| """Research analytical surrogates for sheet LASER / PLASMA thermal cutting. |
| NOT a heat-transfer CFD model, real CNC controller, or empirically calibrated model. |
| Shared planar CNC kinematics, independently modeled electrical hardware heads. |
| G20 and G91 are intentionally rejected; G2/G3 circular interpolation supports I/J. |
| No wear, dross/HAZ/thermal distortion, overlapping-kerf, nesting/yield or real sensor data. |
| """ |
| from __future__ import annotations |
| import math,json,re |
| import numpy as np |
| MAT={'C45':(.00785,1.0),'304SS':(.00800,1.21),'AL6061':(.00270,.80),'S235':(.00785,.91)} |
| COMPONENTS={ |
| 'cnc_laser':('electronics','gantry_hold','axis_xy','z_focus','laser_standby','laser_emission_input','laser_pierce','chiller','assist_gas','exhaust_filter','servo_aux','control_aux'), |
| 'cnc_plasma':('electronics','gantry_hold','axis_xy','torch_height','power_supply_idle','arc_cutting_input','pilot_pierce_arc','air_compressor','gas_flow','fume_extraction','cooling','control_aux')} |
| WORD=re.compile(r'([A-Z])\s*([+-]?(?:\d+(?:\.\d*)?|\.\d+))',re.I) |
| COMMENT=re.compile(r'\([^)]*\)|;[^\n]*') |
| def trapezoid(dist,v,a): |
| if dist<=1.e-12:return 0. |
| v=max(.05,v);a=max(1.,a) |
| return 2*math.sqrt(dist/a) if dist<v*v/a else 2*v/a+(dist-v*v/a)/v |
|
|
| def path_arc(old,xy,w,motion): |
| cx=old[0]+w.get('I',0.);cy=old[1]+w.get('J',0.) |
| r=math.hypot(old[0]-cx,old[1]-cy) |
| r2=math.hypot(xy[0]-cx,xy[1]-cy) |
| if r<1e-7 or abs(r-r2)>max(.025,r*.001):raise ValueError('Invalid G2/G3 arc geometry') |
| a0=math.atan2(old[1]-cy,old[0]-cx);a1=math.atan2(xy[1]-cy,xy[0]-cx) |
| sweep=(a1-a0)%(2*math.pi) if motion=='G3' else (a0-a1)%(2*math.pi) |
| if sweep<1.e-10:sweep=2*math.pi |
| return r*sweep |
|
|
| def kerf(p,feed): |
| t=float(p['thickness_mm']);res=MAT[p['material']][1] |
| if p['mode']=='cnc_laser': |
| kw=.095+.012*t+.023*res+.007*(float(p['laser_power_kW'])/4.) |
| speed_factor=(float(p['cut_feed_mm_min'])/max(feed,1.))**.075 |
| return kw*speed_factor |
| kw=.55+.022*t+.13*res+.0021*float(p['current_A']) |
| speed_factor=(float(p['cut_feed_mm_min'])/max(feed,1.))**.055 |
| return kw*speed_factor |
|
|
| def simulate(rows,teacher=False,machine_gain=None,times_override=None): |
| if not rows:raise ValueError('Empty program') |
| p=json.loads(rows[0]['initial_profile']);mode=p['mode'] |
| if mode not in COMPONENTS:raise ValueError('laser/plasma mode only') |
| if teacher and machine_gain is None:raise ValueError('Private teacher gain required') |
| gain=float(machine_gain) if teacher else 1. |
| den,res=MAT[p['material']];pos=np.array([0.,0.,float(p['safe_z_mm'])]);on=False;gas=False |
| motion='G0';feed=float(p['cut_feed_mm_min']);absolute=True;events=[];prev_state=False |
| for i,row in enumerate(rows): |
| line=COMMENT.sub('',row['gcode'].upper()).strip() |
| pairs=[(a,float(b)) for a,b in WORD.findall(line)];w=dict(pairs) |
| gc=[int(v) for a,v in pairs if a=='G'];mc=[int(v) for a,v in pairs if a=='M'] |
| if any(z in (20,91,93,95) for z in gc):raise ValueError('Unsupported unit/mode: use G21 G90 G94') |
| for g in gc: |
| if g in (0,1,2,3):motion='G'+str(g) |
| elif g==90:absolute=True |
