cyclecad 2.0.1 → 3.0.0

This diff represents the content of publicly available package versions that have been released to one of the supported registries. The information contained in this diff is provided for informational purposes only and reflects changes between package versions as they appear in their respective public registries.
Files changed (48) hide show
  1. package/DELIVERABLES.txt +296 -445
  2. package/ENHANCEMENT_COMPLETION_REPORT.md +383 -0
  3. package/ENHANCEMENT_SUMMARY.txt +308 -0
  4. package/FEATURE_INVENTORY.md +235 -0
  5. package/FUSION360_FEATURES_SUMMARY.md +452 -0
  6. package/FUSION360_PARITY_ENHANCEMENTS.md +461 -0
  7. package/FUSION360_PARITY_SUMMARY.md +520 -0
  8. package/FUSION360_QUICK_REFERENCE.md +351 -0
  9. package/IMPLEMENTATION_GUIDE.md +502 -0
  10. package/INTEGRATION-GUIDE.md +377 -0
  11. package/MODULES_PHASES_6_7.md +780 -0
  12. package/MODULE_API_REFERENCE.md +712 -0
  13. package/MODULE_INVENTORY.txt +264 -0
  14. package/app/index.html +1345 -4930
  15. package/app/js/app.js +1312 -514
  16. package/app/js/brep-kernel.js +1353 -455
  17. package/app/js/help-module.js +1437 -0
  18. package/app/js/kernel.js +364 -40
  19. package/app/js/modules/animation-module.js +1461 -0
  20. package/app/js/modules/assembly-module.js +47 -3
  21. package/app/js/modules/cam-module.js +1572 -0
  22. package/app/js/modules/collaboration-module.js +1615 -0
  23. package/app/js/modules/constraint-module.js +1266 -0
  24. package/app/js/modules/data-module.js +1054 -0
  25. package/app/js/modules/drawing-module.js +54 -8
  26. package/app/js/modules/formats-module.js +873 -0
  27. package/app/js/modules/inspection-module.js +1330 -0
  28. package/app/js/modules/mesh-module-enhanced.js +880 -0
  29. package/app/js/modules/mesh-module.js +968 -0
  30. package/app/js/modules/operations-module.js +40 -7
  31. package/app/js/modules/plugin-module.js +1554 -0
  32. package/app/js/modules/rendering-module.js +1766 -0
  33. package/app/js/modules/scripting-module.js +1073 -0
  34. package/app/js/modules/simulation-module.js +60 -3
  35. package/app/js/modules/sketch-module.js +2029 -91
  36. package/app/js/modules/step-module.js +47 -6
  37. package/app/js/modules/surface-module.js +1040 -0
  38. package/app/js/modules/version-module.js +1830 -0
  39. package/app/js/modules/viewport-module.js +95 -8
  40. package/app/test-agent-v2.html +881 -1316
  41. package/cycleCAD-Architecture-v2.pptx +0 -0
  42. package/docs/ARCHITECTURE.html +838 -1408
  43. package/docs/DEVELOPER-GUIDE.md +1504 -0
  44. package/docs/TUTORIAL.md +740 -0
  45. package/package.json +1 -1
  46. package/~$cycleCAD-Architecture-v2.pptx +0 -0
  47. package/.github/scripts/cad-diff.js +0 -590
  48. package/.github/workflows/cad-diff.yml +0 -117
@@ -0,0 +1,1572 @@
1
+ /**
2
+ * @file cam-module.js
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+ * @description CAM (Computer-Aided Manufacturing) Module.
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+ * Generates toolpaths for CNC milling, turning, and 3D printing.
5
+ * Includes tool library, G-code generation, and toolpath simulation.
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+ *
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+ * @version 1.0.0
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+ * @author Sachin Kumar <vvlars@googlemail.com>
9
+ * @license MIT
10
+ * @module cam
11
+ * @requires viewport, operations
12
+ */
13
+
14
+ 'use strict';
15
+
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+ /**
17
+ * CAM (Computer-Aided Manufacturing) Module
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+ * Handles toolpath generation, G-code output, and manufacturing simulation.
19
+ */
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+ const CAMModule = (() => {
21
+ const MODULE_NAME = 'cam';
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+ let viewport = null;
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+ let scene = null;
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+ let ui = null;
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+
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+ // Tool library with standard tools
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+ const defaultToolLibrary = {
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+ 'flat-endmill-6mm': {
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+ id: 'flat-endmill-6mm',
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+ name: 'Flat End Mill 6mm',
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+ type: 'flat',
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+ diameter: 6,
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+ fluteLength: 20,
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+ overallLength: 50,
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+ material: 'carbide',
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+ coating: 'TiN',
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+ rpm: 12000,
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+ feed: 1200,
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+ chipLoad: 0.1,
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+ cost: 15.50,
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+ },
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+ 'ball-endmill-3mm': {
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+ id: 'ball-endmill-3mm',
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+ name: 'Ball End Mill 3mm',
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+ type: 'ball',
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+ diameter: 3,
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+ fluteLength: 15,
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+ overallLength: 45,
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+ material: 'carbide',
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+ coating: 'TiN',
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+ rpm: 18000,
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+ feed: 800,
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+ chipLoad: 0.08,
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+ cost: 12.75,
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+ },
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+ 'drill-5mm': {
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+ id: 'drill-5mm',
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+ name: 'Drill 5mm',
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+ type: 'drill',
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+ diameter: 5,
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+ pointAngle: 118,
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+ fluteLength: 30,
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+ overallLength: 70,
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+ material: 'HSS',
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+ rpm: 3000,
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+ feed: 200,
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+ chipLoad: 0.15,
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+ cost: 2.50,
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+ },
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+ 'face-mill-50mm': {
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+ id: 'face-mill-50mm',
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+ name: 'Face Mill 50mm',
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+ type: 'face',
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+ diameter: 50,
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+ inserts: 5,
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+ material: 'carbide',
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+ rpm: 4000,
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+ feed: 2000,
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+ chipLoad: 0.2,
