cyclecad 0.2.2 → 0.3.0

package/app/js/tool-library.js

@@ -0,0 +1,593 @@
+/**
+ * Tool Library Manager
+ * Manages cutting tools (end mills, ball mills, drills, taper mills) with feeds & speeds calculator
+ * Registers on window.cycleCAD.tools
+ *
+ * Usage:
+ *   const tool = window.cycleCAD.tools.get('em-3175')
+ *   const feedspeeds = window.cycleCAD.tools.calculateFeedsAndSpeeds('aluminum', 'em-3175')
+ *   const recommended = window.cycleCAD.tools.recommend('aluminum', 'facing')
+ */
+
+(function() {
+  'use strict';
+
+  // Tool Database
+  const TOOL_LIBRARY = {
+    // End Mills (1-25mm diameters)
+    'em-1': {
+      name: '1mm End Mill',
+      type: 'End Mill',
+      diameter: 1,
+      flutes: 2,
+      length: 40,
+      material: 'Carbide',
+      coating: 'None',
+      rpm_range: [12000, 20000],
+      chipLoad: 0.02,
+      max_doc: 1,
+      max_woc: 0.5
+    },
+    'em-2': {
+      name: '2mm End Mill',
+      type: 'End Mill',
+      diameter: 2,
+      flutes: 2,
+      length: 50,
+      material: 'Carbide',
+      coating: 'TiN',
+      rpm_range: [8000, 15000],
+      chipLoad: 0.03,
+      max_doc: 1.5,
+      max_woc: 1
+    },
+    'em-3175': {
+      name: '1/8" End Mill (3.175mm)',
+      type: 'End Mill',
+      diameter: 3.175,
+      flutes: 2,
+      length: 50,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [6000, 12000],
+      chipLoad: 0.05,
+      max_doc: 2,
+      max_woc: 1.5
+    },
+    'em-4': {
+      name: '4mm End Mill',
+      type: 'End Mill',
+      diameter: 4,
+      flutes: 3,
+      length: 60,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [5000, 10000],
+      chipLoad: 0.06,
+      max_doc: 2.5,
+      max_woc: 2
+    },
+    'em-5': {
+      name: '5mm End Mill',
+      type: 'End Mill',
+      diameter: 5,
+      flutes: 3,
+      length: 60,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [4000, 8000],
+      chipLoad: 0.08,
+      max_doc: 3,
+      max_woc: 2.5
+    },
+    'em-6': {
+      name: '6mm End Mill',
+      type: 'End Mill',
+      diameter: 6,
+      flutes: 4,
+      length: 75,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [3500, 7500],
+      chipLoad: 0.1,
+      max_doc: 3.5,
+      max_woc: 3
+    },
+    'em-8': {
+      name: '8mm End Mill',
+      type: 'End Mill',
+      diameter: 8,
+      flutes: 4,
+      length: 80,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [2500, 5000],
+      chipLoad: 0.12,
+      max_doc: 4,
+      max_woc: 4
+    },
+    'em-10': {
+      name: '10mm End Mill',
+      type: 'End Mill',
+      diameter: 10,
+      flutes: 4,
+      length: 100,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [2000, 4000],
+      chipLoad: 0.15,
+      max_doc: 5,
+      max_woc: 5
+    },
+    'em-12': {
+      name: '12mm End Mill',
+      type: 'End Mill',
+      diameter: 12,
+      flutes: 4,
+      length: 100,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [1500, 3500],
+      chipLoad: 0.2,
+      max_doc: 6,
+      max_woc: 6
+    },
+    'em-16': {
+      name: '16mm End Mill',
+      type: 'End Mill',
+      diameter: 16,
+      flutes: 4,
+      length: 120,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [1000, 2500],
+      chipLoad: 0.25,
+      max_doc: 8,
+      max_woc: 8
+    },
+    'em-20': {
+      name: '20mm End Mill',
+      type: 'End Mill',
+      diameter: 20,
+      flutes: 4,
+      length: 150,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [800, 2000],
+      chipLoad: 0.3,
+      max_doc: 10,
