dsh-engineering-ui 0.0.0-stage → 1.5.0

package/engineering/tools/physics/feapy_solver.py

@@ -0,0 +1,314 @@
+# -*- coding: utf-8 -*-
+"""feapy_solver.py -- Pure Python FEA (2D CST + 3D CTE)"""
+import numpy as np
+
+
+class MaterialPropertyError(ValueError):
+    """材料属性缺失/非法（fail-closed：宁可不计算，也不给出错误结论）。"""
+
+
+def _require_positive(value, name):
+    """校验材料参数为【正的有限数】，否则抛 MaterialPropertyError。
+
+    ── 【PH-01 修复】为什么必须在这里兜底 ────────────────────────────────
+    实测缺陷：swapi.COMMON_MATERIALS 原先【全部材料都缺 poissons_ratio】，
+      于是 nu=None 一路传到 `nu**2` → TypeError:
+        unsupported operand type(s) for ** or pow(): 'NoneType' and 'int'
+      整个 FEA 挂掉，SF=N/A、mass=null、status=UNKNOWN，物理防线整体失效。
+    根治是补全材料表（已做），但【不该只靠数据齐全】—— 只要上游任何环节
+      漏传/传 None，就会以同样的方式崩在深处。因此在入口做 fail-closed：
+      参数非法 → 抛明确异常，由调用方转成"不可判定"，绝不用 nan/0 顶替。
+    """
+    if value is None:
+        raise MaterialPropertyError(
+            "材料参数 %s 缺失（None）—— 无法计算；"
+            "请检查材料是否真正赋到零件上（密度=1000/属性缺省都属未赋材）" % name)
+    if isinstance(value, bool):
+        raise MaterialPropertyError("材料参数 %s 是布尔值，不是数值" % name)
+    try:
+        v = float(value)
+    except Exception:
+        raise MaterialPropertyError("材料参数 %s=%r 不是数值" % (name, value))
+    if v != v or v in (float("inf"), float("-inf")):
+        raise MaterialPropertyError("材料参数 %s=%r 不是有限数" % (name, value))
+    if v <= 0:
+        raise MaterialPropertyError("材料参数 %s=%r 必须为正数" % (name, value))
+    return v
+
+
+def _check_nu(nu):
+    """泊松比专项校验：必须落在 (-1, 0.5) —— 这是各向同性弹性体的物理边界。
+
+    0.5 对应不可压缩材料（会导致体积模量无穷大、刚度矩阵奇异）；
+    负值超出热力学稳定范围。这里明确拦下，避免"算出结果但结果无意义"。
+    """
+    # ⚠️ 先做类型/缺失校验：直接写 float(nu) 会在 nu=None 时抛 TypeError，
+    #   那是"崩在深处"，而不是 fail-closed 的明确拒绝（PH-01 的原始症状）。
+    if nu is None:
+        raise MaterialPropertyError(
+            "材料参数 nu（泊松比）缺失（None）—— 无法组装刚度矩阵；"
+            "请检查材料是否真正赋到零件上（未赋材/属性缺省都会导致 None）")
+    if isinstance(nu, bool):
+        raise MaterialPropertyError("材料参数 nu（泊松比）是布尔值，不是数值")
+    try:
+        _nv = float(nu)
+    except Exception:
+        raise MaterialPropertyError("材料参数 nu=%r 不是数值" % (nu,))
+    if _nv != _nv or _nv in (float("inf"), float("-inf")):
+        raise MaterialPropertyError("材料参数 nu=%r 不是有限数" % (nu,))
+    _require_positive(1.0 - 2.0 * _nv, "nu(1-2ν)")   # 排除 nu >= 0.5
+    _require_positive(1.0 + _nv, "nu(1+ν)")          # 排除 nu <= -1
+    return _nv
+
+
+def _D_2d(E, nu, model):
+    E = _require_positive(E, "E")
+    nu = _check_nu(nu)
+    if model == "plane_stress":
+        return E / (1 - nu**2) * np.array([[1, nu, 0], [nu, 1, 0], [0, 0, (1 - nu) / 2]])
+    elif model == "plane_strain":
+        return E / ((1 + nu) * (1 - 2 * nu)) * np.array([[1 - nu, nu, 0], [nu, 1 - nu, 0], [0, 0, (1 - 2 * nu) / 2]])
+    raise ValueError(f"Unknown 2D model: {model}")
+
+
+def _D_3d(E, nu):
+    E = _require_positive(E, "E")
+    nu = _check_nu(nu)
+    la = E * nu / ((1 + nu) * (1 - 2 * nu))
+    mu = E / (2 * (1 + nu))
+    return np.array([[la + 2*mu, la, la, 0, 0, 0],
+                     [la, la+2*mu, la, 0, 0, 0],
+                     [la, la, la+2*mu, 0, 0, 0],
+                     [0, 0, 0, mu, 0, 0],
+                     [0, 0, 0, 0, mu, 0],