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+ cost: 85.00,
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+ },
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+ 'slot-drills-4mm': {
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+ id: 'slot-drills-4mm',
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+ name: 'Slot Drill 4mm',
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+ type: 'slot',
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+ diameter: 4,
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+ fluteLength: 12,
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+ overallLength: 40,
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+ material: 'carbide',
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+ rpm: 15000,
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+ feed: 900,
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+ chipLoad: 0.12,
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+ cost: 11.25,
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+ },
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+ 'chamfer-90deg': {
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+ id: 'chamfer-90deg',
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+ name: 'Chamfer 90°',
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+ type: 'chamfer',
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+ diameter: 10,
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+ angle: 90,
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+ material: 'carbide',
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+ rpm: 8000,
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+ feed: 600,
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+ cost: 18.50,
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+ },
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+ };
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+
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+ // CAM state
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+ const camState = {
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+ workCoordinateSystem: null,
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+ stock: null,
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+ selectedTool: null,
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+ toolLibrary: new Map(Object.entries(defaultToolLibrary)),
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+ toolpaths: new Map(),
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+ gcode: null,
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+ setupParams: {
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+ feedUnits: 'inch/min', // inch/min | mm/min
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+ rapidRate: 5000,
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+ safeHeight: 5,
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+ retractHeight: 10,
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+ spindleDirection: 'cw', // cw | ccw
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+ },
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+ };
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+
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+ const toolpathCounter = { count: 0 };
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+
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+ /**
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+ * Initialize the CAM Module
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+ * @param {Object} deps - Dependencies { viewport, scene }
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+ */
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+ function init(deps) {
132
+ viewport = deps.viewport;
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+ scene = deps.scene;
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+ registerCommands();
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+ window.addEventListener('keydown', handleKeyboard);
136
+ }
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+
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+ /**
139
+ * Define work coordinate system and stock
140
+ * @param {Object} params
141
+ * @param {string} params.stockType - 'box' | 'cylinder' | 'from_model'
142
+ * @param {Object} params.dimensions - { x, y, z } or { diameter, height }
143
+ * @param {THREE.Vector3} params.origin - WCS origin
144
+ * @param {THREE.Vector3} params.zDir - Z axis (spindle) direction
145
+ * @returns {Object} Setup result
146
+ */
147
+ function setupWorkCoordinateSystem(params = {}) {
148
+ const {
149
+ stockType = 'box',
150
+ dimensions = { x: 100, y: 100, z: 50 },
151
+ origin = new THREE.Vector3(0, 0, 0),
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+ zDir = new THREE.Vector3(0, 0, 1),
153
+ } = params;
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+
155
+ // Create WCS frame
156
+ camState.workCoordinateSystem = {
157
+ origin: origin.clone(),
158
+ zDir: zDir.normalize(),
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+ xDir: new THREE.Vector3(1, 0, 0),
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+ yDir: new THREE.Vector3(0, 1, 0),
161
+ type: stockType,
162
+ dimensions,
163
+ };
164
+
165
+ // Create stock visualization
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+ const stockGeom = createStockGeometry(stockType, dimensions);
167
+ const stockMat = new THREE.MeshPhongMaterial({
168
+ color: 0xcccccc,
169
+ transparent: true,
170
+ opacity: 0.2,
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+ wireframe: true,
172
+ });
173
+ const stockMesh = new THREE.Mesh(stockGeom, stockMat);
174
+ stockMesh.position.copy(origin);
175
+ stockMesh.name = 'stock_visualization';
176
+
177
+ camState.stock = stockMesh;
178
+ if (viewport?.scene) {
179
+ viewport.scene.add(stockMesh);
180
+ }
181
+
182
+ console.log('[CAM] WCS setup:', camState.workCoordinateSystem);
183
+ window.dispatchEvent(new CustomEvent('cam:setupComplete', { detail: camState.workCoordinateSystem }));
184
+
185
+ return { status: 'ok', wcs: camState.workCoordinateSystem };
186
+ }
187
+
188
+ /**
189
+ * Generate 2D contour (profile) toolpath
190
+ * @param {Object} params
191
+ * @param {THREE.Vector3[]} params.profile - Profile points (closed loop)
192
+ * @param {number} params.depth - Cut depth
193
+ * @param {string} params.toolId - Tool ID
194
+ * @param {string} params.type - 'inside' | 'outside' | 'on'
195
+ * @param {number} params.stepDown - Depth per pass
196
+ * @returns {Object} Toolpath object
197
+ */
198
+ function generateContour2D(params = {}) {
199
+ const {
200
+ profile = [],
201
+ depth = 10,
202
+ toolId = 'flat-endmill-6mm',
203
+ type = 'outside',
204
+ stepDown = 5,
205
+ } = params;
206
+
207
+ const tool = camState.toolLibrary.get(toolId);
208
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
209
+
210
+ const id = `tp_contour2d_${toolpathCounter.count++}`;
211
+
212
+ // Generate passes
213
+ const passes = [];
214
+ const depthPasses = Math.ceil(depth / stepDown);
215
+
216
+ for (let pass = 0; pass < depthPasses; pass++) {
217
+ const currentDepth = Math.min((pass + 1) * stepDown, depth);
218
+ passes.push({
219
+ depth: currentDepth,
220
+ points: offsetProfile(profile, type === 'inside' ? -tool.diameter / 2 : tool.diameter / 2),
221
+ });
222
+ }
223
+
224
+ const toolpath = {
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+ id,
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+ type: 'contour_2d',
227
+ tool,
228
+ profile,
229
+ depth,
230
+ stepDown,
231
+ passes,
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+ estimatedTime: calculateEstimatedTime(profile, passes, tool),
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+ status: 'generated',
234
+ };
235
+
236
+ camState.toolpaths.set(id, toolpath);
237
+
238
+ // Visualize toolpath
239
+ visualizeToolpath(toolpath);
240
+
241
+ console.log('[CAM] Contour 2D generated:', { id, passes: passes.length, depth });
242
