| """Independent blockwise research surrogate for reciprocating SURFACE grinding. |
| |
| Supported G-code: G21/G17/G90/G94, G0/G1, G4 P, S/F, M3/M5/M8/M9/M2. |
| Simplified flat-wheel swept-band geometry; no arc interpolation, corner blending, |
| thermal/roughness/wheel wear, or real CNC driver. Units mm, s, W, Wh, g. |
| ``teacher=True`` only for offline synthetic labels and PRIVATE coefficient passed as |
| an argument. The predictor always uses ``teacher=False`` and no private gain. |
| """ |
| from __future__ import annotations |
| import json,math,re |
| import numpy as np |
|
|
| COMPONENTS=('electronics','axis_hold','axis_x','axis_y','axis_z', |
| 'wheel_spindle_idle','wheel_acceleration','shearing','ploughing', |
| 'rubbing','coolant','filtration') |
| DENSITY={'C45':.00785,'AL6061':.00270,'304SS':.00800,'CAST_IRON':.00720} |
| SE={'C45':1.0,'AL6061':.52,'304SS':1.35,'CAST_IRON':.78} |
| WORD=re.compile(r'([A-Z])\s*([+-]?(?:\d+(?:\.\d*)?|\.\d+))',re.I) |
| COMMENT=re.compile(r'\([^)]*\)|;[^\n]*') |
|
|
| def motion_time(mm,speed_mm_min,accel): |
| if mm<=0:return 0. |
| v=max(.01,speed_mm_min/60.);a=max(.01,accel) |
| return 2*math.sqrt(mm/a) if mm<v*v/a else 2*v/a+(mm-v*v/a)/v |
|
|
| def simulate(rows,teacher=False,machine_gain=None,times_override=None): |
| profile=json.loads(rows[0]['initial_profile']) |
| d=float(profile['wheel_diameter_mm']);b=float(profile['wheel_width_mm']) |
| wheel_type=profile['wheel_type'];material=profile['material'];rho=DENSITY[material] |
| if teacher and machine_gain is None:raise ValueError('Synthetic teacher requires PRIVATE machine coefficient') |
| gain=float(machine_gain) if teacher else 1. |
| x=y=0.;z=5.;motion='G0';feed=600.;rpm=0.;on=False;cool=False;absolute=True |
| prepared=[];lanedepth={};cutting_time=0.;total_volume=0. |
| for i,row in enumerate(rows): |
| gc=COMMENT.sub('',row['gcode'].upper()).strip();pairs=[(a,float(v)) for a,v in WORD.findall(gc)] |
| words=dict(pairs);gg=[int(v) for a,v in pairs if a=='G'];mm=[int(v) for a,v in pairs if a=='M'] |
| if any(g in (2,3,18,19,91,93,95) for g in gg):raise ValueError('Unsupported grinding G-code') |
| for g in gg: |
| if g==0:motion='G0' |
| elif g==1:motion='G1' |
| elif g==90:absolute=True |
| if 'S' in words:rpm=words['S'] |
| if 'F' in words:feed=words['F'] |
| was_on=on |
| for m in mm: |
| if m in (3,4):on=True |
| if m==5:on=False |
| if m==8:cool=True |
| if m==9:cool=False |
| nx=words.get('X',x);ny=words.get('Y',y);nz=words.get('Z',z) |
| move=any(c in words for c in 'XYZ');dx=nx-x;dy=ny-y;dz=nz-z |
| length=math.sqrt(dx*dx+dy*dy+dz*dz) if move else 0. |
| speed=(float(profile['rapid_mm_min']) if motion=='G0' else feed) |
| t=motion_time(length,speed, float(profile['accel_mm_s2'])*(1.0 if teacher else .86)) if move else 0. |
| if 4 in gg:t=max(0.,words.get('P',0.)) |
| if 3 in mm and not was_on:t+= (1.35+.000037*rpm)*(1 if teacher else .90) |
| if 8 in mm:t+=.35 if teacher else .33 |
| if teacher and length>0:t*=1.0+.016*math.tanh(length/80)+.008*(material=='304SS') |
| if times_override is not None:t=float(times_override[i]) |
| t=max(0.,t) |
| volume=0.;stockdepth=0. |
| |
| |
| |
| if move and motion=='G1' and on and abs(dy)<1e-7 and abs(dz)<1e-7 and abs(dx)>1 and nz<0: |
| lane=round(ny/b) |
| if abs(ny-lane*b)<1e-3: |
| before=lanedepth.get(lane,0.) |
| stockdepth=max(0.,-nz-before) |
| volume=abs(dx)*b*stockdepth |
| lanedepth[lane]=max(-nz,before) |
| total_volume+=volume |
| circumference_ms=math.pi*d*rpm/60000. |
| table_mm_s=abs(dx)/max(t,1.e-9) |
| a_e=max(stockdepth,0.) |
| heq=a_e*table_mm_s/max(circumference_ms*1000,1.) |
| |
| |
| |
| f_wheel=.80 if wheel_type=='CBN' else 1.0 |
| u_shear=12.*SE[material]*f_wheel*(1.+.000065/(heq+.000065)) |
| u_plough=27.*SE[material]*f_wheel/(1.+heq/.000048) |
| |
| in_contact=(move and motion=='G1' and on and abs(dy)<1.e-7 and abs(dz)<1.e-7 and nz<0 and abs(dx)>1) |
| contact_length=math.sqrt(max(0.,min(-nz,.08))*d) if in_contact else 0. |
| rubbing_power=(13.+.009*rpm + 1.4*contact_length*b)*SE[material]*f_wheel if in_contact else 0. |
| powers=np.zeros(12,np.float64) |
| if t>0: |
| powers[0]=(80.+14.*gain)*t/3600. |
| powers[1]=(34.+11.*gain)*t/3600. |
| if move: |
| for ix,dd,ff in [(2,abs(dx),1.),(3,abs(dy),1.08),(4,abs(dz),1.35)]: |
| if dd>0:powers[ix]+=(7.+ff*(.42*dd/max(t,.001)+.0012*(dd/max(t,.001))**2))*t/3600. |
| if on:powers[5]=(350.+.024*rpm+1.6e-6*rpm*rpm)*gain*t/3600. |
| if 3 in mm and not was_on:powers[6]+=(.009*rpm*rpm/1.e3)*gain/3600. |
| |
| powers[7]=u_shear*volume/3600. |
| powers[8]=u_plough*volume/3600. |
| powers[9]=rubbing_power*t/3600. |
| if cool:powers[10]=(160.+23.*gain)*t/3600. |
| if on:powers[11]=95.*t/3600. |
| |
| |
| prepared.append({'code':gc,'command':('G4' if 4 in gg else motion if move else ('M'+str(mm[0]) if mm else 'STATE')), |
| 'time_s':t,'material_removed_mm3':volume,'material_g':volume*rho, |
| 'energy_Wh':float(powers.sum()),'component_energy_Wh':powers.tolist(), |
| 'motion_mm':length,'feed_mm_min':feed,'spindle_rpm':rpm,'wheel_surface_m_s':circumference_ms, |
| 'depth_mm':-nz if nz<0 else 0.,'wheel_width_mm':b,'wheel_diameter_mm':d, |
| 'x_after_mm':nx,'y_after_mm':ny,'z_after_mm':nz,'contact':bool(in_contact), |
| 'chip_thickness_equiv_mm':heq,'removed_volume_cumulative_mm3':total_volume}) |
| x,y,z=nx,ny,nz |
| return prepared |
|
|