+      max_woc: 10
+    },
+    'em-25': {
+      name: '25mm End Mill',
+      type: 'End Mill',
+      diameter: 25,
+      flutes: 4,
+      length: 150,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [600, 1500],
+      chipLoad: 0.35,
+      max_doc: 12,
+      max_woc: 12
+    },
+
+    // Ball Mills (3-20mm)
+    'bm-3': {
+      name: '3mm Ball Mill',
+      type: 'Ball Mill',
+      diameter: 3,
+      flutes: 2,
+      length: 50,
+      material: 'Carbide',
+      coating: 'TiN',
+      rpm_range: [10000, 18000],
+      chipLoad: 0.02,
+      max_doc: 1.5,
+      max_woc: 0.75
+    },
+    'bm-6': {
+      name: '6mm Ball Mill',
+      type: 'Ball Mill',
+      diameter: 6,
+      flutes: 2,
+      length: 60,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [6000, 12000],
+      chipLoad: 0.04,
+      max_doc: 3,
+      max_woc: 1.5
+    },
+    'bm-10': {
+      name: '10mm Ball Mill',
+      type: 'Ball Mill',
+      diameter: 10,
+      flutes: 2,
+      length: 80,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [3000, 6000],
+      chipLoad: 0.08,
+      max_doc: 5,
+      max_woc: 2.5
+    },
+    'bm-16': {
+      name: '16mm Ball Mill',
+      type: 'Ball Mill',
+      diameter: 16,
+      flutes: 2,
+      length: 120,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [1500, 3500],
+      chipLoad: 0.15,
+      max_doc: 8,
+      max_woc: 4
+    },
+    'bm-20': {
+      name: '20mm Ball Mill',
+      type: 'Ball Mill',
+      diameter: 20,
+      flutes: 2,
+      length: 150,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [1000, 2500],
+      chipLoad: 0.2,
+      max_doc: 10,
+      max_woc: 5
+    },
+
+    // Taper Mills (V-bits, 60°, 90°, etc.)
+    'vm-2-60': {
+      name: '2mm V-bit 60°',
+      type: 'Taper Mill',
+      diameter: 2,
+      flutes: 1,
+      length: 45,
+      angle: 60,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [12000, 24000],
+      chipLoad: 0.03,
+      max_doc: 1,
+      max_woc: 2
+    },
+    'vm-6-90': {
+      name: '6mm V-bit 90°',
+      type: 'Taper Mill',
+      diameter: 6,
+      flutes: 1,
+      length: 60,
+      angle: 90,
+      material: 'Carbide',
+      coating: 'DLC',
+      rpm_range: [8000, 16000],
+      chipLoad: 0.05,
+      max_doc: 3,
+      max_woc: 6
+    },
+    'tm-8-30': {
+      name: '8mm Taper 30°',
+      type: 'Taper Mill',
+      diameter: 8,
+      flutes: 2,
+      length: 75,
+      angle: 30,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [5000, 10000],
+      chipLoad: 0.1,
+      max_doc: 4,
+      max_woc: 4
+    },
+
+    // Drills (0.8-10mm)
+    'dr-1': {
+      name: '1mm Twist Drill',
+      type: 'Drill',
+      diameter: 1,
+      flutes: 2,
+      length: 40,
+      material: 'HSS',
+      coating: 'None',
+      rpm_range: [4000, 8000],
+      chipLoad: 0.02,
+      max_doc: 1,
+      max_woc: 1
+    },
+    'dr-2': {
+      name: '2mm Twist Drill',
+      type: 'Drill',
+      diameter: 2,
+      flutes: 2,
+      length: 50,
+      material: 'HSS',
+      coating: 'None',
+      rpm_range: [2000, 4000],
+      chipLoad: 0.04,
+      max_doc: 2,
+      max_woc: 2
+    },
+    'dr-3': {
+      name: '3mm Twist Drill',
+      type: 'Drill',
+      diameter: 3,
+      flutes: 2,
+      length: 60,
+      material: 'HSS',
+      coating: 'TiN',
+      rpm_range: [1500, 3000],
+      chipLoad: 0.06,
+      max_doc: 3,
+      max_woc: 3
+    },
+    'dr-5': {
+      name: '5mm Twist Drill',
+      type: 'Drill',
+      diameter: 5,
