198 lines
8.5 KiB
C++
198 lines
8.5 KiB
C++
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#pragma once
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/**
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* @file cam_optimization.h
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* @brief CAM 综合优化 — 切屑减薄、车铣复合摆线、HSM高速加工、恒接触角铣削、刀具寿命管理
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*
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* cam_advanced.h 提供高级加工策略，本模块在其之上提供面向效率与刀具保护的优化：
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* - chip_thinning_optimization — 切屑减薄优化，调整进给以维持恒定切屑厚度
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* - trochoidal_turn_milling — 车铣复合摆线加工
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* - high_speed_machining — HSM 高速加工策略（浅层大切宽）
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* - constant_engagement_milling — 恒接触角铣削，保持刀具啮合角恒定
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* - tool_life_management — 刀具寿命管理，基于磨损模型预测剩余寿命
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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/core/cam_advanced.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 <utility>
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#include <chrono>
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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::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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// 优化参数类型
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// ═══════════════════════════════════════════════════════════════════════════
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/// 高速加工 (HSM) 参数
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struct HSMParams {
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double step_down = 0.5; ///< 每层切深 (mm) — HSM 通常浅层
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double step_over = 4.0; ///< 横向步距 (mm) — HSM 大切宽
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double feed_rate = 2000.0; ///< 进给速度 (mm/min)
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double spindle_rpm = 15000.0; ///< 主轴转速 (rpm)
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double safe_z = 15.0; ///< 安全高度 (mm)
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double stock_to_leave = 0.3; ///< 留量 (mm)
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double corner_radius = 2.0; ///< 拐角过渡半径 (mm)
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bool trochoidal_corners = true; ///< 拐角处是否使用摆线过渡
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};
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/// 恒接触角铣削参数
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struct ConstantEngagementParams {
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double target_engagement = 45.0; ///< 目标啮合角 (度)
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double step_down = 0.8; ///< 每层切深 (mm)
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double feed_rate = 600.0; ///< 进给速度 (mm/min)
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double safe_z = 15.0; ///< 安全高度 (mm)
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double min_step_over = 0.3; ///< 最小横向步距 (mm)
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double max_step_over = 4.0; ///< 最大横向步距 (mm)
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double engagement_tolerance = 5.0; ///< 啮合角容差 (度)
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};
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/// 刀具寿命管理参数
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struct ToolLifeParams {
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double max_cutting_time_min = 60.0; ///< 最大切削时间 (分钟)
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double max_cutting_length_m = 500.0; ///< 最大切削距离 (米)
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double wear_coefficient = 1.0e-6; ///< 磨损系数 (mm³/N·m)
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double critical_flank_wear = 0.3; ///< 临界后刀面磨损 (mm)
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double spindle_speed_factor = 1.2; ///< 主轴转速修正系数
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bool enable_adaptive_feed = true; ///< 是否启用自适应进给降级
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};
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/// 刀具寿命预估结果
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struct ToolLifeResult {
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double estimated_life_min = 0.0; ///< 预估剩余寿命 (分钟)
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double accumulated_wear_mm = 0.0; ///< 累计磨损量 (mm)
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double material_removed_mm3 = 0.0; ///< 已切除材料体积 (mm³)
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double current_flank_wear = 0.0; ///< 当前后刀面磨损 (mm)
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bool needs_replacement = false;///< 是否需要更换刀具
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double recommended_feed_scale = 1.0; ///< 推荐的进给缩放系数
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std::string warning_message; ///< 警告消息
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};
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/// 车铣复合摆线参数
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struct TurnMillParams {
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double stock_diameter = 0.0; ///< 毛坯直径 (mm)，0 表示从模型推测
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double step_down = 1.0; ///< 每层切深 (mm)
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double trochoid_radius = 2.5; ///< 摆线圈半径 (mm)
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double step_forward = 1.0; ///< 每圈前进量 (mm)
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double feed_rate = 500.0; ///< 进给速度 (mm/min)
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double spindle_rpm = 8000.0; ///< 铣主轴转速 (rpm)
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double turning_rpm = 500.0; ///< 车主轴转速 (rpm)
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double safe_z = 20.0; ///< 安全高度 (mm)
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bool sync_axes = true; ///< C/Y 轴同步
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};
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// ═══════════════════════════════════════════════════════════════════════════
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// CAM 优化函数
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// ═══════════════════════════════════════════════════════════════════════════
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/// 切屑减薄优化 (Chip Thinning Optimization)
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///
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/// 当径向切削深度小于刀具半径时，实际切屑厚度小于设定的每齿进给量。
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/// 此函数调整进给率以补偿切屑减薄效应，维持恒定的实际切屑厚度，