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
243
+
244
+ return { id, type: 'contour_2d', passes: passes.length, estimatedTime: toolpath.estimatedTime };
245
+ }
246
+
247
+ /**
248
+ * Generate pocket (enclosed region clear) toolpath
249
+ * @param {Object} params
250
+ * @param {THREE.Vector3[]} params.region - Region boundary
251
+ * @param {number} params.depth - Pocket depth
252
+ * @param {string} params.toolId - Tool ID
253
+ * @param {number} params.stepDown - Depth per pass
254
+ * @param {number} params.stepOver - Horizontal feed per pass
255
+ * @returns {Object} Toolpath object
256
+ */
257
+ function generatePocket(params = {}) {
258
+ const {
259
+ region = [],
260
+ depth = 10,
261
+ toolId = 'flat-endmill-6mm',
262
+ stepDown = 5,
263
+ stepOver = 3,
264
+ } = params;
265
+
266
+ const tool = camState.toolLibrary.get(toolId);
267
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
268
+
269
+ const id = `tp_pocket_${toolpathCounter.count++}`;
270
+
271
+ // Generate spiral/raster pattern
272
+ const passes = [];
273
+ const depthPasses = Math.ceil(depth / stepDown);
274
+
275
+ for (let dPass = 0; dPass < depthPasses; dPass++) {
276
+ const currentDepth = Math.min((dPass + 1) * stepDown, depth);
277
+ const spiralLines = generateSpiralPattern(region, stepOver);
278
+ passes.push({
279
+ depth: currentDepth,
280
+ lines: spiralLines,
281
+ });
282
+ }
283
+
284
+ const toolpath = {
285
+ id,
286
+ type: 'pocket',
287
+ tool,
288
+ region,
289
+ depth,
290
+ stepDown,
291
+ stepOver,
292
+ passes,
293
+ estimatedTime: calculateEstimatedTime(region, passes, tool),
294
+ status: 'generated',
295
+ };
296
+
297
+ camState.toolpaths.set(id, toolpath);
298
+ visualizeToolpath(toolpath);
299
+
300
+ console.log('[CAM] Pocket generated:', { id, passes: passes.length });
301
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
302
+
303
+ return { id, type: 'pocket', passes: passes.length, estimatedTime: toolpath.estimatedTime };
304
+ }
305
+
306
+ /**
307
+ * Generate drilling toolpath
308
+ * @param {Object} params
309
+ * @param {THREE.Vector3[]} params.points - Drill points
310
+ * @param {number} params.depth - Drill depth
311
+ * @param {string} params.toolId - Tool ID
312
+ * @param {string} params.cycle - 'peck' | 'standard' | 'chip_break'
313
+ * @param {number} params.peckDepth - Peck depth for peck drilling
314
+ * @returns {Object} Toolpath object
315
+ */
316
+ function generateDrilling(params = {}) {
317
+ const {
318
+ points = [],
319
+ depth = 10,
320
+ toolId = 'drill-5mm',
321
+ cycle = 'peck',
322
+ peckDepth = 5,
323
+ } = params;
324
+
325
+ const tool = camState.toolLibrary.get(toolId);
326
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
327
+
328
+ const id = `tp_drill_${toolpathCounter.count++}`;
329
+
330
+ // Generate peck pattern if requested
331
+ let drillSequence = points;
332
+ if (cycle === 'peck') {
333
+ drillSequence = points.flatMap(pt => ({
334
+ point: pt,
335
+ pecks: Math.ceil(depth / peckDepth),
336
+ peckDepth,
337
+ }));
338
+ }
339
+
340
+ const toolpath = {
341
+ id,
342
+ type: 'drilling',
343
+ tool,
344
+ points,
345
+ depth,
346
+ cycle,
347
+ drillSequence,
348
+ estimatedTime: calculateDrillingTime(points, depth, tool),
349
+ status: 'generated',
350
+ };
351
+
352
+ camState.toolpaths.set(id, toolpath);
353
+ visualizeToolpath(toolpath);
354
+
355
+ console.log('[CAM] Drilling generated:', { id, points: points.length });
356
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
357
+
358
+ return { id, type: 'drilling', points: points.length, estimatedTime: toolpath.estimatedTime };
359
+ }
360
+
361
+ /**
362
+ * Generate face milling toolpath
363
+ * @param {Object} params
364
+ * @param {THREE.Vector3[]} params.region - Face region
365
+ * @param {number} params.depth - Cut depth
366
+ * @param {string} params.toolId - Tool ID
367
+ * @param {number} params.stepOver - Feed per pass
368
+ * @returns {Object} Toolpath object
369
+ */
370
+ function generateFace(params = {}) {
371
+ const {
372
+ region = [],
373
+ depth = 2,
374
+ toolId = 'face-mill-50mm',
375
+ stepOver = 10,
376
+ } = params;
377
+
378
+ const tool = camState.toolLibrary.get(toolId);
379
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
380
+
381
+ const id = `tp_face_${toolpathCounter.count++}`;
382
+
383
+ // Generate raster pattern
384
+ const passes = generateRasterPattern(region, stepOver);
385
+
386
+ const toolpath = {
387
+ id,
388
+ type: 'face',
389
+ tool,
390
+ region,
391
+ depth,
392
+ stepOver,
393
+ passes,
394
+ estimatedTime: calculateEstimatedTime(region, passes, tool),
395
+ status: 'generated',
396
+ };
397
+
398
+ camState.toolpaths.set(id, toolpath);
399
+ visualizeToolpath(toolpath);
400
+
401
+ console.log('[CAM] Face milling generated:', { id, passes: passes.length });
402
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
403
+
404
+ return { id, type: 'face', passes: passes.length, estimatedTime: toolpath.estimatedTime };
405
+ }
406
+
407
+ /**
408
+ * Generate adaptive clearing (high-speed roughing)
409
+ * @param {Object} params
410
+ * @param {THREE.Vector3[]} params.region - Region to clear
411
+ * @param {number} params.depth - Clear depth
412
+ * @param {string} params.toolId - Tool ID
413
+ * @param {number} params.stepOver - Horizontal feed
414
+ * @returns {Object} Toolpath object
415
+ */
416
+ function generateAdaptiveClearing(params = {}) {
417
+ const {
418
+ region = [],
419
+ depth = 20,
420
+ toolId = 'flat-endmill-6mm',
421
+ stepOver = 4,
422
+ } = params;
423
+
424
+ const tool = camState.toolLibrary.get(toolId);
425
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
426
+
427
+ const id = `tp_adaptive_${toolpathCounter.count++}`;
428
+
429
+ // Adaptive clearing: constant chip load, variable engagement
430
+ const passes = [];
431
+ const depthPass = Math.min(tool.diameter * 0.75, depth); // engage to 75% dia
432
+ const numPasses = Math.ceil(depth / depthPass);
433
+
434
+ for (let i = 0; i < numPasses; i++) {
435
+ const currentDepth = Math.min((i + 1) * depthPass, depth);
436
+ passes.push({
437
+ depth: currentDepth,
438
+ pattern: generateAdaptivePattern(region, stepOver, currentDepth),
439
+ });
440
+ }
441
+
442
+ const toolpath = {
443
+ id,
444
+ type: 'adaptive_clearing',
445
+ tool,
446
+ region,
447
+ depth,
448
+ stepOver,
449
+ passes,
450
+ estimatedTime: calculateEstimatedTime(region, passes, tool),
451
+ status: 'generated',
452
+ };
453
+
454
+ camState.toolpaths.set(id, toolpath);
455
+ visualizeToolpath(toolpath);
456
+
457
+ console.log('[CAM] Adaptive clearing generated:', { id, passes: passes.length });
458
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
459
+
460
+ return { id, type: 'adaptive_clearing', passes: passes.length, estimatedTime: toolpath.estimatedTime };
461
+ }
462
+
463
+ /**
464
+ * Generate parallel finishing toolpath
465
+ * @param {Object} params
466
+ * @param {THREE.BufferGeometry} params.geometry - Surface geometry
467
+ * @param {string} params.toolId - Tool ID
468
+ * @param {number} params.stepOver - Horizontal step-over
469
+ * @param {string} params.direction - 'x' | 'y' | 'diagonal'
470
+ * @returns {Object} Toolpath object
471
+ */
472
+ function generateParallel(params = {}) {
473
+ const {
474
+ geometry = null,
475
+ toolId = 'ball-endmill-3mm',
476
+ stepOver = 2,
477
+ direction = 'x',
478
+ } = params;
479
+
480
+ const tool = camState.toolLibrary.get(toolId);
481
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
482
+
483
+ const id = `tp_parallel_${toolpathCounter.count++}`;
484
+
485
+ const passes = generateParallelPasses(geometry, stepOver, direction);
486
+
487
+ const toolpath = {
488
+ id,
489
+ type: 'parallel',
490
+ tool,
491
+ geometry,
492
+ stepOver,
493
+ direction,
494
+ passes,
495
+ estimatedTime: calculateEstimatedTime([], passes, tool),
496
+ status: 'generated',
497
+ };
498
+
499
+ camState.toolpaths.set(id, toolpath);
500
+ visualizeToolpath(toolpath);
501
+
502
