formulab 0.1.0 → 0.5.0

package/dist/metal/types.d.ts

@@ -2,17 +2,28 @@
  * Metal Weight Types
  */
 export type MetalShape = 'plate' | 'round' | 'pipe' | 'angle';
-export interface MetalWeightInput {
-    shape: MetalShape;
+export type MaterialName = 'steel' | 'stainless304' | 'aluminum' | 'copper' | 'brass' | 'titanium';
+interface MetalWeightBase {
     length: number;
-    materialName: string;
-    width?: number;
-    thickness?: number;
-    diameter?: number;
-    outerDiameter?: number;
-    innerDiameter?: number;
-    height?: number;
+    materialName: MaterialName;
 }
+export type MetalWeightInput = MetalWeightBase & ({
+    shape: 'plate';
+    width: number;
+    thickness: number;
+} | {
+    shape: 'round';
+    diameter: number;
+} | {
+    shape: 'pipe';
+    outerDiameter: number;
+    innerDiameter: number;
+} | {
+    shape: 'angle';
+    width: number;
+    height: number;
+    thickness: number;
+});
 export interface MetalWeightResult {
     weight: number;
     volume: number;
@@ -83,19 +94,28 @@ export interface PressTonnageInput {
     dieOpening?: number;
     bendType?: BendType;
     punchDiameter?: number;
+    blankDiameter?: number;
     drawRatio?: number;
+    frictionCoefficient?: number;
+    blankHolderPressure?: number;
+    dieRadius?: number;
+    reductionPercent?: number;
     operations?: PressOperation[];
 }
 export interface PressTonnageResult {
     blankingForce: number;
     bendingForce: number;
     drawingForce: number;
+    blankHolderForce: number;
     totalForce: number;
     recommendedPress: number;
+    drawRatio: number;
+    numberOfDraws: number;
     breakdown: {
         operation: string;
         force: number;
     }[];
+    warnings: string[];
 }
 /**
  * Bearing Types
@@ -117,15 +137,19 @@ export interface BearingResult {
  */
 export type BoltCalculationMode = 'torqueToPreload' | 'preloadToTorque';
 export type LubricationCondition = 'dry' | 'oiled' | 'moly' | 'ptfe' | 'custom';
-export interface BoltInput {
-    mode: BoltCalculationMode;
+interface BoltBase {
     diameter: number;
     pitch: number;
-    torque?: number;
-    preload?: number;
     kFactor: number;
     tensileStrength: number;
 }
+export type BoltInput = BoltBase & ({
+    mode: 'torqueToPreload';
+    torque: number;
+} | {
+    mode: 'preloadToTorque';
+    preload: number;
+});
 export interface BoltResult {
     torque: number;
     preload: number;
@@ -453,9 +477,13 @@ export interface WeldHeatResult {
     heatInput: number;
     efficiency: number;
     carbonEquivalent: number;
+    carbonEquivalentPcm: number;
+    coolingTime_t85: number;
+    coolingRate: number;
     preheatTemp: {
         min: number;
         max: number;
+        source: string;
     };
     interpassTemp: {
         min: number;
@@ -463,6 +491,7 @@ export interface WeldHeatResult {
     };
     hazHardnessMax: number;
     crackingRisk: CrackingRisk;
+    hydrogenLevel: 'low' | 'medium' | 'high';
     recommendations: string[];
 }
 /**
@@ -491,4 +520,62 @@ export interface WeldingResult {
     };
     notes: string[];
 }
+/**
+ * Material Grade Converter Types
+ */
+export type MaterialStandard = 'ASTM' | 'EN' | 'JIS' | 'GB' | 'KS';
+export interface MaterialGradeConverterInput {
+    standard: MaterialStandard;
+    grade: string;
+}
+export interface MaterialGradeConverterResult {
+    astm: string | null;
+    en: string | null;
+    jis: string | null;
+    gb: string | null;
+    ks: string | null;
+    category: string;
+    notes: string;
+}
+/**
+ * Pipe Spec Types
+ */
+export type PipeStandard = 'ANSI' | 'DN';
+export type PipeSchedule = 'SCH5' | 'SCH10' | 'SCH40' | 'SCH80' | 'SCH160' | 'XXS';
+export interface PipeSpecInput {
+    standard: PipeStandard;
+    nominalSize: string;
+    schedule: PipeSchedule;
+}
+export interface PipeSpecResult {
+    nominalSize: string;
+    outerDiameter: number;
+    wallThickness: number;
+    innerDiameter: number;
+    weightPerMeter: number;
+    crossSectionArea: number;
+    internalArea: number;
+}
+/**
+ * Flange Spec Types
+ */
+export type FlangeStandard = 'ASME_B16_5' | 'EN_1092_1';
+export type PressureClass = '150' | '300' | '600' | '900' | '1500' | '2500';
+export interface FlangeSpecInput {
+    standard: FlangeStandard;
+    pressureClass: PressureClass;
+    nominalSize: string;
+}
+export interface FlangeSpecResult {
+    nominalSize: string;
+    pressureClass: string;
+    outerDiameter: number;
+    thickness: number;
+    boltCircleDiameter: number;
+    boltHoles: number;
+    boltSize: string;
+    raisedFaceDiameter: number;
+    weight: number;
+}
+export {};
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package/dist/metal/types.d.ts.map

