| """Research-only analytic surrogate for continuous-band METAL SAWING (cut-off). |
| |
| Supported: G21/G90/G94 G0/G1 G4 P M3/M5/M8/M9/M2, S in m/min, |
| F in mm/min, vertical Z feed, mm/seconds/Wh/g. Rectangular solid or round solid. |
| Not a controller, validated machine model, wear model, or measured electrical data. |
| Teacher-specific machine gain is PRIVATE and never included in prediction inputs. |
| Mechanism decomposition: tooth shear + edge ploughing + sliding/rubbing; the |
| sum represents mechanical blade load, not additional spindle idle electrical power. |
| """ |
| from __future__ import annotations |
| import math,re,json |
| import numpy as np |
| COMPONENTS=('electronics','hydraulic_hold','blade_drive_idle','blade_acceleration', |
| 'cutting_shear','ploughing','tooth_rubbing','feed_axis','band_guides', |
| 'coolant','chip_conveyor','control_aux') |
| DENSITY={'C45':.00785,'AL6061':.00270,'304SS':.00800,'CAST_IRON':.00720} |
| RESISTANCE={'C45':1.0,'AL6061':.49,'304SS':1.32,'CAST_IRON':.82} |
| 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 cross_section_area(depth,profile): |
| """Area removed by the blade plane from top down to depth (mm2).""" |
| h=float(profile['height_mm']);d=max(0.,min(h,depth)) |
| if profile['stock_shape']=='rectangular':return d*float(profile['width_mm']) |
| |
| r=h/2.; yy=r-d |
| return r*r*math.acos(max(-1.,min(1.,yy/r)))-yy*math.sqrt(max(0.,r*r-yy*yy)) |
|
|
| def contact_width(depth,profile): |
| if profile['stock_shape']=='rectangular':return float(profile['width_mm']) |
| r=float(profile['height_mm'])/2.; yy=r-depth |
| return 2*math.sqrt(max(0.,r*r-yy*yy)) |
|
|
| def simulate(rows,teacher=False,machine_gain=None,times_override=None): |
| if not rows:raise ValueError('Sawing needs G-code rows') |
| profile=json.loads(rows[0]['initial_profile']) |
| if teacher and machine_gain is None:raise ValueError('private teacher coefficient required') |
| gain=float(machine_gain) if teacher else 1. |
| density=DENSITY[profile['material']];res=RESISTANCE[profile['material']] |
| kerf=float(profile['kerf_mm']);height=float(profile['height_mm']);blade_type=profile['blade_type'] |
| tooth_pitch_mm=25.4/float(profile['tpi']) |
| feed=float(profile['feed_mm_min']);band_speed=0. |
| z=3.;motion='G0';on=False;cool=False;absolute=True |
| events=[];cumulative_area=0.;total_removed=0. |
| for i,row in enumerate(rows): |
| gc=COMMENT.sub('',row['gcode'].upper()).strip();pairs=[(a,float(b)) for a,b in WORD.findall(gc)] |
| w=dict(pairs);gcodes=[int(v) for a,v in pairs if a=='G'];mcodes=[int(v) for a,v in pairs if a=='M'] |
| if any(g in (2,3,18,19,91,93,95) for g in gcodes):raise ValueError('Unsupported sawing G-code') |
| for g in gcodes: |
| if g==0:motion='G0' |
| elif g==1:motion='G1' |
| elif g==90:absolute=True |
| if 'F' in w:feed=w['F'] |
| if 'S' in w:band_speed=w['S'] |
| was_on=on |
| for m in mcodes: |
| if m==3:on=True |
| elif m==5:on=False |
| elif m==8:cool=True |
| elif m==9:cool=False |
| nz=w.get('Z',z);move='Z' in w;dz=nz-z;dist=abs(dz) if move else 0. |
| feed_actual=float(profile['rapid_mm_min']) if motion=='G0' else feed |
| t=motion_time(dist,feed_actual,float(profile['accel_mm_s2'])*(1 if teacher else .85)) if move else 0. |
| if 4 in gcodes:t=max(0.,w.get('P',0.)) |
| if 3 in mcodes and not was_on:t+=(1.15+.007*band_speed)*(1 if teacher else .93) |
| if 8 in mcodes:t+=.24 if teacher else .22 |
| if teacher and move and motion=='G1':t*=1.+.011*math.tanh(dist/30.)+.006*(profile['material']=='304SS') |
| if times_override is not None:t=float(times_override[i]) |
| t=max(0.,t) |
| |
| lo=max(0.,min(height,-z));hi=max(0.,min(height,-nz)) |
| cut=(bool(on and move and motion=='G1' and dz<0 and hi>lo)) |
| removed_area=max(0.,cross_section_area(hi,profile)-cross_section_area(lo,profile)) if cut else 0. |
| vol=kerf*removed_area |
| total_removed+=vol |
| sweep=hi-lo if cut else 0. |
| wavg=removed_area/sweep if sweep>1e-12 else 0. |
| vfeed=sweep/max(t,1.e-8) |
| vblade=band_speed/60. |
| fz=(vfeed*60)*tooth_pitch_mm/max(1.,band_speed*1000.) |
| engaged=wavg/max(tooth_pitch_mm,1.e-5) |
| |
| |
| blade_factor=.84 if blade_type=='CARBIDE' else 1. |
| u_shear=(1.7*res*blade_factor)*(1.+.015/(fz+.015)) |
| u_plough=(.70*res*blade_factor)/(1.+fz/.015) |
| in_contact=bool(on and motion=='G1' and move and -nz>0 and z>=-height-.01 and nz<=0) |
| |
| rubbing_power=(8.+.42*engaged + .12*band_speed)*res*blade_factor if in_contact else 0. |
| p=np.zeros(len(COMPONENTS),np.float64) |
| if t>0: |
| p[0]=(54.+13.*gain)*t/3600. |
| p[1]=(92.+21.*gain)*t/3600. |
| if on:p[2]=(195.+2.7*band_speed+.006*band_speed**2)*gain*t/3600. |
| if 3 in mcodes and not was_on: |
| |
| p[3]=(.5*float(profile['equivalent_blade_mass_kg'])*vblade*vblade)/(3600*.77)*gain |
| p[4]=u_shear*vol/3600. |
| p[5]=u_plough*vol/3600. |
| p[6]=rubbing_power*t/3600. |
| if move: |
| axis_v=dist/max(t,.0001) |
| p[7]=(11.+.8*axis_v+.012*axis_v*axis_v)*gain*t/3600. |
| if on:p[8]=(31.+.18*band_speed)*t/3600. |
| if cool:p[9]=(82.+12.*gain)*t/3600. |
| if on:p[10]=64.*t/3600. |
| p[11]=26.*t/3600. |
| command='G4' if 4 in gcodes else (motion if move else 'M'+str(mcodes[0]) if mcodes else 'STATE') |
| events.append({'command':command,'time_s':t,'energy_Wh':float(p.sum()),'component_energy_Wh':p.tolist(), |
| 'material_g':vol*density,'material_removed_mm3':vol,'cut_width_avg_mm':wavg, |
| 'mean_engaged_teeth':engaged,'feed_per_tooth_mm':fz,'band_speed_m_min':band_speed, |
| 'feed_mm_min':feed,'z_after_mm':nz,'motion_mm':dist,'contact':in_contact, |
| 'kerf_mm':kerf,'height_mm':height,'cut_depth_mm':sweep,'total_volume_mm3':total_removed, |
| 'blade_acceleration_event':bool(3 in mcodes and not was_on)}) |
| z=nz |
| return events |
|
|