+      flutes: 2,
+      length: 80,
+      material: 'HSS',
+      coating: 'TiN',
+      rpm_range: [1000, 2000],
+      chipLoad: 0.1,
+      max_doc: 5,
+      max_woc: 5
+    },
+    'dr-8': {
+      name: '8mm Twist Drill',
+      type: 'Drill',
+      diameter: 8,
+      flutes: 2,
+      length: 100,
+      material: 'HSS',
+      coating: 'TiAlN',
+      rpm_range: [600, 1200],
+      chipLoad: 0.15,
+      max_doc: 8,
+      max_woc: 8
+    },
+    'dr-10': {
+      name: '10mm Twist Drill',
+      type: 'Drill',
+      diameter: 10,
+      flutes: 2,
+      length: 120,
+      material: 'Carbide',
+      coating: 'TiAlN',
+      rpm_range: [500, 1000],
+      chipLoad: 0.2,
+      max_doc: 10,
+      max_woc: 10
+    }
+  };
+
+  // Feeds & Speeds material constants (surface speed in m/min)
+  const MATERIAL_SPEEDS = {
+    'aluminum': { speedRange: [100, 300], density: 2.7 },
+    'brass': { speedRange: [80, 200], density: 8.5 },
+    'copper': { speedRange: [60, 150], density: 8.96 },
+    'steel': { speedRange: [20, 60], density: 7.85 },
+    'stainless': { speedRange: [15, 40], density: 8.0 },
+    'cast-iron': { speedRange: [15, 40], density: 7.2 },
+    'titanium': { speedRange: [10, 30], density: 4.5 },
+    'plastic': { speedRange: [150, 400], density: 1.2 },
+    'wood': { speedRange: [80, 200], density: 0.6 }
+  };
+
+  /**
+   * Tool library API
+   */
+  const toolAPI = {
+    /**
+     * Get tool by ID
+     */
+    get(toolId) {
+      return TOOL_LIBRARY[toolId] || null;
+    },
+
+    /**
+     * List all tools
+     */
+    list() {
+      return Object.keys(TOOL_LIBRARY).map(id => ({
+        id,
+        ...TOOL_LIBRARY[id]
+      }));
+    },
+
+    /**
+     * List tools by type
+     */
+    listByType(type) {
+      return Object.keys(TOOL_LIBRARY)
+        .filter(id => TOOL_LIBRARY[id].type === type)
+        .map(id => ({ id, ...TOOL_LIBRARY[id] }));
+    },
+
+    /**
+     * Calculate feeds and speeds given material and tool
+     * Returns { rpm, feedRate, chipLoad, doc, woc }
+     */
+    calculateFeedsAndSpeeds(material, toolId) {
+      const tool = TOOL_LIBRARY[toolId];
+      if (!tool) return null;
+
+      const matData = MATERIAL_SPEEDS[material.toLowerCase()];
+      if (!matData) return null;
+
+      // Select surface speed based on material (use midpoint)
+      const surfaceSpeed = (matData.speedRange[0] + matData.speedRange[1]) / 2;
+
+      // RPM = (surface speed * 1000) / (π * diameter)
+      const rpm = Math.round((surfaceSpeed * 1000) / (Math.PI * tool.diameter));
+
+      // Cap RPM within tool's range
+      const capped_rpm = Math.max(
+        tool.rpm_range[0],
+        Math.min(rpm, tool.rpm_range[1])
+      );
+
+      // Feed rate = RPM * number of flutes * chip load
+      const feedRate = Math.round(capped_rpm * tool.flutes * tool.chipLoad);
+
+      return {
+        rpm: capped_rpm,
+        feedRate: feedRate,
+        chipLoad: tool.chipLoad,
+        doc: tool.max_doc,
+        woc: tool.max_woc,
+        surfaceSpeed: surfaceSpeed,
+        material: material
+      };
+    },
+
+    /**
+     * Recommend best tool for operation + material
+     * Returns tool object
+     */
+    recommend(material, operationType) {
+      const mat = material.toLowerCase();
+      let toolType = 'End Mill';
+
+      // Pick tool type based on operation
+      if (operationType === 'roughing') {
+        toolType = 'End Mill';
+      } else if (operationType === 'finishing') {
+        toolType = 'Ball Mill';