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package/dist/metal/vibration.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"vibration.d.ts","sourceRoot":"","sources":["../../src/metal/vibration.ts"],"names":[],"mappings":"AAAA,OAAO,KAAK,EAAE,cAAc,EAAE,eAAe,EAAoC,MAAM,YAAY,CAAC;AAuBpG;;GAEG;AACH,wBAAgB,SAAS,CAAC,KAAK,EAAE,cAAc,GAAG,eAAe,CA+IhE"}
+{"version":3,"file":"vibration.d.ts","sourceRoot":"","sources":["../../src/metal/vibration.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,cAAc,EAAE,eAAe,EAAoC,MAAM,YAAY,CAAC;AAuBpG;;GAEG;AACH,wBAAgB,SAAS,CAAC,KAAK,EAAE,cAAc,GAAG,eAAe,CA+IhE"}

package/dist/metal/vibration.js

@@ -1,3 +1,4 @@
+import { roundTo } from '../utils.js';
 const VIBRATION_MATERIALS = {
     steel: { E: 200, rho: 7850, G: 79 },
     stainless: { E: 193, rho: 8000, G: 77 },
@@ -146,8 +147,4 @@ export function vibration(input) {
         materialProps,
     };
 }
-function roundTo(value, decimals) {
-    const factor = Math.pow(10, decimals);
-    return Math.round(value * factor) / factor;
-}
 //# sourceMappingURL=vibration.js.map

package/dist/metal/vibration.js.map

@@ -1 +1 @@
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package/dist/metal/weldHeat.d.ts

@@ -1,6 +1,7 @@
 import type { WeldHeatInput, WeldHeatResult } from './types.js';
 /**
- * Calculate welding heat input and preheating requirements.
+ * Calculate welding heat input, cooling time, and preheating requirements.
+ * Implements AWS D1.1, EN 1011, and Yurioka methodologies.
  */
 export declare function weldHeat(input: WeldHeatInput): WeldHeatResult;
 //# sourceMappingURL=weldHeat.d.ts.map

package/dist/metal/weldHeat.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"weldHeat.d.ts","sourceRoot":"","sources":["../../src/metal/weldHeat.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,aAAa,EAAE,cAAc,EAA4C,MAAM,YAAY,CAAC;AAuK1G;;;GAGG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CAmI7D"}

