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| import cadquery as cq | |
| import numpy as np | |
| import matplotlib.pyplot as plt | |
| import pyvista as pv | |
| from reportlab.lib.pagesizes import letter | |
| from reportlab.pdfgen import canvas | |
| import gradio as gr | |
| import os | |
| # Function for Progressive Die Design | |
| def generate_die(length, width, thickness): | |
| try: | |
| output_dir = "outputs" | |
| os.makedirs(output_dir, exist_ok=True) # Ensure output directory exists | |
| # Create die geometry | |
| plate = cq.Workplane("XY").box(length, width, thickness) | |
| punch = cq.Workplane("XY").rect(10, 10).extrude(5).translate((length / 4, width / 4, thickness / 2)) | |
| die = plate.cut(punch) | |
| # Export STEP file | |
| filename = os.path.join(output_dir, "progressive_die.step") | |
| cq.exporters.export(die, filename) | |
| return filename | |
| except Exception as e: | |
| return f"Error generating die: {str(e)}" | |
| def visualize_die(length, width, thickness): | |
| try: | |
| output_dir = "outputs" | |
| os.makedirs(output_dir, exist_ok=True) # Ensure output directory exists | |
| # Create die geometry | |
| plate = cq.Workplane("XY").box(length, width, thickness) | |
| punch = cq.Workplane("XY").rect(10, 10).extrude(5).translate((length / 4, width / 4, thickness / 2)) | |
| die = plate.cut(punch) | |
| # Export STL file for visualization | |
| stl_file = os.path.join(output_dir, "progressive_die.stl") | |
| cq.exporters.exportShape(die.val(), "STL", stl_file) | |
| # Generate 3D visualization screenshot | |
| pv.global_theme.off_screen = True # Ensure off-screen rendering | |
| mesh = pv.read(stl_file) | |
| plotter = pv.Plotter(off_screen=True) | |
| plotter.add_mesh(mesh, color="blue") | |
| screenshot = os.path.join(output_dir, "progressive_die_visualization.png") | |
| plotter.screenshot(screenshot) | |
| # Ensure the screenshot file exists | |
| if not os.path.exists(screenshot): | |
| raise FileNotFoundError("Screenshot file was not generated.") | |
| return screenshot | |
| except Exception as e: | |
| return f"Error visualizing die: {str(e)}" | |
| # Function for Stress Analysis (including thermal stress and fatigue strength) | |
| def stress_analysis(force, die_width, die_height, material_strength, temperature_change=50, alpha=1e-5, elastic_modulus=200000, fatigue_strength=150): | |
| try: | |
| # Mechanical stress | |
| stress = force / (die_width * die_height) # Stress = Force / Area | |
| safety_factor = material_strength / stress # Safety Factor = Material Strength / Stress | |
| # Thermal stress | |
| thermal_stress = elastic_modulus * alpha * temperature_change | |
| # Fatigue strength | |
| fatigue_stress = fatigue_strength | |
| # Generate data for plotting | |
| x = np.linspace(1, 100, 100) # Operational range (e.g., % load) | |
| stress_curve = stress * x / 100 # Simulated stress | |
| material_strength_curve = np.full_like(x, material_strength) # Constant material strength | |
| safety_factor_curve = material_strength_curve / stress_curve # Varying safety factor | |
| thermal_stress_curve = np.full_like(x, thermal_stress) # Constant thermal stress | |
| fatigue_strength_curve = np.full_like(x, fatigue_stress) # Constant fatigue strength | |
| # Create combined graph | |
| fig, ax = plt.subplots(figsize=(10, 6)) | |
| ax.plot(x, stress_curve, label="Stress (σ)", color="blue") | |
| ax.plot(x, material_strength_curve, label="Material Strength (σ_y)", color="green") | |
| ax.plot(x, safety_factor_curve, label="Safety Factor (SF)", color="orange") | |
| ax.plot(x, thermal_stress_curve, label="Thermal Stress (σ_thermal)", color="purple") | |
| ax.plot(x, fatigue_strength_curve, label="Fatigue Strength (σ_fatigue)", color="brown") | |
| ax.axhline(1, color="red", linestyle="--", label="Critical Safety Threshold (SF=1)") | |
