276 lines
11 KiB
C++
276 lines
11 KiB
C++
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#pragma once
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/**
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* @file cam_5axis.h
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* @brief 5 轴联动 CAM 加工策略
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*
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* 在 3 轴 cam_strategies.h 的基础上扩展为 5 轴联动：
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* - 刀位点 + 刀轴矢量 (CLData)
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* - 侧刃加工 (swarf_machining)
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* - 多轴粗加工 3+2 定位 (multi_axis_roughing)
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* - 多轴精加工 + 碰撞检测 (multi_axis_finishing)
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* - 机床运动学逆解 (inverse_kinematics)
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* - 刀轴策略枚举 (ToolAxisStrategy)
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*
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* @ingroup core
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*/
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#include "vde/core/point.h"
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#include "vde/core/aabb.h"
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#include "vde/core/cam_toolpath.h"
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#include "vde/core/cam_strategies.h"
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#include "vde/mesh/halfedge_mesh.h"
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#include <vector>
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#include <string>
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#include <optional>
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#include <functional>
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namespace vde::brep {
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class BrepModel;
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} // namespace vde::brep
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namespace vde::curves {
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class NurbsSurface;
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} // namespace vde::curves
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namespace vde::core {
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using core::Point3D;
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using core::Vector3D;
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using core::AABB3D;
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// ═══════════════════════════════════════════════════════════════════════════
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// 5 轴刀位数据
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// ═══════════════════════════════════════════════════════════════════════════
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/// 单个刀位点 + 刀轴矢量 (Cutter Location Data)
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struct CLData {
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Point3D position; ///< 刀尖点/TCP 位置
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Vector3D tool_axis; ///< 刀轴单位矢量（从刀尖指向刀柄）
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double feed_rate = 500.0; ///< 进给速度 (mm/min)
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/// 便捷构造
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CLData() : position(Point3D::Zero()), tool_axis(Vector3D::UnitZ()) {}
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CLData(const Point3D& pos, const Vector3D& axis_, double feed = 500.0)
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: position(pos), tool_axis(axis_.normalized()), feed_rate(feed) {}
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};
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/// 5 轴刀路 — CLData 集合
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struct AxisToolpath5 {
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std::string name;
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std::vector<CLData> points; ///< 刀位点序列
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double safe_height = 50.0; ///< 安全高度 (mm)
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/// 刀位点数量
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[[nodiscard]] size_t size() const { return points.size(); }
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/// 是否为空
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[[nodiscard]] bool empty() const { return points.empty(); }
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};
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// ═══════════════════════════════════════════════════════════════════════════
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// 刀轴策略
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// ═══════════════════════════════════════════════════════════════════════════
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/// 刀轴控制策略
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enum class ToolAxisStrategy {
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FixedAngle, ///< 固定角度：刀轴保持与 Z 轴固定偏角
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LeadLag, ///< 导前/滞后角：沿切削方向前倾或后倾
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Tilted, ///< 侧倾：垂直于切削方向倾斜
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NormalToSurface ///< 法向：刀轴始终沿曲面法向
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};
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// ═══════════════════════════════════════════════════════════════════════════
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// 机床配置
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// ═══════════════════════════════════════════════════════════════════════════
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/// 机床结构类型
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enum class MachineType {
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HeadHead, ///< 双摆头：A/B 轴均在主轴侧
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TableTable, ///< 双转台：A/C 轴均在工作台侧
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HeadTable ///< 摆头+转台：主轴侧一轴 + 工作台侧一轴
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};
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/// 旋转轴配置
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enum class MachineAxisConfig {
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AC, ///< A 轴（绕 X 旋转）+ C 轴（绕 Z 旋转）
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BC, ///< B 轴（绕 Y 旋转）+ C 轴（绕 Z 旋转）
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AB ///< A 轴（绕 X 旋转）+ B 轴（绕 Y 旋转）
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};
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/// 机床运动学配置
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struct MachineConfig {
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MachineType machine_type = MachineType::TableTable;
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MachineAxisConfig axis_config = MachineAxisConfig::AC;
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/// 旋转轴行程限制（度）
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double a_min = -120.0;
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double a_max = 120.0;
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double b_min = -120.0;
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double b_max = 120.0;
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double c_min = -9999.0; // C 轴通常无限制（360°连续）
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double c_max = 9999.0;
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/// 主轴端到旋转中心的偏移 (mm)
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Vector3D pivot_offset = Vector3D::Zero();
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/// 刀具长度 (mm)
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double tool_length = 100.0;
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/// 检查旋转角是否在行程范围内
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[[nodiscard]] bool in_range(double a, double b, double c) const;
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/// 解析刀轴矢量为旋转角（根据 axis_config）
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/// @return (a_deg, b_deg, c_deg)，失败返回 std::nullopt
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[[nodiscard]] std::optional<std::tuple<double, double, double>>
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axis_to_angles(const Vector3D& tool_axis) const;
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};
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// ═══════════════════════════════════════════════════════════════════════════
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// 5 轴加工参数
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// ═══════════════════════════════════════════════════════════════════════════
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/// 侧刃加工参数
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struct SwarfParams {
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double step_down = 1.0; ///< 每层切深 (mm)
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double step_over = 0.5; ///< 横向步距 (mm)
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double feed_rate = 600.0; ///< 进给速度 (mm/min)
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double safe_height = 50.0; ///< 安全高度 (mm)
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double tilt_angle = 0.0; ///< 刀轴相对于曲面法线的偏转角 (度)
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};
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/// 多轴粗加工参数
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struct MultiAxisRoughingParams {
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double step_down = 2.0; ///< 每层切深 (mm)
