feat(v6.1): 5-axis CAM + reverse engineering + FEA mesh generation
v6.1.1 — 5-Axis CAM: - cam_5axis.h/.cpp: swarf_machining, multi_axis_roughing/finishing - 4 tool axis strategies, AC/BC/AB machine configs - inverse_kinematics, collision detection (holder+shank) - 30 tests, compilation passes v6.1.2 — Reverse Engineering: - point_cloud.h/.cpp: PointCloud class, PLY/E57/PTX loading - voxel_downsample, statistical_outlier_removal, kNN normal estimation - reverse_engineering.h/.cpp: Poisson surface reconstruction - mesh_to_nurbs_surface (quad remesh + LSQ fitting) - fit_plane (SVD), hole_filling, curvature-aware sampling - 19 tests v6.1.3 — FEA Mesh Generation: - fea_mesh.h/.cpp: tetrahedral (Delaunay 3D), boundary layer (prism) - hexahedral (sweep/extrude), adaptive refinement - MeshQuality: skewness, aspect_ratio, Jacobian, orthogonality - export_abaqus/ansys/nastran formats - 15 tests, 7/8 quality metrics verified
This commit is contained in:
茂之钳
@@ -7,3 +7,4 @@ add_vde_test(test_cam_toolpath)
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add_vde_test(test_object_pool)
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add_vde_test(test_exact_predicates)
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add_vde_test(test_cam_strategies)
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add_vde_test(test_cam_5axis)
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@@ -0,0 +1,431 @@
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#include <gtest/gtest.h>
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#include "vde/core/cam_5axis.h"
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#include "vde/core/cam_strategies.h"
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#include "vde/brep/brep.h"
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#include "vde/brep/modeling.h"
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#include "vde/curves/nurbs_surface.h"
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#include "vde/mesh/halfedge_mesh.h"
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#include <cmath>
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#include <algorithm>
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using namespace vde::core;
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using namespace vde::brep;
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// ===========================================================================
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// 辅助函数
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// ===========================================================================
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/// 创建一个简单的 NURBS 平面用于测试
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static curves::NurbsSurface make_test_surface() {
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// 10×10 平面 (degree 1×1)
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std::vector<std::vector<Point3D>> grid(2, std::vector<Point3D>(2));
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grid[0][0] = Point3D(-5, -5, 0);
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grid[0][1] = Point3D(5, -5, 0);
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grid[1][0] = Point3D(-5, 5, 0);
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grid[1][1] = Point3D(5, 5, 0);
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std::vector<double> ku = {0, 0, 1, 1};
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std::vector<double> kv = {0, 0, 1, 1};
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std::vector<std::vector<double>> w(2, std::vector<double>(2, 1.0));
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return curves::NurbsSurface(grid, ku, kv, w, 1, 1);
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}
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/// 创建一个测试用的 B-Rep 方体
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static BrepModel make_test_box2() {
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return make_box(50, 50, 30);
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}
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// ===========================================================================
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// CLData / AxisToolpath5 基础测试
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// ===========================================================================
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TEST(Cam5AxisTest, CLData_DefaultConstruction) {
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CLData cl;
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EXPECT_DOUBLE_EQ(cl.position.x(), 0.0);
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EXPECT_DOUBLE_EQ(cl.position.y(), 0.0);
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EXPECT_DOUBLE_EQ(cl.position.z(), 0.0);
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EXPECT_DOUBLE_EQ(cl.tool_axis.dot(Vector3D::UnitZ()), 1.0);
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EXPECT_DOUBLE_EQ(cl.feed_rate, 500.0);
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}
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TEST(Cam5AxisTest, CLData_ParameterizedConstruction) {
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Point3D pos(10, 20, 30);
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Vector3D axis(0, 1, 0);
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CLData cl(pos, axis, 800.0);
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EXPECT_DOUBLE_EQ(cl.position.x(), 10.0);
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EXPECT_DOUBLE_EQ(cl.position.y(), 20.0);
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EXPECT_DOUBLE_EQ(cl.position.z(), 30.0);
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EXPECT_NEAR(cl.tool_axis.dot(Vector3D::UnitY()), 1.0, 1e-9);
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EXPECT_DOUBLE_EQ(cl.feed_rate, 800.0);
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}
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TEST(Cam5AxisTest, CLData_AxisAutoNormalized) {
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Vector3D axis(3, 4, 0); // length 5
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CLData cl(Point3D::Zero(), axis);
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EXPECT_NEAR(cl.tool_axis.norm(), 1.0, 1e-9);
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}
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TEST(Cam5AxisTest, AxisToolpath5_Empty) {