package/dist/metal/weldHeat.js

@@ -1,3 +1,4 @@
+import { roundTo } from '../utils.js';
 /** Arc efficiency by welding process */
 const WELD_EFFICIENCY = {
     smaw: 0.72, // Shielded Metal Arc Welding
@@ -12,26 +13,88 @@ const TYPICAL_COMPOSITION = {
     stainlessSteel: { C: 0.08, Mn: 2.00, Cr: 18.0, Mo: 2.5, V: 0, Ni: 10.0, Cu: 0, Si: 1.00 },
     castIron: { C: 3.50, Mn: 0.50, Cr: 0, Mo: 0, V: 0, Ni: 0, Cu: 0, Si: 2.00 },
 };
-/** Preheat temperature by CE and thickness */
-function getPreheatTemp(ce, thickness) {
-    // Simplified preheat calculation based on CE and thickness
+/**
+ * AWS D1.1:2020 Table 5.8 / EN 1011-2 Preheat Requirements
+ * Based on Carbon Equivalent (CE) and combined thickness
+ * Returns preheat temperature based on interaction of CE and thickness
+ */
+function getPreheatTempAWS(ce, thickness, heatInput) {
+    // AWS D1.1 Table 5.8 preheat requirements (simplified)
+    // Uses combined CE (IIW) and governing thickness
+    // Heat input factor - higher heat input allows lower preheat
+    const heatInputFactor = heatInput >= 1.5 ? -25 : heatInput >= 1.0 ? 0 : 25;
     let baseTemp = 20; // ambient
-    if (ce > 0.60)
-        baseTemp = 200;
-    else if (ce > 0.50)
-        baseTemp = 150;
-    else if (ce > 0.45)
-        baseTemp = 100;
-    else if (ce > 0.40)
-        baseTemp = 75;
-    // Thickness adjustment
-    if (thickness > 50)
-        baseTemp += 50;
-    else if (thickness > 25)
-        baseTemp += 25;
+    let source = 'AWS D1.1 Table 5.8';
+    // CE and thickness interaction matrix (AWS D1.1 / EN 1011-2 basis)
+    if (ce <= 0.30) {
+        // Low CE - preheat mainly thickness dependent
+        if (thickness > 50)
+            baseTemp = 50;
+        else if (thickness > 25)
+            baseTemp = 20;
+        else
+            baseTemp = 20;
+    }
+    else if (ce <= 0.40) {
+        // Moderate CE
+        if (thickness > 75)
+            baseTemp = 150;
+        else if (thickness > 50)
+            baseTemp = 100;
+        else if (thickness > 25)
+            baseTemp = 50;
+        else
+            baseTemp = 20;
+    }
+    else if (ce <= 0.45) {
+        // Moderate-high CE
+        if (thickness > 75)
+            baseTemp = 200;
+        else if (thickness > 50)
+            baseTemp = 150;
+        else if (thickness > 25)
+            baseTemp = 100;
+        else if (thickness > 12)
+            baseTemp = 75;
+        else
+            baseTemp = 50;
+    }
+    else if (ce <= 0.50) {
+        // High CE
+        if (thickness > 75)
+            baseTemp = 225;
+        else if (thickness > 50)
+            baseTemp = 175;
+        else if (thickness > 25)
+            baseTemp = 125;
+        else if (thickness > 12)
+            baseTemp = 100;
+        else
+            baseTemp = 75;
+    }
+    else if (ce <= 0.60) {
+        // Very high CE
+        if (thickness > 50)
+            baseTemp = 250;
+        else if (thickness > 25)
+            baseTemp = 200;
+        else if (thickness > 12)
+            baseTemp = 150;
+        else
+            baseTemp = 125;
+        source = 'AWS D1.1 + Engineering judgment';
+    }
+    else {
+        // Extremely high CE - requires special procedures
+        baseTemp = 250 + Math.min(50, (ce - 0.60) * 200);
+        source = 'Engineering judgment - consult welding engineer';
+    }
+    // Apply heat input adjustment
+    baseTemp = Math.max(20, baseTemp + heatInputFactor);
     return {
         min: Math.max(20, baseTemp - 25),
-        max: baseTemp + 25,
+        max: Math.min(350, baseTemp + 25),
+        source,
     };
 }
 /** Interpass temperature limits */
@@ -46,7 +109,71 @@ function getInterpassTemp(baseMetal) {
     }
 }
 /**
- * Calculate welding heat input and preheating requirements.
+ * Calculate cooling time t8/5 (time to cool from 800°C to 500°C)
+ * Based on Rosenthal's equation for thick plate (2D heat flow)
+ *
+ * t8/5 = (4300 - 4.3×T₀) × 10⁵ × H² / ((500 - T₀)² - (800 - T₀)²) for t < 0.75×δ
+ * t8/5 = (6700 - 5×T₀) × H / ((500 - T₀) - (800 - T₀)) for t ≥ 0.75×δ
+ *
+ * Simplified formula for practical use:
+ * t8/5 ≈ K × H² / t² (thin plate) or K × H (thick plate)
+ */
+function calculateCoolingTime(heatInput, thickness, preheatTemp) {
+    const T0 = preheatTemp;
+    // Critical thickness for 2D/3D transition (approximately)
+    const criticalThickness = 0.035 * Math.sqrt(heatInput * 1000); // mm
+    let t85;