+ console.log('[CAM] Parallel finishing generated:', { id, passes: passes.length });
503
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
504
+
505
+ return { id, type: 'parallel', passes: passes.length, estimatedTime: toolpath.estimatedTime };
506
+ }
507
+
508
+ /**
509
+ * Generate FDM slicing (additive/3D printing)
510
+ * @param {Object} params
511
+ * @param {THREE.BufferGeometry} params.geometry - Part geometry
512
+ * @param {number} params.layerHeight - Layer height
513
+ * @param {number} params.nozzleWidth - Nozzle width
514
+ * @param {string} params.infillPattern - 'grid' | 'honeycomb' | 'gyroid'
515
+ * @param {number} params.infillDensity - 0-1 (0.2 = 20%)
516
+ * @returns {Object} Sliced object
517
+ */
518
+ function generateFDMSlicing(params = {}) {
519
+ const {
520
+ geometry = null,
521
+ layerHeight = 0.2,
522
+ nozzleWidth = 0.4,
523
+ infillPattern = 'grid',
524
+ infillDensity = 0.2,
525
+ } = params;
526
+
527
+ const id = `fdm_${toolpathCounter.count++}`;
528
+
529
+ // Compute bounding box
530
+ const bbox = new THREE.Box3().setFromBufferGeometry(geometry);
531
+ const height = bbox.max.z - bbox.min.z;
532
+ const layerCount = Math.ceil(height / layerHeight);
533
+
534
+ // Generate layers
535
+ const layers = [];
536
+ for (let i = 0; i < layerCount; i++) {
537
+ const z = bbox.min.z + i * layerHeight;
538
+ layers.push({
539
+ z,
540
+ index: i,
541
+ perimeter: generatePerimeterPaths(geometry, z),
542
+ infill: generateInfillPattern(geometry, z, infillPattern, infillDensity),
543
+ });
544
+ }
545
+
546
+ const slicing = {
547
+ id,
548
+ type: 'fdm_slicing',
549
+ geometry,
550
+ layerHeight,
551
+ nozzleWidth,
552
+ infillPattern,
553
+ infillDensity,
554
+ layers,
555
+ estimatedTime: layerCount * 2, // ~2min per layer estimate
556
+ filamentLength: estimateFilamentLength(layers),
557
+ filamentWeight: 0, // would need material density
558
+ };
559
+
560
+ camState.toolpaths.set(id, slicing);
561
+ console.log('[CAM] FDM slicing generated:', { id, layers: layerCount });
562
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: slicing }));
563
+
564
+ return { id, type: 'fdm_slicing', layers: layerCount, estimatedTime: slicing.estimatedTime };
565
+ }
566
+
567
+ /**
568
+ * Generate G-code from toolpath
569
+ * @param {string} toolpathId - Toolpath ID
570
+ * @param {string} dialect - 'fanuc' | 'linuxcnc' | 'grbl' | 'marlin'
571
+ * @returns {string} G-code text
572
+ */
573
+ function generateGCode(toolpathId, dialect = 'grbl') {
574
+ const toolpath = camState.toolpaths.get(toolpathId);
575
+ if (!toolpath) throw new Error(`Toolpath ${toolpathId} not found`);
576
+
577
+ let gcode = '';
578
+
579
+ // Header
580
+ gcode += '; Generated by cycleCAD CAM\n';
581
+ gcode += `; Machine: ${dialect}\n`;
582
+ gcode += `; Generated: ${new Date().toISOString()}\n`;
583
+ gcode += `; Tool: ${toolpath.tool.name}\n`;
584
+ gcode += `; Operation: ${toolpath.type}\n`;
585
+ gcode += ';\n';
586
+
587
+ // Unit setup
588
+ if (dialect === 'grbl' || dialect === 'linuxcnc') {
589
+ gcode += 'G90 G21\n'; // absolute, metric
590
+ } else if (dialect === 'fanuc') {
591
+ gcode += 'G90 G21\n'; // absolute, metric
592
+ }
593
+
594
+ // Spindle on
595
+ gcode += `S${toolpath.tool.rpm} M3\n`;
596
+
597
+ // Generate moves based on toolpath type
598
+ if (toolpath.type === 'drilling') {
599
+ gcode += generateDrillingGCode(toolpath, dialect);
600
+ } else if (toolpath.type === 'contour_2d') {
601
+ gcode += generateContourGCode(toolpath, dialect);
602
+ } else if (toolpath.type === 'pocket' || toolpath.type === 'adaptive_clearing') {
603
+ gcode += generatePocketGCode(toolpath, dialect);
604
+ } else if (toolpath.type === 'face') {
605
+ gcode += generateFaceGCode(toolpath, dialect);
606
+ }
607
+
608
+ // End
609
+ gcode += '\nM5\n'; // Spindle off
610
+ gcode += 'M30\n'; // Program end
611
+
612
+ camState.gcode = gcode;
613
+
614
+ console.log('[CAM] G-code generated:', { length: gcode.length, lines: gcode.split('\n').length - 1 });
615
+ window.dispatchEvent(new CustomEvent('cam:gcodeGenerated', { detail: { gcode, length: gcode.length } }));
616
+
617
+ return gcode;
618
+ }
619
+
620
+ /**
621
+ * Simulate toolpath motion in 3D
622
+ * @param {string} toolpathId - Toolpath ID
623
+ * @param {number} speed - Playback speed (1.0 = real-time, 10 = 10x faster)
624
+ * @returns {Object} Simulation controller
625
+ */
626
+ function simulateToolpath(toolpathId, speed = 1.0) {
627
+ const toolpath = camState.toolpaths.get(toolpathId);
628
+ if (!toolpath) throw new Error(`Toolpath ${toolpathId} not found`);
629
+
630
+ const tool = toolpath.tool;
631
+ const simulation = {
632
+ toolpathId,
633
+ isRunning: false,
634
+ progress: 0,
635
+ startTime: 0,
636
+ totalTime: toolpath.estimatedTime * 1000 / speed,
637
+
638
+ // Create tool mesh
639
+ toolMesh: createToolMesh(tool),
640
+ };
641
+
642
+ if (viewport?.scene) {
643
+ viewport.scene.add(simulation.toolMesh);
644
+ }
645
+
646
+ // Animate tool
647
+ const animate = () => {
648
+ if (!simulation.isRunning) return;
649
+
650
+ const elapsed = Date.now() - simulation.startTime;
651
+ simulation.progress = Math.min(elapsed / simulation.totalTime, 1.0);
652
+
653
+ // Position tool along toolpath
654
+ const pathPoints = extractPathPoints(toolpath);
655
+ if (pathPoints.length > 0) {
656
+ const pointIndex = Math.floor(simulation.progress * pathPoints.length);
657
+ const point = pathPoints[Math.min(pointIndex, pathPoints.length - 1)];
658
+ simulation.toolMesh.position.copy(point);
659
+ }
660
+
661
+ if (simulation.progress < 1.0) {
662
+ requestAnimationFrame(animate);
663
+ } else {
664
+ simulation.isRunning = false;
665
+ window.dispatchEvent(new CustomEvent('cam:simulationComplete', { detail: simulation }));
666
+ }
667
+ };
668
+
669
+ return {
670
+ start: () => {
671
+ simulation.isRunning = true;
672
+ simulation.startTime = Date.now();
673
+ animate();
674
+ },
675
+ stop: () => {
676
+ simulation.isRunning = false;
677
+ },
678
+ pause: () => {
679
+ // In real implementation, would handle pause
680
+ },
681
+ getProgress: () => simulation.progress,
682
+ getMesh: () => simulation.toolMesh,
683
+ };
684
+ }
685
+
686
+ /**
687
+ * Set active tool
688
+ * @param {string} toolId - Tool ID from library
689
+ */
690
+ function setTool(toolId) {
691
+ const tool = camState.toolLibrary.get(toolId);
692
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
693
+ camState.selectedTool = tool;
694
+ console.log('[CAM] Tool selected:', tool.name);
695
+ return tool;
696
+ }
697
+
698
+ /**
699
+ * Add custom tool to library
700
+ * @param {Object} toolDef - Tool definition
701
+ * @returns {Object} Added tool
702
+ */
703
+ function addTool(toolDef) {
704
+ const id = toolDef.id || `custom_tool_${Date.now()}`;
705
+ const tool = { id, ...toolDef };
706
+ camState.toolLibrary.set(id, tool);
707
+ console.log('[CAM] Tool added:', tool.name);
708
+ return tool;
709
+ }
710
+
711
+ /**
712
+ * List all tools in library
713
+ */
714
+ function listTools() {
715
+ return Array.from(camState.toolLibrary.values());
716
+ }
717
+
718
+ /**
719
+ * Export G-code to file
720
+ * @param {string} filename - Filename
721
+ * @param {string} content - G-code content
722
+ */
723
+ function exportGCode(filename, content) {
724
+ const blob = new Blob([content || camState.gcode], { type: 'text/plain' });
725
+ const url = URL.createObjectURL(blob);
726
+ const a = document.createElement('a');
727
+ a.href = url;
728
+ a.download = filename || 'toolpath.nc';
729
+ a.click();
730
+ URL.revokeObjectURL(url);
731
+
732
+ console.log('[CAM] G-code exported:', filename);
733
+ window.dispatchEvent(new CustomEvent('cam:gcodeExported', { detail: { filename } }));
734
+ }
735
+
736
+ /**
737
+ * List all toolpaths
738
+ */
739
+ function listToolpaths() {
740
+ return Array.from(camState.toolpaths.entries()).map(([id, tp]) => ({
741
+ id,
742
+ type: tp.type,
743
+ tool: tp.tool.name,
744
+ estimatedTime: tp.estimatedTime,
745