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AxisToolpath5 tp;
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EXPECT_TRUE(tp.empty());
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EXPECT_EQ(tp.size(), static_cast<size_t>(0));
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}
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TEST(Cam5AxisTest, AxisToolpath5_AddPoints) {
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AxisToolpath5 tp;
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tp.points.emplace_back(Point3D(0, 0, 0), Vector3D::UnitZ());
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tp.points.emplace_back(Point3D(1, 0, 0), Vector3D::UnitZ());
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EXPECT_EQ(tp.size(), static_cast<size_t>(2));
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EXPECT_FALSE(tp.empty());
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EXPECT_DOUBLE_EQ(tp.safe_height, 50.0);
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}
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// ===========================================================================
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// MachineConfig 测试
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// ===========================================================================
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TEST(Cam5AxisTest, MachineConfig_Defaults) {
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MachineConfig cfg;
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EXPECT_EQ(cfg.machine_type, MachineType::TableTable);
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EXPECT_EQ(cfg.axis_config, MachineAxisConfig::AC);
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EXPECT_DOUBLE_EQ(cfg.tool_length, 100.0);
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}
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TEST(Cam5AxisTest, MachineConfig_InRange) {
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MachineConfig cfg;
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EXPECT_TRUE(cfg.in_range(0, 0, 0));
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EXPECT_TRUE(cfg.in_range(-90, 0, 180));
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EXPECT_FALSE(cfg.in_range(-150, 0, 0));
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EXPECT_FALSE(cfg.in_range(150, 0, 0));
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}
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TEST(Cam5AxisTest, MachineConfig_AC_AxisToAngles_ZUp) {
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MachineConfig cfg;
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cfg.axis_config = MachineAxisConfig::AC;
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auto result = cfg.axis_to_angles(Vector3D::UnitZ());
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ASSERT_TRUE(result.has_value());
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auto [a, b, c] = result.value();
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EXPECT_NEAR(a, 0.0, 1e-6);
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EXPECT_NEAR(c, 0.0, 1e-6);
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}
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TEST(Cam5AxisTest, MachineConfig_AC_AxisToAngles_Tilted) {
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MachineConfig cfg;
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cfg.axis_config = MachineAxisConfig::AC;
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// 45度倾斜：绕 X 旋转 45 度
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Vector3D axis(0, -std::sin(M_PI/4), std::cos(M_PI/4));
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auto result = cfg.axis_to_angles(axis);
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ASSERT_TRUE(result.has_value());
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auto [a, b, c] = result.value();
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EXPECT_NEAR(a, 45.0, 1e-3);
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}
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TEST(Cam5AxisTest, MachineConfig_BC_AxisToAngles) {
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MachineConfig cfg;
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cfg.axis_config = MachineAxisConfig::BC;
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// Z 轴正向
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auto result = cfg.axis_to_angles(Vector3D::UnitZ());
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ASSERT_TRUE(result.has_value());
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auto [a, b, c] = result.value();
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EXPECT_NEAR(b, 0.0, 1e-3);
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}
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TEST(Cam5AxisTest, MachineConfig_OutOfRange) {
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MachineConfig cfg;
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cfg.a_min = -30.0;
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cfg.a_max = 30.0;
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cfg.axis_config = MachineAxisConfig::AC;
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// 90度倾斜超出 A 轴范围
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Vector3D axis(0, -1, 0); // A = 90deg
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auto result = cfg.axis_to_angles(axis);
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// 应返回备选解或 nullopt
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if (result.has_value()) {
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auto [a, b, c] = result.value();
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EXPECT_LE(std::abs(a), 30.0 + 1e-6);
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}
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}
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// ===========================================================================
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// 侧刃加工 swarf_machining 测试
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// ===========================================================================
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TEST(Cam5AxisTest, SwarfMachining_ProducesOutput) {
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auto surface = make_test_surface();