+    if (thickness <= criticalThickness) {
+        // Thin plate (2D heat flow) - Rosenthal thin plate
+        // t8/5 = (4300 - 4.3×T₀) × 10⁵ × (H/1000)² / (t²) × [(1/(500-T₀)²) - (1/(800-T₀)²)]
+        const factor = (4300 - 4.3 * T0) * 1e5;
+        const tempTerm = 1 / Math.pow(500 - T0, 2) - 1 / Math.pow(800 - T0, 2);
+        t85 = factor * Math.pow(heatInput, 2) * tempTerm / Math.pow(thickness, 2);
+    }
+    else {
+        // Thick plate (3D heat flow) - Rosenthal thick plate
+        // t8/5 = (6700 - 5×T₀) × (H/1000) × [(1/(500-T₀)) - (1/(800-T₀))]
+        const factor = (6700 - 5 * T0);
+        const tempTerm = 1 / (500 - T0) - 1 / (800 - T0);
+        t85 = factor * heatInput * tempTerm;
+    }
+    // Clamp to reasonable range (0.5s - 300s)
+    return Math.max(0.5, Math.min(300, t85));
+}
+/**
+ * Calculate maximum HAZ hardness using Yurioka formula with cooling rate
+ * HV_max = HV_base + ΔHV(t8/5)
+ *
+ * Full Yurioka formula considers:
+ * - Base hardness from composition
+ * - Cooling rate effect (faster cooling = higher hardness)
+ */
+function calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime) {
+    // Base hardness contribution from composition (Yurioka base)
+    const HV_base = 90 + 1050 * C + 47 * Mn + 31 * Cr + 34 * Mo + 38 * V + 12 * Ni + 17 * Si;
+    // Cooling rate factor (empirical adjustment)
+    // Faster cooling (lower t8/5) increases hardness
+    // Normalized to t8/5 = 15s as reference
+    let coolingFactor = 1.0;
+    if (coolingTime < 5) {
+        coolingFactor = 1.3; // Very fast cooling - significant hardening
+    }
+    else if (coolingTime < 10) {
+        coolingFactor = 1.2;
+    }
+    else if (coolingTime < 15) {
+        coolingFactor = 1.1;
+    }
+    else if (coolingTime > 30) {
+        coolingFactor = 0.9; // Slow cooling - less hardening
+    }
+    const HV_max = HV_base * coolingFactor;
+    // Clamp to realistic range (150-700 HV)
+    return Math.min(700, Math.max(150, roundTo(HV_max, 0)));
+}
+/**
+ * Calculate welding heat input, cooling time, and preheating requirements.
+ * Implements AWS D1.1, EN 1011, and Yurioka methodologies.
  */
 export function weldHeat(input) {
     const { process, voltage, current, travelSpeed, baseMetal, thickness } = input;
@@ -56,10 +183,14 @@ export function weldHeat(input) {
             heatInput: 0,
             efficiency: WELD_EFFICIENCY[process],
             carbonEquivalent: 0,
-            preheatTemp: { min: 20, max: 20 },
+            carbonEquivalentPcm: 0,
+            coolingTime_t85: 0,
+            coolingRate: 0,
+            preheatTemp: { min: 20, max: 20, source: 'N/A - invalid input' },
             interpassTemp: { min: 20, max: 250 },
             hazHardnessMax: 0,
             crackingRisk: 'low',
+            hydrogenLevel: 'low',
             recommendations: [],
         };
     }
@@ -75,64 +206,92 @@ export function weldHeat(input) {
     const V = input.vanadium ?? defaultComp.V;
     const Ni = input.nickel ?? defaultComp.Ni;
     const Cu = input.copper ?? defaultComp.Cu;
-    // Carbon Equivalent (IIW formula)
-    // CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15
+    const Si = input.silicon ?? defaultComp.Si;
+    // Carbon Equivalent (IIW formula) - for steels with C > 0.18%
+    // CE_IIW = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15
     const carbonEquivalent = C + Mn / 6 + (Cr + Mo + V) / 5 + (Ni + Cu) / 15;
-    // Determine cracking risk
+    // Carbon Equivalent (Pcm formula) - for low-alloy steels with C < 0.18%
+    // CE_Pcm = C + Si/30 + (Mn+Cu+Cr)/20 + Ni/60 + Mo/15 + V/10 + 5B
+    const carbonEquivalentPcm = C + Si / 30 + (Mn + Cu + Cr) / 20 + Ni / 60 + Mo / 15 + V / 10;
+    // Determine cracking risk based on both CE methods
+    const effectiveCE = C < 0.18 ? carbonEquivalentPcm : carbonEquivalent;
     let crackingRisk;
-    if (carbonEquivalent <= 0.40)
+    if (effectiveCE <= 0.35)
         crackingRisk = 'low';
-    else if (carbonEquivalent <= 0.45)
+    else if (effectiveCE <= 0.40)
         crackingRisk = 'moderate';
-    else if (carbonEquivalent <= 0.60)
+    else if (effectiveCE <= 0.50)
         crackingRisk = 'high';
     else
         crackingRisk = 'veryHigh';
-    // Get preheat and interpass temperatures
-    const preheatTemp = getPreheatTemp(carbonEquivalent, thickness);
+    // Get preheat using AWS D1.1 method with CE and thickness interaction