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/// 避免切削过薄导致刀具摩擦而非切削。
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///
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/// 公式: f_adj = f_nominal × (D / (2 × √(ae×(D−ae)))) 当 ae < D/2
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///
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/// @param toolpath 原始刀路（进给率为名义值）
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/// @param tool 使用的刀具
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/// @return 进给补偿后的刀路
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///
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/// @ingroup core
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[[nodiscard]] Toolpath chip_thinning_optimization(
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const Toolpath& toolpath,
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const Tool& tool);
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/// 车铣复合摆线加工 (Trochoidal Turn-Milling)
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///
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/// 在车铣复合机床上使用铣刀对旋转工件进行摆线切削。
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/// 工件旋转（C 轴）提供车削运动，铣刀沿径向和轴向做摆线切入。
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/// 适用于轴类零件的深槽、偏心特征等。
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///
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/// 策略：
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/// 1. 工件以 turning_rpm 旋转
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/// 2. 铣刀沿径向做摆线切入（trochoid_radius / step_forward）
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/// 3. 轴向分层推进（step_down）
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///
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/// @param body B-Rep 实体模型
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/// @param tool 铣刀参数
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/// @param params 车铣复合参数
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/// @return 车铣复合刀路
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///
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/// @ingroup core
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[[nodiscard]] Toolpath trochoidal_turn_milling(
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const brep::BrepModel& body,
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const Tool& tool,
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const TurnMillParams& params = TurnMillParams{});
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/// 高速加工 (High-Speed Machining)
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///
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/// 采用浅层大切宽策略，配合拐角摆线过渡以维持恒定切削负载。
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/// 不同于传统粗加工的重切削，HSM 利用高主轴转速和快速进给，
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/// 以"高速轻切"的方式实现更高的材料去除率。
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///
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/// 特点：
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/// - 浅切深 (step_down ~0.5mm)，大切宽 (step_over ~4mm)
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/// - 拐角自动摆线过渡，避免负载突变
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/// - 更高进给率 (通常 >2000 mm/min)
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/// - 平滑的刀路轨迹减少加减速
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///
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/// @param toolpath 原始刀路（作基础路径参考）
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/// @param params HSM 参数
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/// @return 优化后的高速刀路
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///
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/// @ingroup core
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[[nodiscard]] Toolpath high_speed_machining(
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const Toolpath& toolpath,
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const HSMParams& params);
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/// 恒接触角铣削 (Constant Engagement Milling)
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///
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/// 在加工过程中动态调整横向步距，使刀具与材料的啮合角始终保持恒定。
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/// 恒定啮合角 = 恒定切削力 = 刀具负载稳定 → 延长刀具寿命、提高表面质量。
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///
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/// 在进入角落或狭窄区域时减小步距，在开放区域时增大步距。
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///
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/// @param body B-Rep 实体模型
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/// @param tool 使用的刀具
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/// @param params 恒接触角参数
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/// @return 恒接触角刀路
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///
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/// @ingroup core
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[[nodiscard]] Toolpath constant_engagement_milling(
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const brep::BrepModel& body,
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const Tool& tool,
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const ConstantEngagementParams& params = ConstantEngagementParams{});
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/// 刀具寿命管理 (Tool Life Management)
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///
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/// 基于 Taylor 刀具寿命公式和累积磨损模型，预测刀具的剩余寿命，
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/// 并在需要时建议降低进给率以延长刀具寿命至完成当前任务。
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///
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/// Taylor 公式: Vc × T^n = C （Vc = 切削速度，T = 刀具寿命，n, C 为材料常数）
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///
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/// @param tool 当前刀具
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/// @param material 工件材料属性
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/// @param params 刀具寿命管理参数
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/// @return 刀具寿命预估结果（包含磨损量和建议进给修正）
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///
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/// @ingroup core
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[[nodiscard]] ToolLifeResult tool_life_management(
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const Tool& tool,
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const Material& material,
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const ToolLifeParams& params = ToolLifeParams{});
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} // namespace vde::core
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