app.py

import cadquery as cq
import numpy as np
import matplotlib.pyplot as plt
import pyvista as pv
from reportlab.lib.pagesizes import letter
from reportlab.pdfgen import canvas
import gradio as gr
import os


# Function for Progressive Die Design
def generate_die(length, width, thickness):
    try:
        plate = cq.Workplane("XY").box(length, width, thickness)
        punch = cq.Workplane("XY").rect(10, 10).extrude(5).translate((length / 4, width / 4, thickness / 2))
        die = plate.cut(punch)
        filename = "progressive_die.step"
        cq.exporters.export(die, filename)
        return filename
    except Exception as e:
        return f"Error generating die: {str(e)}"


# Function to visualize die in 3D
def visualize_die(length, width, thickness):
    try:
        plate = cq.Workplane("XY").box(length, width, thickness)
        punch = cq.Workplane("XY").rect(10, 10).extrude(5).translate((length / 4, width / 4, thickness / 2))
        die = plate.cut(punch)

        # Export to STL for visualization
        cq.exporters.exportShape(die.val(), "STL", "progressive_die.stl")

        # Visualize with PyVista
        mesh = pv.read("progressive_die.stl")
        plotter = pv.Plotter(off_screen=True)
        plotter.add_mesh(mesh, color="blue")
        screenshot = "progressive_die_visualization.png"
        plotter.screenshot(screenshot)
        return screenshot
    except Exception as e:
        return f"Error visualizing die: {str(e)}"


# Function for Stress Analysis (including thermal stress and fatigue strength)
def stress_analysis(force, die_width, die_height, material_strength, temperature_change=50, alpha=1e-5, elastic_modulus=200000, fatigue_strength=150):
    try:
        # Mechanical stress
        stress = force / (die_width * die_height)  # Stress = Force / Area
        safety_factor = material_strength / stress  # Safety Factor = Material Strength / Stress

        # Thermal stress
        thermal_stress = elastic_modulus * alpha * temperature_change

        # Fatigue strength
        fatigue_stress = fatigue_strength

        # Generate data for plotting
        x = np.linspace(1, 100, 100)  # Operational range (e.g., % load)
        stress_curve = stress * x / 100  # Simulated stress
        material_strength_curve = np.full_like(x, material_strength)  # Constant material strength
        safety_factor_curve = material_strength_curve / stress_curve  # Varying safety factor
        thermal_stress_curve = np.full_like(x, thermal_stress)  # Constant thermal stress
        fatigue_strength_curve = np.full_like(x, fatigue_stress)  # Constant fatigue strength

        # Create combined graph
        fig, ax = plt.subplots(figsize=(10, 6))
        ax.plot(x, stress_curve, label="Stress (σ)", color="blue")
        ax.plot(x, material_strength_curve, label="Material Strength (σ_y)", color="green")
        ax.plot(x, safety_factor_curve, label="Safety Factor (SF)", color="orange")
        ax.plot(x, thermal_stress_curve, label="Thermal Stress (σ_thermal)", color="purple")
        ax.plot(x, fatigue_strength_curve, label="Fatigue Strength (σ_fatigue)", color="brown")
        ax.axhline(1, color="red", linestyle="--", label="Critical Safety Threshold (SF=1)")

        ax.set_title("Combined Stress Analysis Parameters")
        ax.set_xlabel("Operational Range (%)")
        ax.set_ylabel("Parameter Value (MPa or Unitless)")
        ax.legend()
        ax.grid()

        plt.tight_layout()
        plt.close(fig)

        return f"Safety Factor: {round(safety_factor, 2)}", fig
    except Exception as e:
        return f"Error in stress analysis: {str(e)}", None


# Function to generate PDF report
def generate_pdf_report(data, filename="report.pdf"):
    try:
        c = canvas.Canvas(filename, pagesize=letter)
        c.drawString(100, 750, "Simulation Report")
        c.drawString(100, 730, f"Max Stress: {data.get('stress', 'N/A')} MPa")
        c.drawString(100, 710, f"Safety Factor: {data.get('safety_factor', 'N/A')}")
        c.save()
        return filename
    except Exception as e:
        return f"Error generating report: {str(e)}"


# Gradio interface functions
def stress_analysis_interface(force, die_width, die_height, material_strength, temperature_change, alpha, elastic_modulus, fatigue_strength):
    safety_factor, fig = stress_analysis(force, die_width, die_height, material_strength, temperature_change, alpha, elastic_modulus, fatigue_strength)
    data = {"stress": force / (die_width * die_height), "safety_factor": safety_factor}
    pdf_filename = generate_pdf_report(data)
    return safety_factor, fig, pdf_filename


# Create Gradio App
with gr.Blocks() as app:
    gr.Markdown("## Press Tool AI Suite")
    gr.Markdown("Select a tool below to get started:")

    with gr.Tabs():
        with gr.Tab("Progressive Die Design"):
            gr.Markdown("### Enter Dimensions for Progressive Die")
            length = gr.Number(label="Length (mm)", value=100)
            width = gr.Number(label="Width (mm)", value=50)
            thickness = gr.Number(label="Thickness (mm)", value=10)
            die_output = gr.Textbox(label="Die Output File")
            visualization_output = gr.Image(label="3D Visualization")
            die_button = gr.Button("Generate Die")
            die_button.click(
                lambda l, w, t: (generate_die(l, w, t), visualize_die(l, w, t)),
                inputs=[length, width, thickness],
                outputs=[die_output, visualization_output],
            )

        with gr.Tab("Stress Analysis"):
            gr.Markdown("### Select Simulation Tool and Enter Parameters for Stress Analysis")
            force = gr.Number(label="Force (N)", value=10000)
            die_width = gr.Number(label="Width (m)", value=0.05)
            die_height = gr.Number(label="Height (m)", value=0.01)
            material_strength = gr.Number(label="Material Strength (MPa)", value=250)
            temperature_change = gr.Number(label="Temperature Change (°C)", value=50)
            alpha = gr.Number(label="Thermal Expansion Coefficient (1/°C)", value=1e-5)
            elastic_modulus = gr.Number(label="Elastic Modulus (MPa)", value=200000)
            fatigue_strength = gr.Number(label="Fatigue Strength (MPa)", value=150)

            safety_factor_output = gr.Textbox(label="Safety Factor")
            stress_chart = gr.Plot()
            pdf_file = gr.File(label="Download Report")
            stress_button = gr.Button("Analyze Stress")
            stress_button.click(
                stress_analysis_interface,
                inputs=[force, die_width, die_height, material_strength, temperature_change, alpha, elastic_modulus, fatigue_strength],
                outputs=[safety_factor_output, stress_chart, pdf_file],
            )

# Launch the app
app.launch()