+    const preheatTemp = getPreheatTempAWS(carbonEquivalent, thickness, heatInput);
     const interpassTemp = getInterpassTemp(baseMetal);
-    // Estimate maximum HAZ hardness (simplified Yurioka formula approximation)
-    // HV_max ≈ 90 + 1050xC + 47xMn + 31xCr + 34xMo + 38xV + 12xNi
-    // This is a rough approximation
-    const hazHardnessMax = Math.min(600, Math.round(90 + 1050 * C + 47 * Mn + 31 * Cr + 34 * Mo + 38 * V + 12 * Ni));
+    // Calculate cooling time t8/5
+    const coolingTime_t85 = calculateCoolingTime(heatInput, thickness, preheatTemp.min);
+    const coolingRate = 300 / coolingTime_t85; // (800-500)/t8/5
+    // Estimate maximum HAZ hardness with cooling rate consideration
+    const hazHardnessMax = calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime_t85);
+    // Determine hydrogen control level required
+    let hydrogenLevel;
+    if (carbonEquivalent > 0.50 || hazHardnessMax > 400 || crackingRisk === 'veryHigh') {
+        hydrogenLevel = 'low'; // Must use low-hydrogen consumables
+    }
+    else if (carbonEquivalent > 0.40 || hazHardnessMax > 350 || crackingRisk === 'high') {
+        hydrogenLevel = 'medium';
+    }
+    else {
+        hydrogenLevel = 'high'; // Standard consumables acceptable
+    }
     // Generate recommendations
     const recommendations = [];
     if (preheatTemp.min > 20) {
-        recommendations.push(`Preheat to ${preheatTemp.min}-${preheatTemp.max}°C before welding`);
+        recommendations.push(`Preheat to ${preheatTemp.min}-${preheatTemp.max}°C before welding (${preheatTemp.source})`);
+    }
+    if (coolingTime_t85 < 8) {
+        recommendations.push(`Fast cooling (t8/5=${roundTo(coolingTime_t85, 1)}s) - increase heat input or preheat to reduce cracking risk`);
+    }
+    else if (coolingTime_t85 > 50) {
+        recommendations.push(`Slow cooling (t8/5=${roundTo(coolingTime_t85, 1)}s) - may result in reduced toughness`);
     }
     if (heatInput < 0.5) {
         recommendations.push('Consider increasing heat input to reduce cooling rate');
     }
-    else if (heatInput > 2.5) {
-        recommendations.push('Consider reducing heat input to minimize HAZ width');
+    else if (heatInput > 3.0) {
+        recommendations.push('High heat input may cause excessive grain growth in HAZ');
+    }
+    if (hydrogenLevel === 'low') {
+        recommendations.push('Use low-hydrogen electrodes (E7018, ER70S-6) or processes (GMAW, SAW)');
+        recommendations.push('Maintain consumables dry per AWS A5.1 requirements');
     }
     if (crackingRisk === 'high' || crackingRisk === 'veryHigh') {
-        recommendations.push('Use low-hydrogen electrodes or processes');
-        recommendations.push('Consider post-weld heat treatment (PWHT)');
+        recommendations.push('Consider post-weld heat treatment (PWHT) per AWS D1.1 Table 5.12');
     }
     if (hazHardnessMax > 350) {
-        recommendations.push('High HAZ hardness expected - control cooling rate');
+        recommendations.push(`High HAZ hardness expected (${hazHardnessMax} HV) - control cooling rate and consider PWHT`);
     }
     if (baseMetal === 'stainlessSteel') {
-        recommendations.push('Maintain low interpass temperature to prevent sensitization');
+        recommendations.push('Maintain low interpass temperature (<150°C) to prevent sensitization');
+        recommendations.push('Use matching filler metal with controlled ferrite content');
     }
     if (baseMetal === 'castIron') {
-        recommendations.push('Use nickel-based filler metals');
+        recommendations.push('Use nickel-based filler metals (ENiFe-CI, ENi-CI)');
         recommendations.push('Peen weld passes while hot to relieve stress');
+        recommendations.push('Consider butter layers for thick sections');
     }
     return {
         heatInput: roundTo(heatInput, 2),
         efficiency,
-        carbonEquivalent: roundTo(carbonEquivalent, 2),
+        carbonEquivalent: roundTo(carbonEquivalent, 3),
+        carbonEquivalentPcm: roundTo(carbonEquivalentPcm, 3),
+        coolingTime_t85: roundTo(coolingTime_t85, 1),
+        coolingRate: roundTo(coolingRate, 1),
         preheatTemp,
         interpassTemp,
         hazHardnessMax,
         crackingRisk,
+        hydrogenLevel,
         recommendations,
     };
 }
-function roundTo(value, decimals) {
-    const factor = Math.pow(10, decimals);
-    return Math.round(value * factor) / factor;
-}
 //# sourceMappingURL=weldHeat.js.map