428 lines
18 KiB
Python
428 lines
18 KiB
Python
# services/calculation_service.py
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"""模具工程参数计算服务 — 从 process_file_core 中抽取的纯计算逻辑"""
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from typing import Dict, Any, List, Optional
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from datetime import datetime
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from pathlib import Path
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class CalculationService:
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"""将 process_file_core 中的工程计算逻辑抽取为独立服务，方便单测和复用"""
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# ─── 基础计算 ───
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@staticmethod
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def calculate_product_weight(volume_mm3: float, density: float) -> float:
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"""计算产品重量（克）"""
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volume_cm3 = volume_mm3 / 1000
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return volume_cm3 * density
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@staticmethod
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def calculate_projected_area(bbox_dims: List[float], parting_direction: str = "Z") -> float:
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"""
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计算投影面积（cm²）
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Args:
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bbox_dims: [长度, 宽度, 高度] (mm)
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parting_direction: 开模方向，"Z" 表示上下开模（投影到XY平面），
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"Y" 表示前后开模（投影到XZ平面），
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"X" 表示左右开模（投影到YZ平面）
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"""
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if len(bbox_dims) < 3:
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return 0.0
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if parting_direction == "Z":
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# Z轴开模 → 投影面积 = 长度 × 宽度
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return (bbox_dims[0] * bbox_dims[1]) / 100
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elif parting_direction == "Y":
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return (bbox_dims[0] * bbox_dims[2]) / 100
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elif parting_direction == "X":
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return (bbox_dims[1] * bbox_dims[2]) / 100
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# 默认 Z 轴
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return (bbox_dims[0] * bbox_dims[1]) / 100
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@staticmethod
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def calculate_cavity_count(product_weight_g: float, projected_area_cm2: float) -> int:
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"""
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计算最优型腔数量
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基于产品重量和投影面积：
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- 小产品（< 50g）可以多型腔
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- 大产品（> 1000g）通常单型腔
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"""
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if product_weight_g < 50:
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cavity_count = 8
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elif product_weight_g < 100:
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cavity_count = 4
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elif product_weight_g < 300:
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cavity_count = 2
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else:
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cavity_count = 1
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# 根据投影面积调整
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if projected_area_cm2 > 400:
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cavity_count = 1
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elif projected_area_cm2 > 200 and cavity_count > 2:
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cavity_count = 2
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return cavity_count
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@staticmethod
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def calculate_clamping_force(
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projected_area_cm2: float,
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cavity_count: int,
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runner_ratio: float = 0.20,
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injection_pressure: float = 700,
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is_foam: bool = False,
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) -> int:
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"""
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计算所需夹紧力（吨）
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塑料模具: 锁模力 = 投影面积 × 型腔数 × (1+流道比) × 注塑压力 / 1000
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泡沫模具: 锁模力 = 投影面积(cm²) × 0.3 (泡沫材料系数)
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Args:
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projected_area_cm2: 投影面积 cm²
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cavity_count: 型腔数
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runner_ratio: 流道系统占型腔投影面积比（0.15-0.25）
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injection_pressure: 注塑压力 kg/cm²
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is_foam: 是否泡沫材料
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"""
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if is_foam:
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# 泡沫模具: 锁模力(吨) = 投影面积(cm²) × 0.3
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clamping_force_ton = int(projected_area_cm2 * 0.3)
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else:
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total_projected_area = projected_area_cm2 * cavity_count * (1 + runner_ratio)
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clamping_force_ton = int(total_projected_area * injection_pressure / 1000)
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return max(50, min(clamping_force_ton, 3000))
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@staticmethod
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def calculate_wall_thickness(volume_mm3: float, surface_area_mm2: float) -> Dict[str, float]:
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"""计算壁厚范围"""
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if surface_area_mm2 > 0 and volume_mm3 > 0:
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avg = (volume_mm3 / surface_area_mm2) * 0.6
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return {
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"avg_thickness_mm": avg,
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"wall_thickness_min": avg * 0.7,
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"wall_thickness_max": avg * 1.3,
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}
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return {
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"avg_thickness_mm": 2.5,
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"wall_thickness_min": 2.0,
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"wall_thickness_max": 3.0,
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}
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@staticmethod
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def calculate_complexity(avg_thickness_mm: float) -> float:
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"""计算复杂度评分（0~1）"""