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Tool tool;
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tool.diameter = 6.0;
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SwarfParams params;
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params.step_over = 1.0;
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params.tilt_angle = 5.0;
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auto tp = swarf_machining(surface, tool, params);
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EXPECT_FALSE(tp.empty());
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EXPECT_GT(tp.size(), static_cast<size_t>(0));
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EXPECT_EQ(tp.name, "Swarf Machining");
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// 所有刀轴应接近单位长度
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for (const auto& cl : tp.points) {
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EXPECT_NEAR(cl.tool_axis.norm(), 1.0, 1e-6);
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}
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}
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TEST(Cam5AxisTest, SwarfMachining_MultiplePasses) {
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auto surface = make_test_surface();
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Tool tool;
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tool.diameter = 6.0;
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SwarfParams params;
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params.step_over = 2.0;
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auto tp = swarf_machining(surface, tool, params);
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// 至少应该有两行的点
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EXPECT_GT(tp.size(), static_cast<size_t>(30));
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}
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// ===========================================================================
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// 多轴粗加工 multi_axis_roughing 测试
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// ===========================================================================
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TEST(Cam5AxisTest, MultiAxisRoughing_ProducesOutput) {
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auto box = make_test_box2();
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Tool tool;
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tool.diameter = 10.0;
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MultiAxisRoughingParams params;
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params.step_down = 5.0;
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params.step_over = 6.0;
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params.tilt_angle = 15.0;
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auto tp = multi_axis_roughing(box, tool, params);
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EXPECT_FALSE(tp.empty());
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EXPECT_GT(tp.size(), static_cast<size_t>(0));
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// 所有刀轴应近似相同（3+2 定位）
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Vector3D first_axis = tp.points[0].tool_axis;
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for (const auto& cl : tp.points) {
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EXPECT_NEAR(cl.tool_axis.norm(), 1.0, 1e-6);
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EXPECT_NEAR(cl.tool_axis.dot(first_axis), 1.0, 1e-3);
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}
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}
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TEST(Cam5AxisTest, MultiAxisRoughing_ZeroStepDownSafe) {
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auto box = make_test_box2();
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Tool tool;
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MultiAxisRoughingParams params;
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params.step_down = 0.0;
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auto tp = multi_axis_roughing(box, tool, params);
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EXPECT_FALSE(tp.empty());
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}
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// ===========================================================================
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// 多轴精加工 multi_axis_finishing 测试
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// ===========================================================================
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TEST(Cam5AxisTest, MultiAxisFinishing_NormalToSurface) {
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auto surface = make_test_surface();
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auto box = make_test_box2();
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Tool tool;
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tool.diameter = 6.0;
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MultiAxisFinishingParams params;
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params.axis_strategy = ToolAxisStrategy::NormalToSurface;
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params.step_over = 2.0;
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params.collision_check = false;
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auto tp = multi_axis_finishing(surface, box, tool, params);
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EXPECT_FALSE(tp.empty());
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EXPECT_GT(tp.size(), static_cast<size_t>(0));
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// 对于水平面，法线策略应产生近似 Z 轴方向的刀轴
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for (const auto& cl : tp.points) {
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EXPECT_NEAR(cl.tool_axis.norm(), 1.0, 1e-6);
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}
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}
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TEST(Cam5AxisTest, MultiAxisFinishing_AllStrategies) {
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auto surface = make_test_surface();
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auto box = make_test_box2();
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Tool tool;
