale_factor)
+
+        from OCC.Core.BRepBuilderAPI import BRepBuilderAPI_Transform
+        scaled_shape = BRepBuilderAPI_Transform(shape, trsf, True).Shape()
+
+        return scaled_shape
+
+    def _apply_draft_angles(self, shape: Any, parting_surface: Any) -> Any:
+        """添加拔模角（简化实现）"""
+        # 实际实现需要复杂的拔模面处理
+        # 这里返回原始形状（假设已在CAD中处理）
+        logger.warning("拔模角处理为简化实现，建议在设计阶段处理")
+        return shape
+
+    def _split_cavity_core(self, shape: Any, parting_surface: Any) -> Tuple[Any, Any]:
+        """分离型腔和型芯"""
+        try:
+            # 使用分型面切割产品
+            # 上半部分为型腔（Cavity）
+            # 下半部分为型芯（Core）
+
+            # 这里需要实现BRepAlgoAPI_Section或类似的切割操作
+            # 简化：返回相同的形状（实际需实现切割逻辑）
+
+            return shape, shape  # (cavity, core)
+
+        except Exception as e:
+            logger.error(f"型腔分离失败: {e}")
+            return shape, shape
+
+    def _extract_shape_geometry(self, shape: Any, shape_type: str) -> Dict[str, Any]:
+        """提取形状几何数据为JSON格式"""
+        try:
+            # 网格化
+            mesh = BRepMesh_IncrementalMesh(shape, 0.1)
+            mesh.Perform()
+
+            # 提取顶点和面
+            from OCC.Core.TopExp import TopExp_Explorer
+            from OCC.Core.TopAbs import TopAbs_FACE
+            from OCC.Core.BRep import BRep_Tool
+            from OCC.Core.Poly import Poly_Triangulation
+            from OCC.Core.TopLoc import TopLoc_Location
+
+            vertices = []
+            faces = []
+
+            explorer = TopExp_Explorer(shape, TopAbs_FACE)
+            vertex_index = 0
+
+            while explorer.More():
+                # 使用 explorer.Current() 直接获取面
+                face = explorer.Current()
+                location = TopLoc_Location()
+                triangulation = BRep_Tool.Triangulation(face, location)
+
+                if triangulation:
+                    # 提取顶点
+                    nb_nodes = triangulation.NbNodes()
+                    for i in range(1, nb_nodes + 1):
+                        node = triangulation.Node(i)
+                        # 应用位置变换
+                        transformed = node.Transformed(location.Transformation())
+                        vertices.extend([
+                            float(transformed.X()),
+                            float(transformed.Y()),
+                            float(transformed.Z())
+                        ])
+
+                    # 提取三角形面
+                    nb_triangles = triangulation.NbTriangles()
+                    for i in range(1, nb_triangles + 1):
+                        triangle = triangulation.Triangle(i)
+                        # 三角形顶点索引需要加上之前的顶点数量
+                        idx1 = triangle.Value(1) + vertex_index - 1
+                        idx2 = triangle.Value(2) + vertex_index - 1
+                        idx3 = triangle.Value(3) + vertex_index - 1
+                        faces.extend([int(idx1), int(idx2), int(idx3)])
+
+                    vertex_index += nb_nodes
+
+                explorer.Next()
+
+            vertex_count = len(vertices) // 3
+            face_count = len(faces) // 3
+
+            return {
+                "type": shape_type,
+                "vertices": vertices,
+                "faces": faces,
+                "vertex_count": vertex_count,
+                "face_count": face_count,
+                "triangulation": "BRepMesh三角化"
+            }
+
+        except Exception as e:
+            logger.error(f"{shape_type}几何提取失败: {e}")
+            return {
+                "type": shape_type,
+                "vertices": [],
+                "faces": [],
+                "vertex_count": 0,
+                "face_count": 0,
+                "triangulation": f"提取失败: {str(e)}"
+            }
+
+    def _extract_parting_surface_geometry(self, surface: Any) -> Dict[str, Any]:
+        """提取分型面几何数据"""
+        # 尝试从surface获取边界信息，失败则使用默认值
+        try:
+            from OCC.Core.BRepAdaptor import BRepAdaptor_Surface
+            adaptor = BRepAdaptor_Surface(surface)
+            u_min, u_max = adaptor.FirstUParameter(), adaptor.LastUParameter()
+            v_min, v_max = adaptor.FirstVParameter(), adaptor.LastVParameter()
+
+            bounds = {
+                "u_range": [float(u_min), float(u_max)],
+                "v_range": [float(v_min), float(v_max)]
+            }
+        except Exception as e:
+            logger.warning(f"分型面边界提取失败，使用默认值: {e}")
+            bounds = {
+                "u_range": [-200, 200],
+                "v_range": [-200, 200]
+            }
+
+        # 分型面是水平面，法向量为 [0, 0, 1]，原点在 Z 轴中心
+        return {
+            "type": "plane",
+            "normal": [0, 0, 1],
+            "origin": [0, 0, 0],
+            "bounds": bounds
+        }
+
+        return {
+            "type": "plane",
+            "normal": [0, 0, 1],
+            "origin": [0, 0, 0],
+            "bounds": bounds
+        }
+
+    def _calculate_mold_size(self, analysis: Dict) -> Dict[str, float]:
+        """估算模具尺寸"""
+        product_bbox = analysis["bounding_box"]["dimensions"]
+
+        # 模具通常比产品大20-50mm
+        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 - 铝模具专用"""
+        return "Aluminum Alloy 7075 (铝合金模具)"
+
+    def _calculate_product_weight(self, analysis: Dict) -> str:
+        """计算产品重量（泡沫材料，密度约0.1 g/cm³）"""
+        volume_cm3 = analysis.get("volume", 0) / 1000
+        weight_g = volume_cm3 * 0.1  # EPP泡沫密度约0.1 g/cm³
+        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