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double step_over = 3.0; ///< 横向步距 (mm)
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double stock_to_leave = 1.0; ///< 留量 (mm)
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double feed_rate = 800.0; ///< 进给速度 (mm/min)
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double safe_height = 50.0; ///< 安全高度 (mm)
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/// 3+2 定位角度 — 固定刀轴方向（相对于 Z 轴的倾斜角, 度）
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double tilt_angle = 15.0;
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double lead_angle = 0.0; ///< 导前角 (度)
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};
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/// 多轴精加工参数
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struct MultiAxisFinishingParams {
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double step_over = 0.3; ///< 行距 (mm)
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double feed_rate = 500.0; ///< 进给速度 (mm/min)
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double safe_height = 50.0; ///< 安全高度 (mm)
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ToolAxisStrategy axis_strategy = ToolAxisStrategy::NormalToSurface;
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double max_tilt = 30.0; ///< 最大倾斜角 (度)
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double lead_angle = 3.0; ///< 导前角 (度)
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/// 碰撞检测参数
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bool collision_check = true; ///< 是否启用碰撞检测
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double shank_clearance = 2.0; ///< 刀柄安全间隙 (mm)
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double holder_clearance = 5.0; ///< 刀杆安全间隙 (mm)
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};
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// ═══════════════════════════════════════════════════════════════════════════
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// 5 轴加工策略函数
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// ═══════════════════════════════════════════════════════════════════════════
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/// 侧刃加工 (Swarf Machining)
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///
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/// 使用刀具侧刃贴合曲面进行切削，刀轴沿曲面法线偏转。
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/// 适用于直纹面侧壁加工。
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///
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/// @param surface 目标 NURBS 曲面
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/// @param tool 刀具参数
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/// @param params 侧刃加工参数
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/// @return 5 轴刀路
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///
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/// @ingroup core
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[[nodiscard]] AxisToolpath5 swarf_machining(
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const curves::NurbsSurface& surface,
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const Tool& tool,
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const SwarfParams& params);
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/// 多轴粗加工 (3+2 定位加工)
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///
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/// 使用 3+2 定位方式对实体进行分层粗加工。
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/// 自动优化刀轴方向以最大化材料去除率，同时避免干涉。
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///
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/// @param body B-Rep 实体
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/// @param tool 刀具参数
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/// @param params 多轴粗加工参数
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/// @param config 机床运动学配置（用于刀轴方向可行性检查）
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/// @return 5 轴刀路
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///
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/// @ingroup core
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[[nodiscard]] AxisToolpath5 multi_axis_roughing(
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const brep::BrepModel& body,
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const Tool& tool,
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const MultiAxisRoughingParams& params,
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const MachineConfig& config = MachineConfig{});
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/// 多轴精加工
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///
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/// 对曲面进行 5 轴联动精加工。刀轴平滑变化，
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/// 包含刀柄和刀杆的碰撞检测。
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///
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/// @param surface 目标 NURBS 曲面
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/// @param body 完整 B-Rep 模型（碰撞检测用）
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/// @param tool 刀具参数
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/// @param params 多轴精加工参数
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/// @param config 机床运动学配置
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/// @return 5 轴刀路
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///
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/// @ingroup core
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[[nodiscard]] AxisToolpath5 multi_axis_finishing(
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const curves::NurbsSurface& surface,
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const brep::BrepModel& body,
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const Tool& tool,
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const MultiAxisFinishingParams& params,
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const MachineConfig& config = MachineConfig{});
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/// 机床运动学逆解
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///
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/// 将工件坐标系下的刀路 (CLData) 转换为机床各轴坐标。
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/// 根据机床配置 (AC/BC/AB + 双转台/摆头) 计算 X/Y/Z/A/B/C。
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///
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/// @param toolpath 工件坐标系下的 5 轴刀路
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/// @param config 机床运动学配置
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/// @return 机床坐标刀路（points 中 position 存 X/Y/Z，tool_axis 存 A/B/C 度）
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///
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/// @ingroup core
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[[nodiscard]] AxisToolpath5 inverse_kinematics(
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const AxisToolpath5& toolpath,
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const MachineConfig& config);
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/// 刀轴碰撞检测
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///
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/// 检查刀柄和刀杆是否与工件发生碰撞。
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///
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/// @param position 刀尖位置
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/// @param tool_axis 刀轴方向
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/// @param body B-Rep 工件
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/// @param tool 刀具参数
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/// @param shank_clearance 刀柄安全间隙
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/// @param holder_clearance 刀杆安全间隙
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/// @return true 如果发生碰撞
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///
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/// @ingroup core
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[[nodiscard]] bool check_collision(
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const Point3D& position,
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const Vector3D& tool_axis,
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const brep::BrepModel& body,
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const Tool& tool,
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double shank_clearance = 2.0,
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double holder_clearance = 5.0);
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/// 刀轴方向优化
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///
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/// 给定候选刀轴方向列表，选择最优方向：
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/// - 优先选择更接近 Z 轴（减小旋转轴行程）
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/// - 避免超出机床行程的配置
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/// - 考虑切削条件（避免刀尖切削）
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///
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/// @param candidates 候选刀轴方向
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/// @param config 机床配置
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/// @return 最优刀轴方向（归一化），若无可行方向返回 Z 轴
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///
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/// @ingroup core
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[[nodiscard]] Vector3D optimize_tool_axis(
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const std::vector<Vector3D>& candidates,
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const MachineConfig& config);
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} // namespace vde::core
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