| ax.set_title("Combined Stress Analysis Parameters") | |
| ax.set_xlabel("Operational Range (%)") | |
| ax.set_ylabel("Parameter Value (MPa or Unitless)") | |
| ax.legend() | |
| ax.grid() | |
| plt.tight_layout() | |
| plt.close(fig) | |
| return f"Safety Factor: {round(safety_factor, 2)}", fig | |
| except Exception as e: | |
| return f"Error in stress analysis: {str(e)}", None | |
| # Tool Optimization Function | |
| def optimize_tool(speed, feed_rate, depth_of_cut, material): | |
| """ | |
| Optimizes machining parameters for maximum tool life. | |
| """ | |
| try: | |
| # Simple formula for tool life estimation | |
| tool_life = 1000 / (speed * feed_rate * depth_of_cut) | |
| # Recommend adjustments for better tool life | |
| recommended_speed = 0.8 * speed | |
| recommended_feed_rate = 0.9 * feed_rate | |
| return { | |
| "Estimated Tool Life (hrs)": round(tool_life, 2), | |
| "Recommended Speed (m/min)": round(recommended_speed, 2), | |
| "Recommended Feed Rate (mm/rev)": round(recommended_feed_rate, 2), | |
| } | |
| except Exception as e: | |
| return {"Error": str(e)} | |
| # Create Gradio App | |
| with gr.Blocks() as app: | |
| gr.Markdown("## Press Tool AI Suite") | |
| gr.Markdown("Select a tool below to get started:") | |
| with gr.Tabs(): | |
| with gr.Tab("Progressive Die Design"): | |
| gr.Markdown("### Enter Dimensions for Progressive Die") | |
| length = gr.Number(label="Length (mm)", value=100) | |
| width = gr.Number(label="Width (mm)", value=50) | |
| thickness = gr.Number(label="Thickness (mm)", value=10) | |
| die_output = gr.Textbox(label="STEP File Location") | |
| visualization_output = gr.Image(label="3D Visualization") | |
| die_button = gr.Button("Generate Die") | |
| die_button.click( | |
| lambda l, w, t: (generate_die(l, w, t), visualize_die(l, w, t)), | |
| inputs=[length, width, thickness], | |
| outputs=[die_output, visualization_output], | |
| ) | |
| with gr.Tab("Stress Analysis"): | |
| gr.Markdown("### Select Simulation Tool and Enter Parameters for Stress Analysis") | |
| force = gr.Number(label="Force (N)", value=10000) | |
| die_width = gr.Number(label="Width (m)", value=0.05) | |
| die_height = gr.Number(label="Height (m)", value=0.01) | |
| material_strength = gr.Number(label="Material Strength (MPa)", value=250) | |
| temperature_change = gr.Number(label="Temperature Change (°C)", value=50) | |
| alpha = gr.Number(label="Thermal Expansion Coefficient (1/°C)", value=1e-5) | |
| elastic_modulus = gr.Number(label="Elastic Modulus (MPa)", value=200000) | |
| fatigue_strength = gr.Number(label="Fatigue Strength (MPa)", value=150) | |
| safety_factor_output = gr.Textbox(label="Safety Factor") | |
| stress_chart = gr.Plot() | |
| stress_button = gr.Button("Analyze Stress") | |
| stress_button.click( | |
| lambda f, dw, dh, ms, tc, a, em, fs: stress_analysis(f, dw, dh, ms, tc, a, em, fs), | |
| inputs=[force, die_width, die_height, material_strength, temperature_change, alpha, elastic_modulus, fatigue_strength], | |
| outputs=[safety_factor_output, stress_chart], | |
| ) | |
| with gr.Tab("Tool Optimization"): | |
| gr.Markdown("### Enter Machining Parameters for Tool Optimization") | |
| speed = gr.Number(label="Cutting Speed (m/min)", value=100) | |
| feed_rate = gr.Number(label="Feed Rate (mm/rev)", value=0.2) | |
| depth_of_cut = gr.Number(label="Depth of Cut (mm)", value=1.0) | |
| material = gr.Dropdown(choices=["Steel", "Aluminum", "Titanium"], label="Material", value="Steel") | |
| optimization_results = gr.JSON(label="Optimization Results") | |
| optimize_button = gr.Button("Optimize Tool") | |
| optimize_button.click( | |
| lambda s, fr, dc, m: optimize_tool(s, fr, dc, m), | |
| inputs=[speed, feed_rate, depth_of_cut, material], | |
| outputs=optimization_results, | |
| ) | |
| # Launch the app | |
| app.launch() | |