| if 'F' in w:feed=w['F'] |
| old=pos.copy();new=pos.copy() |
| for k,j in [('X',0),('Y',1),('Z',2)]: |
| if k in w:new[j]=w[k] if absolute else new[j]+w[k] |
| ismove=any(k in w for k in 'XYZ') |
| dx=float(new[0]-old[0]);dy=float(new[1]-old[1]);dz=float(new[2]-old[2]) |
| path=math.sqrt(dx*dx+dy*dy+dz*dz) if ismove else 0. |
| if ismove and motion in ('G2','G3'): |
| path=math.hypot(path_arc(old,new,w,motion),dz) |
| |
| was_on=on |
| for m in mc: |
| if m==3:on=True |
| elif m==5:on=False |
| elif m==8:gas=True |
| elif m==9:gas=False |
| rapid='G0'==motion |
| v=(float(p['rapid_mm_min']) if rapid else max(1.,feed))/60. |
| a=float(p['accel_mm_s2'])*(1. if teacher else .88) |
| if ismove:t=trapezoid(path,v,a) |
| else:t=0. |
| if 4 in gc:t=max(0.,w.get('P',0.)) |
| if 3 in mc and not was_on:t+=float(p['ignition_delay_s'])*(1. if teacher else .93) |
| if 8 in mc:t+=.17 if teacher else .15 |
| if teacher and ismove and not rapid:t*=1+.009*math.tanh(path/50.) |
| if times_override is not None:t=float(times_override[i]) |
| t=max(0.,t) |
| cutting=bool(on and ismove and motion in ('G1','G2','G3') and path>0 and abs(new[2]-float(p['cut_z_mm']))<.2) |
| kwidth=kerf(p,feed) if cutting else 0. |
| volume=path*kwidth*float(p['thickness_mm']) if cutting else 0. |
| |
| piercing=bool(on and (3 in mc)) |
| pierce_vol=math.pi/4*(1.35*kerf(p,float(p['cut_feed_mm_min'])))**2*float(p['thickness_mm']) if piercing else 0. |
| volume+=pierce_vol |
| c=np.zeros(12,dtype=np.float64) |
| if t>0: |
| def add(k,watts):c[k]+=max(0.,watts)*t/3600. |
| |
| add(0,68.+8.*gain);add(1,42.+10.*gain) |
| if ismove: |
| speed=path/max(t,1e-8) |
| add(2,(40.+.65*speed+.007*speed**2)*gain) |
| if abs(dz)>1e-8:add(3,(9.+1.2*abs(dz)/max(t,1e-8))*gain) |
| if mode=='cnc_laser': |
| |
| opt=float(p['laser_power_kW'])*1000. |
| eff=float(p['wall_plug_efficiency']) |
| add(4,(230.+40.*gain)*(1 if on else .55)) |
| if on: |
| add(5,opt/max(eff,.10)*(1. if cutting else .30)*gain) |
| if piercing:add(6,opt/max(eff,.10)*.55*gain) |
| add(7,(370.+.22*opt+170.*gain) if on else 220.) |
| if gas:add(8,(float(p['assist_gas_power_W'])+65.*gain)) |
| add(9,240. if gas else 95.) |
| add(10,75.*gain);add(11,42.) |
| else: |
| arc=float(p['current_A'])*float(p['arc_voltage_V']) |
| eff=float(p['power_supply_efficiency']) |
| add(4,(110.+30.*gain)*(1. if on else .25)) |
| if on:add(5,arc/max(eff,.1)*(1. if cutting else .24)*gain) |
| if piercing:add(6,arc/max(eff,.1)*.75*gain) |
| if gas:add(7,(float(p['compressor_power_W'])+40.*gain)) |
| if gas:add(8,170.+.34*float(p['current_A'])) |
| add(9,360. if gas else 90.) |
| add(10,190. if on else 90.) |
| add(11,49.) |
| event={'command':('G4' if 4 in gc else motion if ismove else f'M{mc[0]}' if mc else 'STATE'), |
| 'time_s':t,'energy_Wh':float(c.sum()),'component_energy_Wh':c.tolist(), |
| 'material_g':float(volume*den),'material_removed_mm3':volume,'kerf_mm':kwidth, |
| 'motion_mm':path,'cutting':cutting,'piercing':piercing,'feed_mm_min':feed, |
| 'x_after_mm':float(new[0]),'y_after_mm':float(new[1]),'z_after_mm':float(new[2]), |
| 'source_on':bool(on),'gas_on':bool(gas)} |
| events.append(event);pos=new;prev_state=on |
| return events |
|
|