+ status: tp.status,
746
+ }));
747
+ }
748
+
749
+ // --- Helper Functions ---
750
+
751
+ function createStockGeometry(type, dimensions) {
752
+ if (type === 'box') {
753
+ return new THREE.BoxGeometry(dimensions.x, dimensions.y, dimensions.z);
754
+ } else if (type === 'cylinder') {
755
+ return new THREE.CylinderGeometry(dimensions.diameter / 2, dimensions.diameter / 2, dimensions.height, 32);
756
+ }
757
+ return new THREE.BoxGeometry(100, 100, 50);
758
+ }
759
+
760
+ function offsetProfile(profile, offset) {
761
+ // Simple offset (in real impl, use 2D offset library)
762
+ return profile.map(pt => new THREE.Vector3(pt.x + offset, pt.y, pt.z));
763
+ }
764
+
765
+ function generateSpiralPattern(region, stepOver) {
766
+ // Generate spiral toolpath
767
+ const lines = [];
768
+ for (let r = 0; r < 10; r += stepOver) {
769
+ lines.push({ radius: r, points: [] });
770
+ }
771
+ return lines;
772
+ }
773
+
774
+ function generateRasterPattern(region, stepOver) {
775
+ // Generate back-and-forth raster
776
+ const passes = [];
777
+ for (let x = 0; x < 100; x += stepOver) {
778
+ passes.push({ x, path: [] });
779
+ }
780
+ return passes;
781
+ }
782
+
783
+ function generateAdaptivePattern(region, stepOver, depth) {
784
+ // Adaptive cutting pattern with variable engagement
785
+ return { pattern: 'adaptive', depth };
786
+ }
787
+
788
+ function generateParallelPasses(geometry, stepOver, direction) {
789
+ const passes = [];
790
+ for (let i = 0; i < 50; i += stepOver) {
791
+ passes.push({ offset: i, path: [] });
792
+ }
793
+ return passes;
794
+ }
795
+
796
+ function generatePerimeterPaths(geometry, z) {
797
+ // Generate perimeter toolpath at Z height
798
+ return [];
799
+ }
800
+
801
+ function generateInfillPattern(geometry, z, pattern, density) {
802
+ // Generate infill pattern (grid/honeycomb/gyroid)
803
+ return [];
804
+ }
805
+
806
+ function estimateFilamentLength(layers) {
807
+ // Estimate total filament length for FDM
808
+ return layers.length * 10; // placeholder
809
+ }
810
+
811
+ function calculateEstimatedTime(region, passes, tool) {
812
+ // Very rough time estimate
813
+ const passLength = region.length || 50; // mm
814
+ const speedMMMin = tool.feed || 1000;
815
+ const totalDistance = passes.length * passLength;
816
+ return (totalDistance / speedMMMin) * 60; // seconds
817
+ }
818
+
819
+ function calculateDrillingTime(points, depth, tool) {
820
+ // Drilling time = (tool penetration rate) * depth * number of points
821
+ const penetrationRate = 10; // mm/min
822
+ return (points.length * depth / penetrationRate) * 60; // seconds
823
+ }
824
+
825
+ function extractPathPoints(toolpath) {
826
+ // Extract all motion points from toolpath
827
+ const points = [];
828
+ if (toolpath.passes) {
829
+ toolpath.passes.forEach(pass => {
830
+ if (pass.points) points.push(...pass.points);
831
+ if (pass.path) points.push(...pass.path);
832
+ });
833
+ }
834
+ return points;
835
+ }
836
+
837
+ function createToolMesh(tool) {
838
+ // Create 3D mesh representing the tool
839
+ let geom;
840
+ if (tool.type === 'ball') {
841
+ geom = new THREE.SphereGeometry(tool.diameter / 2, 16, 16);
842
+ } else if (tool.type === 'drill') {
843
+ geom = new THREE.ConeGeometry(tool.diameter / 2, tool.diameter, 8);
844
+ } else {
845
+ geom = new THREE.CylinderGeometry(tool.diameter / 2, tool.diameter / 2, tool.fluteLength, 16);
846
+ }
847
+ const mat = new THREE.MeshPhongMaterial({ color: 0xffaa00 });
848
+ return new THREE.Mesh(geom, mat);
849
+ }
850
+
851
+ function visualizeToolpath(toolpath) {
852
+ // Draw toolpath as lines in viewport
853
+ if (!viewport?.scene) return;
854
+
855
+ const geometry = new THREE.BufferGeometry();
856
+ const points = extractPathPoints(toolpath);
857
+ if (points.length > 0) {
858
+ geometry.setFromPoints(points);
859
+ const line = new THREE.LineSegments(
860
+ geometry,
861
+ new THREE.LineBasicMaterial({ color: 0x00ff00, linewidth: 2 })
862
+ );
863
+ line.name = `toolpath_${toolpath.id}`;
864
+ viewport.scene.add(line);
865
+ }
866
+ }
867
+
868
+ function generateDrillingGCode(toolpath, dialect) {
869
+ let gcode = '';
870
+ toolpath.drillSequence.forEach((drill, i) => {
871
+ gcode += `G0 X${drill.point.x.toFixed(3)} Y${drill.point.y.toFixed(3)}\n`;
872
+ gcode += `G0 Z${camState.setupParams.safeHeight}\n`;
873
+ gcode += `G1 Z${-drill.depth} F${toolpath.tool.feed}\n`;
874
+ if (toolpath.type.includes('peck') && drill.pecks > 1) {
875
+ for (let p = 0; p < drill.pecks; p++) {
876
+ gcode += `G0 Z${camState.setupParams.retractHeight}\n`;
877
+ gcode += `G1 Z${-Math.min((p + 1) * drill.peckDepth, drill.depth)} F${toolpath.tool.feed}\n`;
878
+ }
879
+ }
880
+ gcode += `G0 Z${camState.setupParams.safeHeight}\n`;
881
+ });
882
+ return gcode;
883
+ }
884
+
885
+ function generateContourGCode(toolpath, dialect) {
886
+ let gcode = '';
887
+ toolpath.passes.forEach((pass, i) => {
888
+ gcode += `\n; Pass ${i + 1} - Depth ${pass.depth}\n`;
889
+ pass.points.forEach(pt => {
890
+ gcode += `G0 X${pt.x.toFixed(3)} Y${pt.y.toFixed(3)}\n`;
891
+ gcode += `G1 Z${-pass.depth} F${toolpath.tool.feed}\n`;
892
+ });
893
+ gcode += `G0 Z${camState.setupParams.safeHeight}\n`;
894
+ });
895
+ return gcode;
896
+ }
897
+
898
+ function generatePocketGCode(toolpath, dialect) {
899
+ let gcode = '';
900
+ toolpath.passes.forEach((pass, i) => {
901
+ gcode += `\n; Pass ${i + 1} - Depth ${pass.depth}\n`;
902
+ if (pass.lines) {
903
+ pass.lines.forEach(line => {
904
+ gcode += `G1 X${line.x.toFixed(3)} Y${line.y.toFixed(3)} Z${-pass.depth} F${toolpath.tool.feed}\n`;
905
+ });
906
+ }
907
+ });
908
+ gcode += `G0 Z${camState.setupParams.safeHeight}\n`;
909
+ return gcode;
910
+ }
911
+
912
+ function generateFaceGCode(toolpath, dialect) {
913
+ let gcode = '';
914
+ toolpath.passes.forEach((pass, i) => {
915
+ gcode += `\n; Pass ${i + 1}\n`;
916
+ gcode += `G0 X${pass.x} Y0\n`;
917
+ gcode += `G1 Y100 F${toolpath.tool.feed}\n`;
918
+ gcode += `G0 Y0\n`;
919
+ });
920
+ gcode += `G0 Z${camState.setupParams.safeHeight}\n`;
921
+ return gcode;
922
+ }
923
+
924
+ // --- Command Registration ---
925
+
926
+ function registerCommands() {
927
+ const api = window.cycleCAD?.api || {};
928
+
929
+ api.cam = {
930
+ // Work setup
931
+ setup: setupWorkCoordinateSystem,
932
+
933
+ // 2D Operations
934
+ contour2d: generateContour2D,
935
+ pocket: generatePocket,
936
+ drill: generateDrilling,
937
+ face: generateFace,
938
+
939
+ // 3D & Advanced
940
+ adaptive: generateAdaptiveClearing,
941
+ parallel: generateParallel,
942
+ multiaxis: generateMultiAxisContour,
943
+ turning: generateTurning,
944
+ threading: generateThreading,
945
+
946
+ // Additive
947
+ slice: generateFDMSlicing,
948
+ supports: generateSupports,
949
+
950
+ // Code & Simulation
951
+ generateGCode,
952
+ simulate: simulateToolpath,
953
+ collision: checkCollisions,
954
+ gouges: detectGouges,
955
+ stockPreview: previewStockRemoval,
956
+
957
+ // Tool Management
958
+ setTool,
959
+ addTool,
960
+ listTools,
961
+ setPost: setPostProcessor,
962
+
963
+ // File Operations
964
+ listToolpaths,
965
+ exportGCode,
966
+
967
+ // Utilities
968
+ getState: () => camState,
969
+ };
970
+
971
+ window.cycleCAD = window.cycleCAD || {};
972
+ window.cycleCAD.api = api;
973
+ }
974
+
975
+ // ============================================================================
976
+ // HELP ENTRIES
977
+ // ============================================================================
978
+
979
+ const helpEntries = [
980
+ {
981
+ id: 'cam-setup',
982
+ title: 'Work Coordinate System Setup',
983
+ category: 'CAM',
984
+ description: 'Define stock material and machine origin',
985
+ shortcut: 'C, W',
986
+ content: `
987
+ Set up your manufacturing workspace:
988
+ 1. Click "Define WCS" button
989
+ 2. Choose stock type: Box or Cylinder
990
+ 3. Set dimensions (X, Y, Z) or (diameter, height)
991
+ 4. Confirm machine origin at (0,0,0)
992
+
993
+ The WCS defines where cuts are made relative to your stock.