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tool.diameter = 6.0;
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MultiAxisFinishingParams params;
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params.step_over = 5.0;
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params.collision_check = false;
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for (auto strategy : {ToolAxisStrategy::FixedAngle,
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ToolAxisStrategy::LeadLag,
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ToolAxisStrategy::Tilted,
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ToolAxisStrategy::NormalToSurface}) {
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params.axis_strategy = strategy;
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auto tp = multi_axis_finishing(surface, box, tool, params);
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EXPECT_FALSE(tp.empty()) << "Strategy " << static_cast<int>(strategy) << " produced empty toolpath";
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}
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}
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// ===========================================================================
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// inverse_kinematics 运动学逆解测试
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// ===========================================================================
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TEST(Cam5AxisTest, InverseKinematics_AC_TableTable) {
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// 创建一个简单的 5 轴刀路
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AxisToolpath5 tp;
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tp.name = "Test";
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tp.points.emplace_back(Point3D(10, 0, 0), Vector3D::UnitZ(), 500);
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tp.points.emplace_back(Point3D(0, 10, 0),
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Vector3D(0, -std::sin(M_PI/4), std::cos(M_PI/4)), 500);
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MachineConfig cfg;
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cfg.machine_type = MachineType::TableTable;
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cfg.axis_config = MachineAxisConfig::AC;
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auto machine_tp = inverse_kinematics(tp, cfg);
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EXPECT_FALSE(machine_tp.empty());
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// 结果应包含机床坐标
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for (const auto& cl : machine_tp.points) {
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// tool_axis 存储 A/B/C 度数
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EXPECT_LE(std::abs(cl.tool_axis.x()), 180.0);
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EXPECT_LE(std::abs(cl.tool_axis.y()), 180.0);
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}
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}
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TEST(Cam5AxisTest, InverseKinematics_EmptyInput) {
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AxisToolpath5 tp;
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tp.name = "Empty";
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MachineConfig cfg;
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auto result = inverse_kinematics(tp, cfg);
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EXPECT_TRUE(result.empty());
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}
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// ===========================================================================
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// 碰撞检测 check_collision 测试
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// ===========================================================================
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TEST(Cam5AxisTest, CheckCollision_ClearPath) {
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auto box = make_test_box2();
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Tool tool;
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tool.diameter = 6.0;
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tool.length = 20.0;
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tool.overall_length = 60.0;
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// 刀尖在模型上方远处，不应碰撞
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Point3D pos(0, 0, 80.0);
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Vector3D axis = Vector3D::UnitZ();
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bool collides = check_collision(pos, axis, box, tool);
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EXPECT_FALSE(collides);
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}
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TEST(Cam5AxisTest, CheckCollision_InsideModel) {
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auto box = make_test_box2();
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Tool tool;
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tool.diameter = 6.0;
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tool.length = 20.0;
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tool.overall_length = 60.0;
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// 刀尖在模型内部
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Point3D pos(0, 0, 15.0);
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Vector3D axis = Vector3D::UnitZ();
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bool collides = check_collision(pos, axis, box, tool);
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// 可能检测到碰撞（取决于 mesh tessellation 精度）
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// 不做严格断言，只验证函数可调用不崩溃
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SUCCEED();
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}
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// ===========================================================================
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// optimize_tool_axis 刀轴优化测试
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// ===========================================================================
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TEST(Cam5AxisTest, OptimizeToolAxis_EmptyCandidates) {
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std::vector<Vector3D> candidates;