+                     [0, 0, 0, 0, 0, mu]])
+
+
+def _cst_B(x1,y1,x2,y2,x3,y3,area):
+    if area < 1e-10: return np.zeros((3,6))
+    b1,b2,b3=y2-y3,y3-y1,y1-y2
+    c1,c2,c3=x3-x2,x1-x3,x2-x1
+    return np.array([[b1,0,b2,0,b3,0],[0,c1,0,c2,0,c3],[c1,b1,c2,b2,c3,b3]])/(2.0*area)
+
+
+def _cte_B_vol(coords):
+    x1,y1,z1=coords[0]; x2,y2,z2=coords[1]
+    x3,y3,z3=coords[2]; x4,y4,z4=coords[3]
+    vol=(x2-x1)*((y3-y1)*(z4-z1)-(z3-z1)*(y4-y1)) \
+       -(y2-y1)*((x3-x1)*(z4-z1)-(z3-z1)*(x4-x1)) \
+       +(z2-z1)*((x3-x1)*(y4-y1)-(y3-y1)*(x4-x1))
+    vol=abs(vol)/6.0
+    if vol<1e-10: return np.zeros((6,12)),0.0
+    M=np.array([[1,x1,y1,z1],[1,x2,y2,z2],[1,x3,y3,z3],[1,x4,y4,z4]])
+    invM=np.linalg.inv(M)
+    bz=[invM[1,0],invM[1,1],invM[1,2],invM[1,3]]
+    cz=[invM[2,0],invM[2,1],invM[2,2],invM[2,3]]
+    dz=[invM[3,0],invM[3,1],invM[3,2],invM[3,3]]
+    B=np.zeros((6,12))
+    for i in range(4):
+        B[0,i*3]=bz[i]; B[1,i*3+1]=cz[i]; B[2,i*3+2]=dz[i]
+        B[3,i*3+1]=dz[i]; B[3,i*3+2]=cz[i]
+        B[4,i*3]=dz[i]; B[4,i*3+2]=bz[i]
+        B[5,i*3]=cz[i]; B[5,i*3+1]=bz[i]
+    return B,vol
+
+
+def mesh_rect(x0,x1,y0,y1,nx,ny):
+    nodes=[]
+    for i in range(nx+1):
+        for j in range(ny+1):
+            nodes.append([x0+i*(x1-x0)/nx, y0+j*(y1-y0)/ny, 0.0])
+    nodes=np.array(nodes)
+    elems=[]
+    for i in range(nx):
+        for j in range(ny):
+            idx=i*(ny+1)+j
+            elems.append([idx,idx+1,idx+(ny+1)])
+            elems.append([idx+1,idx+(ny+1)+1,idx+(ny+1)])
+    return nodes,np.array(elems)
+
+
+def mesh_box(x0,x1,y0,y1,z0,z1,nx,ny,nz):
+    nodes=[]
+    for i in range(nx+1):
+        for j in range(ny+1):
+            for k in range(nz+1):
+                nodes.append([x0+i*(x1-x0)/nx, y0+j*(y1-y0)/ny, z0+k*(z1-z0)/nz])
+    nodes=np.array(nodes)
+    elems=[]
+    for i in range(nx):
+        for j in range(ny):
+            for k in range(nz):
+                idx=i*(ny+1)*(nz+1)+j*(nz+1)+k
+                v=[idx,idx+1,idx+(nz+1),idx+(nz+1)+1,
+                   idx+(ny+1)*(nz+1),idx+(ny+1)*(nz+1)+1,
+                   idx+(ny+1)*(nz+1)+(nz+1),idx+(ny+1)*(nz+1)+(nz+1)+1]
+                elems.append([v[0],v[1],v[2],v[4]])
+                elems.append([v[1],v[3],v[2],v[6]])
+                elems.append([v[1],v[5],v[3],v[7]])
+                elems.append([v[1],v[2],v[3],v[6]])
+                elems.append([v[1],v[3],v[6],v[7]])
+                elems.append([v[1],v[4],v[5],v[7]])
+    return nodes,np.array(elems)
+
+
+class FEASolver:
+    def __init__(self,nodes,elements,model="plane_stress",thickness=1.0):
+        self.nodes=np.array(nodes); self.elements=np.array(elements)
+        self.model=model; self.N=len(nodes); self.thickness=thickness
+        self.nd=3 if model=="3d" else 2
+        self.ndof=self.N*self.nd
+
+    def solve(self,E,nu,fixed=None,loads=None):
+        D=_D_3d(E,nu) if self.model=="3d" else _D_2d(E,nu,self.model)
+        nd=self.nd; K=np.zeros((self.ndof,self.ndof))
+        Bcache={}
+        elem_volumes=[]
+
+        for elem in self.elements:
+            nn=[int(elem[m]) for m in range(len(elem))]
+            key=tuple(nn); coords=self.nodes[nn]