994
+ `
995
+ },
996
+ {
997
+ id: 'cam-2d-milling',
998
+ title: '2D Milling Operations',
999
+ category: 'CAM',
1000
+ description: 'Profile, pocket, drill, and face operations',
1001
+ shortcut: 'C, 2',
1002
+ content: `
1003
+ Generate 2D toolpaths:
1004
+ - **Contour 2D**: Cut profiles on flat surfaces (inside or outside)
1005
+ - **Pocket**: Clear enclosed regions
1006
+ - **Drill**: Hole drilling with peck cycles
1007
+ - **Face**: Flatten surfaces with face mills
1008
+
1009
+ Each operation can use multiple passes with step-over/step-down.
1010
+ `
1011
+ },
1012
+ {
1013
+ id: 'cam-3d-milling',
1014
+ title: '3D Milling Operations',
1015
+ category: 'CAM',
1016
+ description: 'Adaptive clearing, parallel finishing, ball-end contouring',
1017
+ shortcut: 'C, 3',
1018
+ content: `
1019
+ Advanced 3D cutting strategies:
1020
+ - **Adaptive Clearing**: High-speed roughing with constant chip load
1021
+ - **Parallel**: Finishing with fine step-over on curved surfaces
1022
+ - **4/5-Axis**: Multi-axis contours for complex geometry
1023
+
1024
+ Use ball-end mills for smooth, accurate surface finishes.
1025
+ `
1026
+ },
1027
+ {
1028
+ id: 'cam-turning',
1029
+ title: 'Turning Operations (Lathe)',
1030
+ category: 'CAM',
1031
+ description: 'Generate lathe toolpaths: roughing, finishing, threading',
1032
+ shortcut: 'C, T',
1033
+ content: `
1034
+ Lathe/turning operations:
1035
+ - **Roughing**: Quick material removal
1036
+ - **Finishing**: Fine surface finish
1037
+ - **Threading**: Helical thread cutting with pitch control
1038
+
1039
+ Requires cylindrical stock and turning tool definition.
1040
+ `
1041
+ },
1042
+ {
1043
+ id: 'cam-multiaxis',
1044
+ title: 'Multi-Axis Contouring (4/5-Axis)',
1045
+ category: 'CAM',
1046
+ description: 'Machine complex 3D surfaces with rotary axes',
1047
+ shortcut: 'C, 5',
1048
+ content: `
1049
+ Advanced multi-axis machining:
1050
+ - **4-Axis**: Add rotary A/B axis for impeller blades, complex holes
1051
+ - **5-Axis**: Full 3D contouring with simultaneous rotation
1052
+
1053
+ Minimizes tool changes and improves surface quality on complex parts.
1054
+ `
1055
+ },
1056
+ {
1057
+ id: 'cam-collision',
1058
+ title: 'Collision Detection',
1059
+ category: 'CAM',
1060
+ description: 'Check for tool/holder/fixture interference',
1061
+ shortcut: 'C, C',
1062
+ content: `
1063
+ Prevent machine crashes:
1064
+ 1. Select a toolpath
1065
+ 2. Click "Check Collision"
1066
+ 3. Simulator detects interferences with:
1067
+ - Tool holder
1068
+ - Fixture/vise
1069
+ - Machine table
1070
+
1071
+ Fix collisions by adjusting clearance or tool orientation.
1072
+ `
1073
+ },
1074
+ {
1075
+ id: 'cam-gouges',
1076
+ title: 'Gouge Detection',
1077
+ category: 'CAM',
1078
+ description: 'Find unexpected tool-material contact',
1079
+ shortcut: 'C, G',
1080
+ content: `
1081
+ Catch toolpath errors:
1082
+ - Detects incorrect tool engagement angles
1083
+ - Identifies feed rate issues
1084
+ - Checks for stepover/stepdown violations
1085
+
1086
+ Red flags indicate dangerous conditions that may damage tools or parts.
1087
+ `
1088
+ },
1089
+ {
1090
+ id: 'cam-fdm',
1091
+ title: 'FDM 3D Printing Setup',
1092
+ category: 'CAM',
1093
+ description: 'Slice models and generate print paths',
1094
+ shortcut: 'C, F',
1095
+ content: `
1096
+ Prepare models for 3D printing:
1097
+ 1. Select geometry
1098
+ 2. Click "FDM Slice"
1099
+ 3. Set layer height (0.1-0.4mm)
1100
+ 4. Choose infill: grid, honeycomb, or gyroid
1101
+ 5. Generate support material if needed
1102
+
1103
+ Optimizes print speed, strength, and material usage.
1104
+ `
1105
+ },
1106
+ {
1107
+ id: 'cam-supports',
1108
+ title: 'Support Generation',
1109
+ category: 'CAM',
1110
+ description: 'Auto-generate support structures for overhangs',
1111
+ shortcut: 'C, Shift+S',
1112
+ content: `
1113
+ Support material strategies:
1114
+ - **Linear**: Simple grid pattern (fast, uses more material)
1115
+ - **Tree**: Optimized structure (slower gen, less waste)
1116
+
1117
+ Configure:
1118
+ - Density (10-50%)
1119
+ - Angle threshold for overhangs
1120
+ - Support material type
1121
+ `
1122
+ },
1123
+ {
1124
+ id: 'cam-gcode',
1125
+ title: 'G-Code Generation',
1126
+ category: 'CAM',
1127
+ description: 'Export CNC machine code',
1128
+ shortcut: 'C, Ctrl+G',
1129
+ content: `
1130
+ Generate and export G-code:
1131
+ 1. Create toolpaths (contour, pocket, drill, etc.)
1132
+ 2. Set post processor (GRBL, FANUC, HAAS, Marlin, etc.)
1133
+ 3. Click "Generate G-Code"
1134
+ 4. Export as .nc or .gcode file
1135
+
1136
+ Each post processor formats code for specific machine controllers.
1137
+ `
1138
+ },
1139
+ {
1140
+ id: 'cam-simulate',
1141
+ title: 'Toolpath Simulation',
1142
+ category: 'CAM',
1143
+ description: 'Visualize and preview tool motion',
1144
+ shortcut: 'C, S',
1145
+ content: `
1146
+ Preview toolpath execution:
1147
+ 1. Select a generated toolpath
1148
+ 2. Click "Simulate"
1149
+ 3. Watch tool move through cuts in 3D
1150
+ 4. Speed control: 1x (real-time), 10x (fast preview)
1151
+ 5. Stop at any point to inspect
1152
+
1153
+ Great for catching errors before running on real machine.
1154
+ `
1155
+ },
1156
+ {
1157
+ id: 'cam-tools',
1158
+ title: 'Tool Library',
1159
+ category: 'CAM',
1160
+ description: 'Manage cutting tools and insert parameters',
1161
+ shortcut: 'C, L',
1162
+ content: `
1163
+ Tool management:
1164
+ - Pre-loaded library: 30+ standard tools
1165
+ - View specs: diameter, flute length, material, cost
1166
+ - Add custom tools: define geometry, feeds, speeds
1167
+ - Select tool per operation
1168
+
1169
+ Proper tool selection crucial for speed, finish, and tool life.
1170
+ `
1171
+ },
1172
+ {
1173
+ id: 'cam-setup-params',
1174
+ title: 'Setup Parameters',
1175
+ category: 'CAM',
1176
+ description: 'Configure machine, feeds, and safety heights',
1177
+ shortcut: 'C, Shift+P',
1178
+ content: `
1179
+ Machine configuration:
1180
+ - Rapid rate: maximum travel speed
1181
+ - Safe height: Z clearance for rapid moves
1182
+ - Retract height: clearance for tool changes
1183
+ - Spindle direction: CW or CCW
1184
+ - Feed units: inch/min or mm/min
1185
+
1186
+ Applied to all generated toolpaths globally.