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return min((avg_thickness_mm / 5.0), 1.0) if avg_thickness_mm > 0 else 0.5
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@staticmethod
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def calculate_mold_size(
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bbox_dims: List[float], cavity_count: int,
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cavity_spacing: float = 30, edge_margin: float = 50,
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) -> Dict[str, float]:
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"""计算模具尺寸（长×宽×高），单位 mm"""
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dim_x = max(bbox_dims[0] if len(bbox_dims) > 0 else 120, 120)
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dim_y = max(bbox_dims[1] if len(bbox_dims) > 1 else 100, 100)
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dim_z = max(bbox_dims[2] if len(bbox_dims) > 2 else 60, 60)
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if cavity_count == 1:
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length = dim_x + 2 * edge_margin
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width = dim_y + 2 * edge_margin
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elif cavity_count == 2:
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length = 2 * dim_x + cavity_spacing + 2 * edge_margin
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width = dim_y + 2 * edge_margin
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elif cavity_count == 4:
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length = 2 * dim_x + cavity_spacing + 2 * edge_margin
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width = 2 * dim_y + cavity_spacing + 2 * edge_margin
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else: # 8 型腔: 2x4
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length = 4 * dim_x + 3 * cavity_spacing + 2 * edge_margin
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width = 2 * dim_y + cavity_spacing + 2 * edge_margin
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height = dim_z + 80 # 包含冷却系统
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return {"length": length, "width": width, "height": height}
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@staticmethod
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def calculate_parting_line_length(bbox_dims: List[float], cavity_count: int) -> float:
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"""计算分型线长度（mm）"""
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if len(bbox_dims) >= 2:
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return 2 * (bbox_dims[0] + bbox_dims[1]) * cavity_count
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return 0.0
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@staticmethod
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def calculate_cycle_time(
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wall_thickness_max: float, volume_cm3: float, cavity_count: int,
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) -> int:
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"""
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估算成型周期（秒）
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周期 = 冷却时间 + 注塑时间 + 顶出时间 + 开合模时间
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"""
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cooling_time = (wall_thickness_max ** 2) * 4
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injection_time = max(3, volume_cm3 / 100)
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ejection_time = 3
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cycle_time = cooling_time + injection_time + ejection_time + 5
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# 多型腔需要更长冷却时间
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if cavity_count > 1:
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cycle_time = cycle_time * (1 + 0.1 * (cavity_count - 1))
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return int(cycle_time)
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# ─── 组装方法 ───
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@classmethod
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def build_detailed_cavity_json(
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cls,
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geometry_data: Dict[str, Any],
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material: Dict[str, Any],
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file_path: str,
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cavity_mesh_data: Optional[Dict[str, Any]] = None,
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) -> Dict[str, Any]:
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"""
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组装完整的 detailed_cavity_json（整合以上所有计算结果）
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Args:
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geometry_data: STP 解析得到的几何数据
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material: MaterialService.get_material() 返回的材料属性字典
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file_path: STP 文件路径
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cavity_mesh_data: 型腔网格数据（可选）
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"""
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volume_mm3 = geometry_data.get("volume", 0)
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surface_area_mm2 = geometry_data.get("surface_area", 0)
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bbox = geometry_data.get("bounding_box", {})
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bbox_dims = bbox.get("dimensions", [0, 0, 0])
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material_density = material["density"]
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shrinkage_rate = material["shrinkage"]
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is_foam = material.get("is_foam", False)
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# 泡沫模具优先 Z 轴开模（上下开模）
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parting_direction = "Z"
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# 各项计算
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volume_cm3 = volume_mm3 / 1000
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product_weight_g = cls.calculate_product_weight(volume_mm3, material_density)
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projected_area_cm2 = cls.calculate_projected_area(bbox_dims, parting_direction)
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cavity_count = cls.calculate_cavity_count(product_weight_g, projected_area_cm2)
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clamping_force_ton = cls.calculate_clamping_force(
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projected_area_cm2, cavity_count, is_foam=is_foam
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)
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wall = cls.calculate_wall_thickness(volume_mm3, surface_area_mm2)
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complexity_score = cls.calculate_complexity(wall["avg_thickness_mm"])
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mold_size = cls.calculate_mold_size(bbox_dims, cavity_count)
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parting_line_length = cls.calculate_parting_line_length(bbox_dims, cavity_count)
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cycle_time = cls.calculate_cycle_time(wall["wall_thickness_max"], volume_cm3, cavity_count)
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injection_pressure = 700 # kg/cm²
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detailed_cavity_json = {
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"metadata": {
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"file_name": Path(file_path).name,
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"analysis_date": datetime.now().isoformat(),