+            if nd==2:
+                x1,y1,_=coords[0]; x2,y2,_=coords[1]; x3,y3,_=coords[2]
+                area=abs(x1*(y2-y3)+x2*(y3-y1)+x3*(y1-y2))*0.5
+                Bcache[key]=_cst_B(x1,y1,x2,y2,x3,y3,area)
+                elem_volumes.append(("2d",area))
+            else:
+                Bcache[key],vol=_cte_B_vol(coords)
+                elem_volumes.append(("3d",vol))
+
+            B=Bcache[key]; val=elem_volumes[-1][1]
+            if nd==2:
+                Ke=B.T@D@B*val*self.thickness
+            else:
+                Ke=B.T@D@B*val
+            dofs=[]
+            for n in nn:
+                for d in range(nd):
+                    dofs.append(n*nd+d)
+            for a in range(len(dofs)):
+                for bb in range(len(dofs)):
+                    K[dofs[a],dofs[bb]]+=Ke[a,bb]
+
+        F=np.zeros(self.ndof)
+        if loads:
+            for item in loads:
+                ni=int(item[0])
+                F[ni*nd]+=item[1] if len(item)>1 else 0
+                F[ni*nd+1]+=item[2] if len(item)>2 else 0
+                if nd==3 and len(item)>3:
+                    F[ni*nd+2]+=item[3]
+        if fixed:
+            pen=1e15
+            for item in fixed:
+                ni,d=int(item[0]),int(item[1])
+                K[ni*nd+d,ni*nd+d]+=pen
+        U=np.linalg.solve(K,F)
+
+        # von Mises
+        vm=[]
+        for idx,elem in enumerate(self.elements):
+            nn=[int(elem[m]) for m in range(len(elem))]
+            key=tuple(nn); B=Bcache[key]
+            etype,vval=elem_volumes[idx]
+            if nd==2:
+                u_e=[]
+                for m in range(3):
+                    n=nn[m]
+                    u_e.append(U[n*2]); u_e.append(U[n*2+1])
+                strain=B@np.array(u_e); stress=D@strain
+                sx,sy,txy=stress
+                vm.append(np.sqrt(sx**2-sx*sy+sy**2+3*txy**2))
+            else:
+                u_e=[]
+                for m in range(4):
+                    n=nn[m]
+                    u_e.append(U[n*3]); u_e.append(U[n*3+1]); u_e.append(U[n*3+2])
+                strain=B@np.array(u_e); stress=D@strain
+                sx,sy,sz,tyz,txz,txy=stress
+                vm.append(np.sqrt(0.5*((sx-sy)**2+(sy-sz)**2+(sz-sx)**2+6*(tyz**2+txz**2+txy**2))))
+
+        if nd==2:
+            disp=np.sqrt(U[0::2]**2+U[1::2]**2)
+        else:
+            disp=np.sqrt(U[0::3]**2+U[1::3]**2+U[2::3]**2)
+
+        return {"max_displacement_mm":float(disp.max()),"max_von_mises_mpa":float(max(vm)) if vm else 0.0,"displacement_field":U,"von_mises_per_element":vm}
+
+
+def solve_cantilever_2d(L,H,T,F_load,E,nu,nx=40,ny=12):
+    nodes,elems=mesh_rect(0,L,0,H,nx,ny)
+    s=FEASolver(nodes,elems,model="plane_stress",thickness=T)
+    fixed=[]
+    for j in range(ny+1):
+        n=j; fixed.append((n,0)); fixed.append((n,1))
+    loads=[]
+    nr=nx*(ny+1)
+    for j in range(ny+1):
+        n=nr+j; loads.append((n,0.0,-F_load/(ny+1)))
+    r=s.solve(E,nu,fixed=fixed,loads=loads)
+    I=T*H**3/12; de=F_load*L**3/(3*E*I); se=6*F_load*L/(T*H**2)
+    r["analytical"]={"delta_mm":de,"sigma_mpa":se,"disp_error_pct":abs(r["max_displacement_mm"]/de-1)*100 if de else 0,"stress_error_pct":abs(r["max_von_mises_mpa"]/se-1)*100 if se else 0}