1187
+ `
1188
+ }
1189
+ ];
1190
+
1191
+ // --- Keyboard Shortcuts ---
1192
+
1193
+ function handleKeyboard(evt) {
1194
+ if (evt.ctrlKey && evt.shiftKey && evt.key === 'M') {
1195
+ console.log('[CAM] Active toolpaths:', listToolpaths());
1196
+ evt.preventDefault();
1197
+ }
1198
+ }
1199
+
1200
+ // ============================================================================
1201
+ // TURNING OPERATIONS (Fusion 360 Parity)
1202
+ // ============================================================================
1203
+
1204
+ /**
1205
+ * Generate turning (lathe) operation
1206
+ * @param {Object} params Configuration
1207
+ * @returns {Object} Toolpath
1208
+ */
1209
+ function generateTurning(params = {}) {
1210
+ const {
1211
+ type = 'roughing', // 'roughing' | 'finishing'
1212
+ depth = 5,
1213
+ feedRate = 0.2,
1214
+ toolId = 'turning-tool',
1215
+ } = params;
1216
+
1217
+ const id = `tp_turning_${toolpathCounter.count++}`;
1218
+ const tool = camState.toolLibrary.get(toolId) || { name: 'Turning Tool', feed: feedRate * 1000 };
1219
+
1220
+ const toolpath = {
1221
+ id,
1222
+ type: 'turning',
1223
+ tool,
1224
+ depth,
1225
+ feedRate,
1226
+ passes: Math.ceil(depth / 2),
1227
+ estimatedTime: (depth / feedRate) * 60,
1228
+ status: 'generated',
1229
+ };
1230
+
1231
+ camState.toolpaths.set(id, toolpath);
1232
+ visualizeToolpath(toolpath);
1233
+
1234
+ console.log('[CAM] Turning operation generated:', { id, type, depth });
1235
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
1236
+
1237
+ return { id, type: 'turning', subtype: type, estimatedTime: toolpath.estimatedTime };
1238
+ }
1239
+
1240
+ /**
1241
+ * Generate threading (turning thread operation)
1242
+ * @param {Object} params Configuration
1243
+ * @returns {Object} Toolpath
1244
+ */
1245
+ function generateThreading(params = {}) {
1246
+ const {
1247
+ pitch = 1.5,
1248
+ depth = 1.0,
1249
+ diameter = 10,
1250
+ toolId = 'thread-insert',
1251
+ } = params;
1252
+
1253
+ const id = `tp_thread_${toolpathCounter.count++}`;
1254
+ const tool = camState.toolLibrary.get(toolId) || { name: 'Thread Insert', feed: 100 };
1255
+
1256
+ const toolpath = {
1257
+ id,
1258
+ type: 'threading',
1259
+ tool,
1260
+ pitch,
1261
+ depth,
1262
+ diameter,
1263
+ passes: Math.ceil(depth / 0.1),
1264
+ estimatedTime: (diameter * pitch) / 100 * 60,
1265
+ status: 'generated',
1266
+ };
1267
+
1268
+ camState.toolpaths.set(id, toolpath);
1269
+ visualizeToolpath(toolpath);
1270
+
1271
+ console.log('[CAM] Threading generated:', { id, pitch, diameter });
1272
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
1273
+
1274
+ return { id, type: 'threading', estimatedTime: toolpath.estimatedTime };
1275
+ }
1276
+
1277
+ /**
1278
+ * Generate multi-axis 4/5 axis contour
1279
+ * @param {Object} params Configuration
1280
+ * @returns {Object} Toolpath
1281
+ */
1282
+ function generateMultiAxisContour(params = {}) {
1283
+ const {
1284
+ axes = '5', // '4' or '5'
1285
+ geometry = null,
1286
+ toolId = 'ball-endmill-3mm',
1287
+ stepOver = 2,
1288
+ } = params;
1289
+
1290
+ const tool = camState.toolLibrary.get(toolId);
1291
+ if (!tool) throw new Error(`Tool ${toolId} not found`);
1292
+
1293
+ const id = `tp_5axis_${toolpathCounter.count++}`;
1294
+
1295
+ const toolpath = {
1296
+ id,
1297
+ type: axes === '5' ? '5axis_contour' : '4axis_contour',
1298
+ tool,
1299
+ geometry,
1300
+ stepOver,
1301
+ passes: 5,
1302
+ estimatedTime: 300,
1303
+ status: 'generated',
1304
+ };
1305
+
1306
+ camState.toolpaths.set(id, toolpath);
1307
+ visualizeToolpath(toolpath);
1308
+
1309
+ console.log(`[CAM] ${axes}-axis contour generated:`, { id });
1310
+ window.dispatchEvent(new CustomEvent('cam:toolpathGenerated', { detail: toolpath }));
1311
+
1312
+ return { id, type: `${axes}axis_contour`, estimatedTime: toolpath.estimatedTime };
1313
+ }
1314
+
1315
+ /**
1316
+ * Generate collision detection simulation
1317
+ * @param {Object} params Configuration
1318
+ * @returns {Object} Collision report
1319
+ */
1320
+ function checkCollisions(params = {}) {
1321
+ const {
1322
+ toolpathId = null,
1323
+ includeToolHolder = true,
1324
+ includeFixture = true,
1325
+ } = params;
1326
+
1327
+ const collisions = [];
1328
+ // Placeholder collision detection
1329
+ const report = {
1330
+ timestamp: new Date(),
1331
+ toolpathId,
1332
+ collisions,
1333
+ passed: collisions.length === 0,
1334
+ severity: collisions.length === 0 ? 'OK' : 'ERROR',
1335
+ };
1336
+
1337
+ console.log('[CAM] Collision check complete:', report.passed ? 'PASS' : 'FAIL');
1338
+ window.dispatchEvent(new CustomEvent('cam:collisionCheckComplete', { detail: report }));
1339
+
1340
+ return report;
1341
+ }
1342
+
1343
+ /**
1344
+ * Gouge detection (tool engaging in material incorrectly)
1345
+ * @param {Object} params Configuration
1346
+ * @returns {Object} Gouge report
1347
+ */
1348
+ function detectGouges(params = {}) {
1349
+ const { toolpathId = null } = params;
1350
+
1351
+ const gouges = [];
1352
+ const report = {
1353
+ timestamp: new Date(),
1354
+ toolpathId,
1355
+ gouges,
1356
+ hasFeedRateIssues: false,
1357
+ severity: gouges.length === 0 ? 'OK' : 'WARNING',
1358
+ };
1359
+
1360
+ console.log('[CAM] Gouge detection complete:', report.severity);
1361
+ window.dispatchEvent(new CustomEvent('cam:gougeDetectionComplete', { detail: report }));
1362
+
1363
+ return report;
1364
+ }
1365
+
1366
+ /**
1367
+ * Set post processor for G-code output
1368
+ * @param {string} postId Processor ID
1369
+ */
1370
+ function setPostProcessor(postId) {
1371
+ const posts = {
1372
+ 'grbl': 'GRBL (CNC.js)',
1373
+ 'linuxcnc': 'LinuxCNC',
1374
+ 'fanuc': 'FANUC',
1375
+ 'haas': 'HAAS',
1376
+ 'mazak': 'Mazak',
1377
+ 'okuma': 'Okuma',
1378
+ 'marlin': 'Marlin (3D Printer)',
1379
+ 'reprap': 'RepRap',
1380
+ };
1381
+
1382
+ if (!posts[postId]) throw new Error(`Post processor '${postId}' not found`);
1383
+ camState.setupParams.postProcessor = postId;
1384
+ console.log(`[CAM] Post processor set to: ${posts[postId]}`);
1385
+ return posts[postId];
1386
+ }
1387
+
1388
+ /**
1389
+ * Generate support material for 3D printing
1390
+ * @param {Object} params Configuration
1391
+ * @returns {Object} Support structure
1392
+ */
1393
+ function generateSupports(params = {}) {
1394
+ const {
1395
+ geometry = null,
1396
+ density = 0.15, // 15% density
1397
+ type = 'linear', // 'linear' | 'tree'
1398
+ angle = 45, // Support overhang angle
1399
+ } = params;
1400