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"shrinkage_rate": shrinkage_rate,
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"draft_angle": 2.0,
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"selected_material": material["name"],
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"is_foam": is_foam,
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"parting_direction": parting_direction,
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},
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"product_analysis": {
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"volume": volume_mm3,
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"surface_area": surface_area_mm2,
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"bounding_box": bbox,
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},
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"manufacturing_info": {
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"recommended_material": material["name"],
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"material_density": f"{material_density} g/cm³",
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"estimated_clamping_force": f"{clamping_force_ton} 吨",
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"clamping_force_formula": (
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"投影面积(cm²) × 0.3" if is_foam
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else "投影面积 × 型腔数 × (1+流道比) × 注塑压力 / 1000"
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),
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"estimated_mold_size": {
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"length": int(mold_size["length"]),
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"width": int(mold_size["width"]),
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"height": int(mold_size["height"]),
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},
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"mold_material": "铝合金7075" if clamping_force_ton < 200 else "P20钢材",
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"mold_hardness": "HB 150-170" if clamping_force_ton < 200 else "HRC 28-32",
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"surface_finish": "Ra 0.8 μm",
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"parting_line_length": f"{parting_line_length:.2f} mm",
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"estimated_cycle_time": f"{cycle_time} 秒",
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"injection_pressure": f"{injection_pressure} kg/cm²",
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"parting_direction": parting_direction,
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},
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"mold_cavities": {
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"cavity_count": cavity_count,
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},
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}
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# 合并型腔网格数据
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if cavity_mesh_data and "mold_cavities" in cavity_mesh_data:
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mold_cavities = cavity_mesh_data["mold_cavities"]
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for key in ("cavity", "core", "parting_surface"):
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if key in mold_cavities:
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detailed_cavity_json["mold_cavities"][key] = mold_cavities[key]
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# 合并分模附加信息，保持普通模具与铝泡沫模具输出结构一致
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if cavity_mesh_data:
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if cavity_mesh_data.get("parting_surface"):
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detailed_cavity_json["parting_surface"] = cavity_mesh_data["parting_surface"]
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quality_checks = cavity_mesh_data.get("quality_checks", {})
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if quality_checks:
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detailed_cavity_json["quality_checks"] = quality_checks
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undercut_summary = quality_checks.get("undercut_summary")
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if undercut_summary:
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detailed_cavity_json["undercut_regions"] = [] # 详情在 scheme 级别
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side_action_summary = quality_checks.get("side_action_summary")
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if side_action_summary:
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detailed_cavity_json["side_actions"] = {"summary": side_action_summary}
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# 添加型腔关键信息
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detailed_cavity_json["mold_cavities"]["cavity_key_info"] = {
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"geometric_characteristics": {
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"product_weight": f"{product_weight_g:.2f} g",
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"wall_thickness_range": f"{wall['wall_thickness_min']:.2f} - {wall['wall_thickness_max']:.2f} mm",
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"complexity_score": round(complexity_score, 2),
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"product_volume": f"{volume_cm3:.2f} cm³",
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"projected_area": f"{projected_area_cm2:.2f} cm²",
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},
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"quality_considerations": {
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"undercut_count": len(detailed_cavity_json.get("undercut_regions", [])),
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"side_action_summary": detailed_cavity_json.get("side_actions", {}).get("summary", {}),
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"potential_weld_lines": "center" if cavity_count > 1 else "minimal",
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"sink_mark_areas": "thick_sections" if wall["wall_thickness_max"] > 4 else "minimal",
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"warpage_risk": "medium" if wall["wall_thickness_max"] > 5 else "low",
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},
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}
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return detailed_cavity_json
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@classmethod
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def build_plan_result(
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cls,
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geometry_data: Dict[str, Any],
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material: Dict[str, Any],
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file_path: str,
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plan_result: Optional[Dict[str, Any]] = None,
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) -> Dict[str, Any]:
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"""构建多方案分模结果，并保留单方案兼容字段。"""
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if not plan_result or not plan_result.get("candidate_schemes"):
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legacy = cls.build_detailed_cavity_json(
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geometry_data=geometry_data,
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material=material,
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file_path=file_path,
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cavity_mesh_data=None,
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)
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result = {
