ViewDesignEngine/tests/core/test_cam_optimization.cpp

#include <gtest/gtest.h>
#include "vde/core/cam_optimization.h"
#include "vde/core/cam_advanced.h"
#include "vde/core/cam_strategies.h"
#include "vde/core/cam_toolpath.h"
#include "vde/brep/brep.h"
#include "vde/brep/modeling.h"
#include <cmath>

using namespace vde::core;
using namespace vde::brep;

// ===========================================================================
//  Helpers
// ===========================================================================

static BrepModel make_test_box(double w = 50.0, double h = 30.0, double d = 20.0) {
    return make_box(w, h, d);
}

static Toolpath make_basic_toolpath() {
    Toolpath tp;
    tp.name = "TestBasic";
    tp.safe_z = 15.0;
    PathSegment s1{Point3D(0,0,15), Point3D(10,0,-1),
                   Point3D::Zero(), PathSegmentType::Linear, 500.0, -1.0};
    PathSegment s2{Point3D(10,0,-1), Point3D(20,0,-1),
                   Point3D::Zero(), PathSegmentType::Linear, 500.0, -1.0};
    PathSegment s3{Point3D(20,0,-1), Point3D(20,10,-1),
                   Point3D::Zero(), PathSegmentType::Linear, 500.0, -1.0};
    tp.segments = {s1, s2, s3};
    return tp;
}

// ===========================================================================
//  chip_thinning_optimization 测试
// ===========================================================================

TEST(CamOptimizationTest, ChipThinning_AdjustsFeedForSmallAe) {
    Toolpath tp = make_basic_toolpath();
    Tool tool;
    tool.diameter = 10.0;  // R=5mm, 小径向切深 → 应触发补偿
    tool.flutes = 2;

    auto result = chip_thinning_optimization(tp, tool);

    EXPECT_EQ(result.segments.size(), tp.segments.size());
    EXPECT_GT(result.segments[0].feed_rate, 0);
    // 名称应有变化
    EXPECT_NE(result.name, tp.name);
}

TEST(CamOptimizationTest, ChipThinning_EmptyToolpath) {
    Toolpath empty_tp;
    Tool tool;
    tool.diameter = 10.0;

    auto result = chip_thinning_optimization(empty_tp, tool);
    EXPECT_EQ(result.segments.size(), 0u);
}

TEST(CamOptimizationTest, ChipThinning_LargeToolNoChange) {
    // 刀具直径很大，径向切深接近刀具半径 → 不补偿
    Toolpath tp = make_basic_toolpath();
    Tool tool;
    tool.diameter = 100.0;  // 非常大的刀具

    auto result = chip_thinning_optimization(tp, tool);

    // 大刀具时补偿因子应接近 1
    for (size_t i = 0; i < result.segments.size(); ++i) {
        if (result.segments[i].type == PathSegmentType::Linear) {
            EXPECT_NEAR(result.segments[i].feed_rate, tp.segments[i].feed_rate, 300.0);
        }
    }
}

// ===========================================================================
//  trochoidal_turn_milling 测试
// ===========================================================================

TEST(CamOptimizationTest, TrochoidalTurnMill_GeneratesSegments) {
    auto box = make_test_box(30, 30, 15);
    Tool tool;
    tool.diameter = 8.0;
    TurnMillParams params;
    params.step_down = 5.0;
    params.trochoid_radius = 2.0;
    params.safe_z = 15.0;

    auto tp = trochoidal_turn_milling(box, tool, params);

    EXPECT_EQ(tp.name, "TrochoidalTurnMill");
    EXPECT_GT(tp.segments.size(), 5u) << "Should generate turn-mill toolpath";
    EXPECT_DOUBLE_EQ(tp.safe_z, 15.0);
}

TEST(CamOptimizationTest, TrochoidalTurnMill_IncludesRetract) {
    auto box = make_test_box(20, 20, 10);
    Tool tool;
    tool.diameter = 6.0;
    TurnMillParams params;
    params.safe_z = 20.0;
    params.step_down = 10.0;  // 单层

    auto tp = trochoidal_turn_milling(box, tool, params);

    // 最后一段应为提刀
    EXPECT_FALSE(tp.segments.empty());
    EXPECT_EQ(tp.segments.back().type, PathSegmentType::Rapid);
}

// ===========================================================================
//  high_speed_machining 测试
// ===========================================================================

TEST(CamOptimizationTest, HighSpeedMachining_IncreasesFeed) {
    Toolpath tp = make_basic_toolpath();
    HSMParams params;
    params.feed_rate = 2000.0;
    params.step_down = 0.5;
    params.trochoidal_corners = false;

    auto result = high_speed_machining(tp, params);

    EXPECT_EQ(result.segments.size(), tp.segments.size());

    // HSM 应提升进给率
    for (size_t i = 0; i < result.segments.size(); ++i) {
        if (result.segments[i].type == PathSegmentType::Linear) {
            EXPECT_GE(result.segments[i].feed_rate, params.feed_rate * 0.5);
        }
    }
}