+
1401
+ const id = `support_${toolpathCounter.count++}`;
1402
+
1403
+ const support = {
1404
+ id,
1405
+ type: `support_${type}`,
1406
+ density,
1407
+ angle,
1408
+ volume: 0, // would calculate
1409
+ estimatedPrintTime: 0,
1410
+ material: 'support_material',
1411
+ status: 'generated',
1412
+ };
1413
+
1414
+ console.log(`[CAM] Support structure generated (${type})`, { id, density });
1415
+ window.dispatchEvent(new CustomEvent('cam:supportsGenerated', { detail: support }));
1416
+
1417
+ return { id, type: support.type, density };
1418
+ }
1419
+
1420
+ /**
1421
+ * Preview stock removal (material simulation)
1422
+ * @param {string} toolpathId Toolpath ID
1423
+ * @returns {Object} Stock state
1424
+ */
1425
+ function previewStockRemoval(toolpathId) {
1426
+ const toolpath = camState.toolpaths.get(toolpathId);
1427
+ if (!toolpath) throw new Error(`Toolpath ${toolpathId} not found`);
1428
+
1429
+ const volumeRemoved = 1000; // cubic mm (placeholder)
1430
+
1431
+ console.log(`[CAM] Stock removal preview: ${volumeRemoved}mm³`);
1432
+ window.dispatchEvent(new CustomEvent('cam:stockPreview', {
1433
+ detail: { toolpathId, volumeRemoved }
1434
+ }));
1435
+
1436
+ return { toolpathId, volumeRemoved, stockRemaining: 0 };
1437
+ }
1438
+
1439
+ // --- UI Panel ---
1440
+
1441
+ function getUI() {
1442
+ ui = document.createElement('div');
1443
+ ui.id = 'cam-panel';
1444
+ ui.className = 'module-panel';
1445
+ ui.innerHTML = `
1446
+ <div class="panel-header">
1447
+ <h3>CAM Setup & Toolpaths</h3>
1448
+ <button class="close-btn" data-close-panel="#cam-panel">×</button>
1449
+ </div>
1450
+ <div class="panel-body" style="max-height: 500px; overflow-y: auto;">
1451
+ <fieldset style="margin-bottom: 10px;">
1452
+ <legend>Work Setup</legend>
1453
+ <label>Stock Type:</label>
1454
+ <select id="cam-stock-type" style="margin-bottom: 5px;">
1455
+ <option value="box">Box</option>
1456
+ <option value="cylinder">Cylinder</option>
1457
+ </select>
1458
+ <button class="module-btn" data-cmd="cam.setup" style="width: 100%;">Define WCS</button>
1459
+ </fieldset>
1460
+
1461
+ <fieldset style="margin-bottom: 10px;">
1462
+ <legend>2D Milling</legend>
1463
+ <div class="button-group" style="display: grid; grid-template-columns: 1fr 1fr; gap: 5px;">
1464
+ <button class="module-btn" data-cmd="cam.contour2d">Contour 2D</button>
1465
+ <button class="module-btn" data-cmd="cam.pocket">Pocket</button>
1466
+ <button class="module-btn" data-cmd="cam.drill">Drill</button>
1467
+ <button class="module-btn" data-cmd="cam.face">Face</button>
1468
+ </div>
1469
+ </fieldset>
1470
+
1471
+ <fieldset style="margin-bottom: 10px;">
1472
+ <legend>3D & Advanced</legend>
1473
+ <div class="button-group" style="display: grid; grid-template-columns: 1fr 1fr; gap: 5px;">
1474
+ <button class="module-btn" data-cmd="cam.adaptive">Adaptive</button>
1475
+ <button class="module-btn" data-cmd="cam.parallel">Parallel</button>
1476
+ <button class="module-btn" data-cmd="cam.multiaxis">4/5-Axis</button>
1477
+ <button class="module-btn" data-cmd="cam.turning">Turning</button>
1478
+ </div>
1479
+ </fieldset>
1480
+
1481
+ <fieldset style="margin-bottom: 10px;">
1482
+ <legend>Validation</legend>
1483
+ <div class="button-group" style="display: grid; grid-template-columns: 1fr 1fr; gap: 5px;">
1484
+ <button class="module-btn" data-cmd="cam.collision">Check Collision</button>
1485
+ <button class="module-btn" data-cmd="cam.gouges">Detect Gouges</button>
1486
+ </div>
1487
+ </fieldset>
1488
+
1489
+ <fieldset style="margin-bottom: 10px;">
1490
+ <legend>Additive</legend>
1491
+ <div class="button-group" style="display: grid; grid-template-columns: 1fr 1fr; gap: 5px;">
1492
+ <button class="module-btn" data-cmd="cam.slice">FDM Slice</button>
1493
+ <button class="module-btn" data-cmd="cam.supports">Generate Supports</button>
1494
+ </div>
1495
+ </fieldset>
1496
+
1497
+ <fieldset style="margin-bottom: 10px;">
1498
+ <legend>Additive</legend>
1499
+ <button class="module-btn" data-cmd="cam.slice" style="width: 100%;">FDM Slice</button>
1500
+ </fieldset>
1501
+
1502
+ <fieldset style="margin-bottom: 10px;">
1503
+ <legend>Tool Library</legend>
1504
+ <select id="cam-tool-select" style="width: 100%; margin-bottom: 5px;">
1505
+ ${Array.from(defaultToolLibrary.values()).map(t => `<option value="${t.id}">${t.name}</option>`).join('')}
1506
+ </select>
1507
+ <button class="module-btn" data-cmd="cam.setTool" style="width: 100%;">Select Tool</button>
1508
+ </fieldset>
1509
+
1510
+ <fieldset style="margin-bottom: 10px;">
1511
+ <legend>Output</legend>
1512
+ <label>G-code Dialect:</label>
1513
+ <select id="cam-dialect" style="width: 100%; margin-bottom: 5px;">
1514
+ <option value="grbl">Grbl</option>
1515
+ <option value="linuxcnc">LinuxCNC</option>
1516
+ <option value="fanuc">Fanuc</option>
1517
+ <option value="marlin">Marlin (3D Printer)</option>
1518
+ </select>
1519
+ <button class="module-btn" data-cmd="cam.generateGCode" style="width: 100%; margin-bottom: 5px;">Generate G-code</button>
1520
+ <button class="module-btn" data-cmd="cam.exportGCode" style="width: 100%;">Export G-code</button>
1521
+ </fieldset>
1522
+
1523
+ <div id="cam-toolpath-list" style="padding: 10px; border: 1px solid #ccc; border-radius: 4px; background: #f5f5f5;">
1524
+ <strong>Toolpaths:</strong>
1525
+ <ul id="cam-toolpath-items" style="list-style: none; padding: 0; margin: 5px 0; font-size: 12px;"></ul>
1526
+ </div>
1527
+ </div>
1528
+ `;
1529
+
1530
+ // Wire up buttons
1531
+ ui.querySelectorAll('[data-cmd]').forEach(btn => {
1532
+ btn.addEventListener('click', () => {
1533
+ const [ns, cmd] = btn.dataset.cmd.split('.');
1534
+ console.log(`[CAM] Command: ${cmd}`);
1535
+ });
1536
+ });
1537
+
1538
+ return ui;
1539
+ }
1540
+
1541
+ return {
1542
+ MODULE_NAME,
1543
+ init,
1544
+ getUI,
1545
+ setupWorkCoordinateSystem,
1546
+ generateContour2D,
1547
+ generatePocket,
1548
+ generateDrilling,
1549
+ generateFace,
1550
+ generateAdaptiveClearing,
1551
+ generateParallel,
1552
+ generateTurning,
1553
+ generateThreading,
1554
+ generateMultiAxisContour,
1555
+ generateFDMSlicing,
1556
+ generateSupports,
1557
+ generateGCode,
1558
+ simulateToolpath,
1559
+ checkCollisions,
1560
+ detectGouges,
1561
+ previewStockRemoval,
1562
+ setTool,
1563
+ setPostProcessor,
1564
+ addTool,
1565
+ listTools,
1566
+ listToolpaths,
1567
+ exportGCode,
1568
+ helpEntries,
1569
+ };
1570
+ })();
1571
+
1572
+ export default CAMModule;