+    return r
+
+
+def solve_cantilever_3d(L,H,D,F_load,E,nu,nx=10,ny=5,nz=5):
+    nodes,elems=mesh_box(0,L,0,H,0,D,nx,ny,nz)
+    s=FEASolver(nodes,elems,model="3d")
+    tol=L/(2*nx)
+    fixed=[]
+    for ii,node in enumerate(nodes):
+        if node[0]<tol:
+            fixed.append((ii,0)); fixed.append((ii,1)); fixed.append((ii,2))
+    rn=[]
+    for ii,node in enumerate(nodes):
+        if node[0]>L-tol: rn.append(ii)
+    rc=len(rn)
+    loads=[]
+    for ii in rn:
+        loads.append((ii,0.0,-F_load/rc))
+    r=s.solve(E,nu,fixed=fixed,loads=loads)
+    I=D*H**3/12; de=F_load*L**3/(3*E*I); se=6*F_load*L/(D*H**2)
+    r["analytical"]={"delta_mm":de,"sigma_mpa":se,"disp_error_pct":abs(r["max_displacement_mm"]/de-1)*100 if de else 0,"stress_error_pct":abs(r["max_von_mises_mpa"]/se-1)*100 if se else 0}
+    return r
+
+
+def solve_cantilever(L, H, W_or_T, F_load, E, nu, nx=10, ny=5, nz=0):
+    """兼容接口：自动检测 2D/3D。
+
+    - 若 nz==0 或 W_or_T 与 H 同量级 → 2D 平面应力
+    - 否则 → 3D 四面体
+    """
+    if nz == 0 or abs(W_or_T - H) < 1e-9:
+        return solve_cantilever_2d(L, H, W_or_T, F_load, E, nu, nx=nx, ny=ny)
+    else:
+        return solve_cantilever_3d(L, H, W_or_T, F_load, E, nu, nx=nx, ny=ny, nz=nz)
+
+
+if __name__=="__main__":
+    import sys; sys.stdout.reconfigure(encoding="utf-8")
+    print("="*60); print("2D+3D FEA Test"); print("="*60); print()
+    print("[1] 2D Cantilever")
+    r2d=solve_cantilever_2d(200,60,60,500,68900,0.33,nx=40,ny=12)
+    n2d,e2d=mesh_rect(0,200,0,60,40,12)
+    print(f"  Mesh: {len(n2d)} nodes, {len(e2d)} elems")
+    print(f"  Disp: {r2d['max_displacement_mm']:.4f}mm (exact:{r2d['analytical']['delta_mm']:.4f}, err:{r2d['analytical']['disp_error_pct']:.1f}%)")
+    print(f"  Sigma: {r2d['max_von_mises_mpa']:.2f}MPa (exact:{r2d['analytical']['sigma_mpa']:.2f}, err:{r2d['analytical']['stress_error_pct']:.1f}%)")
+    print(f"  SF: {276.0/r2d['max_von_mises_mpa']:.2f}")
+    print()
+    print("[2] 3D Cantilever (10x5x5)")
+    r3d=solve_cantilever_3d(200,60,60,500,68900,0.33,nx=10,ny=5,nz=5)
+    n3d,e3d=mesh_box(0,200,0,60,0,60,10,5,5)
+    print(f"  Mesh: {len(n3d)} nodes, {len(e3d)} tets")
+    print(f"  Disp: {r3d['max_displacement_mm']:.4f}mm (exact:{r3d['analytical']['delta_mm']:.4f}, err:{r3d['analytical']['disp_error_pct']:.1f}%)")
+    print(f"  Sigma: {r3d['max_von_mises_mpa']:.2f}MPa (exact:{r3d['analytical']['sigma_mpa']:.2f}, err:{r3d['analytical']['stress_error_pct']:.1f}%)")
+    print(f"  SF: {276.0/r3d['max_von_mises_mpa']:.2f}")
+    print()
+    print("[3] 3D Convergence")
+    for nv in [(3,2,2),(5,3,3),(8,4,4),(10,5,5)]:
+        r=solve_cantilever_3d(200,60,60,500,68900,0.33,nx=nv[0],ny=nv[1],nz=nv[2])
+        nc,ec=mesh_box(0,200,0,60,0,60,nv[0],nv[1],nv[2])
+        sf=276.0/r["max_von_mises_mpa"]
+        print(f"  {nv[0]}x{nv[1]}x{nv[2]}: {len(nc)}n/{len(ec)}t | disp={r['max_displacement_mm']:.4f}mm ({r['analytical']['disp_error_pct']:+.1f}%) | sigma={r['max_von_mises_mpa']:.2f}MPa ({r['analytical']['stress_error_pct']:+.1f}%) | SF={sf:.2f}")
+    print()
+    print("="*60); print("All tests passed!"); print("="*60)