TEST(CamOptimizationTest, HighSpeedMachining_AddsCornerTransitions) {
    // 创建有拐角的刀路
    Toolpath tp;
    tp.name = "CornerTest";
    tp.safe_z = 15.0;
    PathSegment s1{Point3D(0,0,5), Point3D(10,0,-1),
                   Point3D::Zero(), PathSegmentType::Linear, 500.0, -1.0};
    PathSegment s2{Point3D(10,0,-1), Point3D(10,10,-1),
                   Point3D::Zero(), PathSegmentType::Linear, 500.0, -1.0};  // 90° 拐角
    tp.segments = {s1, s2};

    HSMParams params;
    params.feed_rate = 2500.0;
    params.trochoidal_corners = true;
    params.corner_radius = 2.0;

    auto result = high_speed_machining(tp, params);

    // 拐角过渡应增加段数
    EXPECT_GT(result.segments.size(), tp.segments.size());
}

TEST(CamOptimizationTest, HighSpeedMachining_EmptyToolpath) {
    Toolpath empty_tp;
    HSMParams params;

    auto result = high_speed_machining(empty_tp, params);
    EXPECT_EQ(result.segments.size(), 0u);
}

// ===========================================================================
//  constant_engagement_milling 测试
// ===========================================================================

TEST(CamOptimizationTest, ConstantEngagement_GeneratesSpiral) {
    auto box = make_test_box(40, 40, 10);
    Tool tool;
    tool.diameter = 8.0;
    ConstantEngagementParams params;
    params.target_engagement = 45.0;
    params.step_down = 5.0;
    params.safe_z = 15.0;

    auto tp = constant_engagement_milling(box, tool, params);

    EXPECT_EQ(tp.name, "ConstantEngagement");
    EXPECT_GT(tp.segments.size(), 10u) << "Should generate multi-ring spiral";
    EXPECT_DOUBLE_EQ(tp.safe_z, 15.0);
}

TEST(CamOptimizationTest, ConstantEngagement_DifferentEngagementAngles) {
    auto box = make_test_box(30, 30, 10);
    Tool tool;
    tool.diameter = 8.0;

    ConstantEngagementParams low_eng;
    low_eng.target_engagement = 20.0;
    low_eng.step_down = 10.0;

    ConstantEngagementParams high_eng;
    high_eng.target_engagement = 60.0;
    high_eng.step_down = 10.0;

    auto tp_low = constant_engagement_milling(box, tool, low_eng);
    auto tp_high = constant_engagement_milling(box, tool, high_eng);

    // 低啮合角 = 更密的螺旋圈 → 更多段
    EXPECT_GT(tp_low.segments.size(), 0u);
    EXPECT_GT(tp_high.segments.size(), 0u);
    // 低啮合角应有更多段（步距更密）
    EXPECT_GE(tp_low.segments.size(), tp_high.segments.size() * 0.5);
}

// ===========================================================================
//  tool_life_management 测试
// ===========================================================================

TEST(CamOptimizationTest, ToolLifeManagement_ReturnsValidResult) {
    Tool tool;
    tool.diameter = 10.0;
    tool.flutes = 4;
    tool.type = ToolType::ENDMILL;

    Material mat;
    mat.name = "Aluminum";
    mat.hardness_brinell = 95.0;
    mat.specific_cutting_force = 800.0;

    ToolLifeParams params;
    params.max_cutting_time_min = 60.0;
    params.max_cutting_length_m = 500.0;

    auto result = tool_life_management(tool, mat, params);

    // 铝合金 → 刀具寿命应较长
    EXPECT_GT(result.estimated_life_min, 0);
    EXPECT_GT(result.material_removed_mm3, 0);
    EXPECT_FALSE(result.needs_replacement);
    EXPECT_TRUE(result.warning_message.empty() || !result.needs_replacement);
}

TEST(CamOptimizationTest, ToolLifeManagement_HardMaterialShortLife) {
    Tool tool;
    tool.diameter = 6.0;
    tool.flutes = 2;
    tool.type = ToolType::BALLNOSE;

    Material steel;
    steel.name = "HardenedSteel";
    steel.hardness_brinell = 400.0;
    steel.specific_cutting_force = 4000.0;

    Material aluminum;
    aluminum.name = "Aluminum";
    aluminum.hardness_brinell = 80.0;
    aluminum.specific_cutting_force = 600.0;

    ToolLifeParams params;
    auto result_steel = tool_life_management(tool, steel, params);
    auto result_alum = tool_life_management(tool, aluminum, params);

    // 硬材料的寿命应远小于软材料
    EXPECT_LT(result_steel.estimated_life_min,
              result_alum.estimated_life_min);
}

TEST(CamOptimizationTest, ToolLifeManagement_WearNearLimit) {
    Tool tool;
    tool.diameter = 8.0;
    tool.flutes = 3;
    tool.type = ToolType::ENDMILL;

    Material mat;
    mat.name = "Steel";
    mat.hardness_brinell = 250.0;
    mat.specific_cutting_force = 2500.0;

    // 使用较小的临界磨损值来触发报警
    ToolLifeParams params;
    params.critical_flank_wear = 0.05;  // 非常小的临界值
    params.max_cutting_time_min = 120.0;
    params.wear_coefficient = 5.0e-5;  // 高磨损系数

    auto result = tool_life_management(tool, mat, params);

    // 应该有磨损量记录
    EXPECT_GT(result.accumulated_wear_mm, 0);
    EXPECT_GT(result.current_flank_wear, 0);
}