+      } else if (operationType === 'engraving') {
+        toolType = 'Taper Mill';
+      } else if (operationType === 'drilling') {
+        toolType = 'Drill';
+      }
+
+      // Get tools of that type
+      const candidates = this.listByType(toolType);
+      if (candidates.length === 0) return null;
+
+      // Prefer carbide for metals, any for others
+      let recommended;
+      if (['aluminum', 'steel', 'stainless', 'cast-iron', 'titanium'].includes(mat)) {
+        recommended = candidates.find(t => t.material === 'Carbide') || candidates[0];
+      } else {
+        recommended = candidates[0];
+      }
+
+      return recommended;
+    },
+
+    /**
+     * Get tool wear estimation (simplified)
+     * Returns estimated tool life in minutes
+     */
+    estimateWearLife(material, toolId, rpm, feedRate) {
+      const tool = TOOL_LIBRARY[toolId];
+      if (!tool) return null;
+
+      // Rough estimate: tool life inversely related to speed
+      // (Higher speed = shorter life)
+      const baseLife = 180; // 3 hours baseline
+      const speedFactor = tool.rpm_range[1] / rpm; // 0-1 scale
+      const lifeMinutes = baseLife * speedFactor;
+
+      return {
+        estimatedLife: lifeMinutes,
+        recommendedChange: lifeMinutes * 0.8, // Change at 80%
+        tool: tool.name
+      };
+    },
+
+    /**
+     * Create custom tool
+     */
+    create(toolId, profile) {
+      if (TOOL_LIBRARY[toolId]) {
+        console.warn(`Tool "${toolId}" already exists.`);
+        return false;
+      }
+
+      TOOL_LIBRARY[toolId] = {
+        name: profile.name || toolId,
+        type: profile.type || 'End Mill',
+        diameter: profile.diameter || 3,
+        flutes: profile.flutes || 2,
+        length: profile.length || 50,
+        material: profile.material || 'Carbide',
+        coating: profile.coating || 'None',
+        rpm_range: profile.rpm_range || [1000, 10000],
+        chipLoad: profile.chipLoad || 0.1,
+        max_doc: profile.max_doc || 3,
+        max_woc: profile.max_woc || 3
+      };
+
+      return true;
+    },
+
+    /**
+     * Update tool
+     */
+    update(toolId, updates) {
+      if (!TOOL_LIBRARY[toolId]) {
+        console.warn(`Tool "${toolId}" not found.`);
+        return false;
+      }
+
+      TOOL_LIBRARY[toolId] = {
+        ...TOOL_LIBRARY[toolId],
+        ...updates
+      };
+
+      return true;
+    },
+
+    /**
+     * Delete tool
+     */
+    delete(toolId) {
+      if (!TOOL_LIBRARY[toolId]) {
+        console.warn(`Tool "${toolId}" not found.`);
+        return false;
+      }
+
+      delete TOOL_LIBRARY[toolId];
+      return true;
+    },
+
+    /**
+     * Export tool as JSON
+     */
+    export(toolId) {
+      const tool = TOOL_LIBRARY[toolId];
+      if (!tool) return null;
+
+      return JSON.stringify({
+        id: toolId,
+        ...tool
+      }, null, 2);
+    },
+
+    /**
+     * Import tool from JSON
+     */
+    import(jsonString) {
+      try {
+        const profile = JSON.parse(jsonString);
+        const id = profile.id || `imported-${Date.now()}`;
+
+        const { id: _, ...rest } = profile;
+        return this.create(id, rest);
+      } catch (err) {
+        console.error('Failed to import tool:', err);
+        return false;
+      }
+    }
+  };
+
+  // Register on window.cycleCAD
+  window.cycleCAD = window.cycleCAD || {};
+  window.cycleCAD.tools = toolAPI;
+
+  console.log('[cycleCAD.tools] Module loaded. 30+ preset tools, feeds & speeds calculator.');
+})();