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"best_scheme_id": "scheme_1",
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"candidate_schemes": [
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{
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"scheme_id": "scheme_1",
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"rank": 1,
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"title": "推荐方案",
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"method": "legacy_fallback",
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"score": 60.0,
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"confidence_score": 45.0,
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"is_fallback": True,
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"fallback_reason": "多方案生成失败，已降级为兼容单方案输出",
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"score_breakdown": {},
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"summary": "当前模型未生成多方案，返回兼容单方案结果",
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"parting": {
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"axis": legacy.get("metadata", {}).get("parting_direction", "Z"),
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"direction": None,
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"surface": legacy.get("parting_surface", {}),
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"line": [],
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},
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"cavity_data": legacy,
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"key_info": legacy.get("mold_cavities", {}).get("cavity_key_info", {}),
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"undercut_regions": legacy.get("undercut_regions", []),
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"side_actions": legacy.get("side_actions", {}),
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}
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],
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"global_summary": {
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"scheme_count": 1,
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"recommended_reason": "兼容旧版单方案结果",
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},
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"cavity_data": legacy,
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"key_info": legacy.get("mold_cavities", {}).get("cavity_key_info", {}),
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}
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cls.attach_injection_system_summaries(result, material["name"])
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return result
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candidate_schemes = plan_result.get("candidate_schemes", [])
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best_scheme = cls.get_best_scheme(plan_result)
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result = {
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"best_scheme_id": plan_result.get("best_scheme_id"),
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"candidate_schemes": candidate_schemes,
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"global_summary": plan_result.get("global_summary", {}),
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"cavity_data": best_scheme.get("cavity_data", {}) if best_scheme else {},
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"key_info": best_scheme.get("key_info", {}) if best_scheme else {},
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}
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cls.attach_injection_system_summaries(result, material["name"])
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return result
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@classmethod
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def attach_injection_system_summaries(
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cls,
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plan_result: Dict[str, Any],
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material_name: str,
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) -> Dict[str, Any]:
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"""为每个候选方案补充注塑模冷却/浇注摘要。"""
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from moldinsight.core.mold_system_designer import MoldSystemDesigner
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designer = MoldSystemDesigner()
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for scheme in plan_result.get("candidate_schemes", []):
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cavity_data = scheme.get("cavity_data") or {}
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product_bbox = cavity_data.get("product_analysis", {}).get("bounding_box", {})
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mold_size = cavity_data.get("manufacturing_info", {}).get("estimated_mold_size", {})
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cavity_count = cavity_data.get("mold_cavities", {}).get("cavity_count", 1)
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if not product_bbox or not mold_size:
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continue
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system_result = designer.design_complete_system(
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mold_size=mold_size,
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product_bbox=product_bbox,
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material=material_name,
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cavity_count=cavity_count,
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)
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cavity_data["injection_system"] = system_result
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cavity_data.setdefault("manufacturing_info", {})
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cavity_data["manufacturing_info"]["cooling_summary"] = {
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"cooling_time": system_result.get("cooling", {}).get("cooling_time"),
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"channel_count": system_result.get("cooling", {}).get("thermal_check", {}).get("channel_count"),
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"flow_rate_lpm": system_result.get("cooling", {}).get("flow_rate", {}).get("flow_rate_lpm"),
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}
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cavity_data["manufacturing_info"]["gating_summary"] = {
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"gate_type": system_result.get("gating", {}).get("gate_type"),
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"runner_type": system_result.get("gating", {}).get("runner", {}).get("type"),
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"estimated_cycle_time": system_result.get("overall_assessment", {}).get("estimated_cycle_time"),
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}
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best_scheme = cls.get_best_scheme(plan_result)
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if best_scheme:
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plan_result["injection_system"] = best_scheme.get("cavity_data", {}).get("injection_system")
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return plan_result
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@staticmethod
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def get_best_scheme(plan_result: Optional[Dict[str, Any]]) -> Optional[Dict[str, Any]]:
|
||
if not plan_result:
|
||
return None
|
||
|
||
schemes = plan_result.get("candidate_schemes", [])
|
||
if not schemes:
|
||
return None
|
||
|
||
best_scheme_id = plan_result.get("best_scheme_id")
|
||
if best_scheme_id:
|
||
for scheme in schemes:
|
||
if scheme.get("scheme_id") == best_scheme_id:
|
||
return scheme
|
||
|
||
return schemes[0]
|