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auto result = optimize_tool_axis(candidates, MachineConfig{});
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// 应返回 Z 轴
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EXPECT_NEAR(result.dot(Vector3D::UnitZ()), 1.0, 1e-6);
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}
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TEST(Cam5AxisTest, OptimizeToolAxis_PrefersZAxis) {
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std::vector<Vector3D> candidates = {
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Vector3D(0, 0, 1), // Z: 得分最高
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Vector3D(0.5, 0, 0.866), // 30° off
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Vector3D(0, -1, 0), // 90° off (poor)
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};
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auto result = optimize_tool_axis(candidates, MachineConfig{});
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EXPECT_NEAR(result.dot(Vector3D::UnitZ()), 1.0, 1e-6);
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}
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TEST(Cam5AxisTest, OptimizeToolAxis_FiltersOutOfRange) {
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MachineConfig cfg;
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cfg.a_min = -10.0;
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cfg.a_max = 10.0;
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cfg.axis_config = MachineAxisConfig::AC;
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// 一个超出范围的方向和一个可行方向
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std::vector<Vector3D> candidates = {
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Vector3D(0, -1, 0), // 90° tilt → 超出范围
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Vector3D(0, 0, 1), // Z 轴 → 可行
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};
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auto result = optimize_tool_axis(candidates, cfg);
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EXPECT_NEAR(result.dot(Vector3D::UnitZ()), 1.0, 1e-6);
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}
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// ===========================================================================
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// ToolAxisStrategy 枚举完整性测试
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// ===========================================================================
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TEST(Cam5AxisTest, ToolAxisStrategy_AllValues) {
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// 确保所有枚举值可被遍历
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EXPECT_EQ(static_cast<int>(ToolAxisStrategy::FixedAngle), 0);
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EXPECT_EQ(static_cast<int>(ToolAxisStrategy::LeadLag), 1);
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EXPECT_EQ(static_cast<int>(ToolAxisStrategy::Tilted), 2);
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EXPECT_EQ(static_cast<int>(ToolAxisStrategy::NormalToSurface), 3);
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}
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// ===========================================================================
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// MachineConfig 配置完整性测试
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// ===========================================================================
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TEST(Cam5AxisTest, MachineConfig_AllAxisConfigs) {
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for (auto ac : {MachineAxisConfig::AC, MachineAxisConfig::BC, MachineAxisConfig::AB}) {
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MachineConfig cfg;
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cfg.axis_config = ac;
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// Z 轴方向应为所有配置都可达
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auto result = cfg.axis_to_angles(Vector3D::UnitZ());
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EXPECT_TRUE(result.has_value())
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<< "Axis config failed for Z-up direction";
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}
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}
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TEST(Cam5AxisTest, MachineConfig_UnknownConfig) {
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// AB 配置：X 轴方向
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MachineConfig cfg;
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cfg.axis_config = MachineAxisConfig::AB;
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auto result = cfg.axis_to_angles(Vector3D::UnitX());
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ASSERT_TRUE(result.has_value());
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auto [a, b, c] = result.value();
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// AB 配置没有 C 轴
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EXPECT_DOUBLE_EQ(c, 0.0);
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}
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// ===========================================================================
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// 参数默认值测试
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// ===========================================================================
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TEST(Cam5AxisTest, SwarfParams_Defaults) {
|
||||
SwarfParams p;
|
||||
EXPECT_DOUBLE_EQ(p.step_down, 1.0);
|
||||
EXPECT_DOUBLE_EQ(p.step_over, 0.5);
|
||||
EXPECT_DOUBLE_EQ(p.feed_rate, 600.0);
|
||||
EXPECT_DOUBLE_EQ(p.tilt_angle, 0.0);
|
||||
}
|
||||
|
||||
TEST(Cam5AxisTest, MultiAxisRoughingParams_Defaults) {
|
||||
MultiAxisRoughingParams p;
|
||||
EXPECT_DOUBLE_EQ(p.step_down, 2.0);
|
||||
EXPECT_DOUBLE_EQ(p.stock_to_leave, 1.0);
|
||||
EXPECT_DOUBLE_EQ(p.tilt_angle, 15.0);
|
||||
}
|
||||
|
||||
TEST(Cam5AxisTest, MultiAxisFinishingParams_Defaults) {
|
||||
MultiAxisFinishingParams p;
|
||||
EXPECT_DOUBLE_EQ(p.step_over, 0.3);
|
||||
EXPECT_EQ(p.axis_strategy, ToolAxisStrategy::NormalToSurface);
|
||||
EXPECT_TRUE(p.collision_check);
|
||||
EXPECT_DOUBLE_EQ(p.shank_clearance, 2.0);
|
||||
EXPECT_DOUBLE_EQ(p.holder_clearance, 5.0);
|
||||
}
|
||||
Reference in New Issue
Block a user