Update app.py

app.py

@@ -6,7 +6,6 @@ from reportlab.lib.pagesizes import letter
 from reportlab.pdfgen import canvas
 import gradio as gr
 import os
-from ansys.mapdl.core import launch_mapdl  # For ANSYS integration
 
 
 # Function for Progressive Die Design
@@ -43,16 +42,43 @@ def visualize_die(length, width, thickness):
         return f"Error visualizing die: {str(e)}"
 
 
-# Function for Python-based Stress Analysis
-def stress_analysis(force, die_width, die_height, material_strength):
+# 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:
-        stress = force / (die_width * die_height)
-        safety_factor = material_strength / stress
+        # 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()
 
-        fig, ax = plt.subplots()
-        ax.bar(["Stress", "Material Strength"], [stress, material_strength])
-        ax.set_ylabel("Stress (MPa)")
-        ax.set_title("Stress Analysis")
+        plt.tight_layout()
         plt.close(fig)
 
         return f"Safety Factor: {round(safety_factor, 2)}", fig
@@ -60,53 +86,6 @@ def stress_analysis(force, die_width, die_height, material_strength):
         return f"Error in stress analysis: {str(e)}", None
 
 
-# ANSYS Integration for Stress Analysis
-def run_ansys_simulation(force, die_width, die_height, material_strength):
-    try:
-        # Launch ANSYS MAPDL instance
-        mapdl = launch_mapdl()
-        mapdl.prep7()  # Enter pre-processing module
-
-        # Define geometry and material properties
-        mapdl.rectng(0, die_width, 0, die_height)
-        mapdl.mp('EX', 1, material_strength)
-        mapdl.et(1, 'PLANE183')
-
-        # Apply loads
-        mapdl.nsel('S', 'LOC', 'X', 0)
-        mapdl.d('ALL', 'UX', 0)
-        mapdl.f('ALL', 'FY', -force)
-
-        # Solve
-        mapdl.run('/SOLU')
-        mapdl.solve()
-        mapdl.finish()
-
-        # Post-processing
-        mapdl.post1()
-        stress = mapdl.get_value('NODE', 1, 'S', 'EQV')  # Retrieve max equivalent stress
-        mapdl.exit()
-
-        return f"Max Stress: {stress:.2f} MPa"
-    except Exception as e:
-        return f"Error running ANSYS simulation: {str(e)}"
-
-
-# SolidWorks Placeholder for Stress Analysis
-def solidworks_stress_analysis(force, die_width, die_height, material_strength):
-    # Replace this function with SolidWorks API or external script
-    try:
-        output_file = "/path/to/solidworks/output.txt"  # Replace with actual path
-        if os.path.exists(output_file):
-            with open(output_file, "r") as file:
-                result = file.read()
-            return result.strip()
-        else:
-            return "SolidWorks simulation output not found."
-    except Exception as e:
-        return f"Error running SolidWorks simulation: {str(e)}"
-
-
 # Function to generate PDF report
 def generate_pdf_report(data, filename="report.pdf"):
     try:
@@ -120,43 +99,12 @@ def generate_pdf_report(data, filename="report.pdf"):
         return f"Error generating report: {str(e)}"
 
 
-# Tool Optimization Function
-def optimize_tool(speed, feed_rate, depth_of_cut, material):
-    try:
-        tool_life = 1000 / (speed * feed_rate * depth_of_cut)
-        recommended_speed = 0.8 * speed
-        recommended_feed_rate = 0.9 * feed_rate
-
-        return {
-            "Estimated Tool Life (hrs)": round(tool_life, 2),
-            "Recommended Speed (m/min)": round(recommended_speed, 2),
-            "Recommended Feed Rate (mm/rev)": round(recommended_feed_rate, 2)
-        }
-    except Exception as e:
-        return {"Error": str(e)}
-
-
 # Gradio interface functions
-def stress_analysis_interface(force, die_width, die_height, material_strength, simulation_tool):
-    if simulation_tool == "Python":
-        # Python-based stress analysis
-        safety_factor, fig = stress_analysis(force, die_width, die_height, material_strength)
-        data = {"stress": force / (die_width * die_height), "safety_factor": safety_factor}
-        pdf_filename = generate_pdf_report(data)
-        return safety_factor, fig, pdf_filename
-
-    elif simulation_tool == "ANSYS":
-        # Run ANSYS-based simulation
-        result = run_ansys_simulation(force, die_width, die_height, material_strength)
-        return result, None, None
-
-    elif simulation_tool == "SolidWorks":
-        # Run SolidWorks-based simulation
-        result = solidworks_stress_analysis(force, die_width, die_height, material_strength)
-        return result, None, None
-
-    else:
-        return "Invalid simulation tool selected", None, None
+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
@@ -181,83 +129,24 @@ with gr.Blocks() as app:
 
         with gr.Tab("Stress Analysis"):
             gr.Markdown("### Select Simulation Tool and Enter Parameters for Stress Analysis")
-            simulation_tool = gr.Dropdown(
-                choices=["Python", "ANSYS", "SolidWorks"],
-                label="Simulation Tool",
-                value="Python",
-            )
             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)
-            safety_factor_output = gr.Textbox(label="Safety Factor or Simulation Result")
+            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 (Python Only)")
+            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, simulation_tool],
+                inputs=[force, die_width, die_height, material_strength, temperature_change, alpha, elastic_modulus, fatigue_strength],
                 outputs=[safety_factor_output, stress_chart, pdf_file],
             )
-            # Function for Python-based Stress Analysis with a combined graph
-def stress_analysis(force, die_width, die_height, material_strength):
-    try:
-        # Calculate parameters
-        stress = force / (die_width * die_height)  # Stress = Force / Area
-        safety_factor = material_strength / stress  # Safety Factor = Material Strength / Stress
-
-        # Data for plotting
-        x = ["Stress", "Material Strength", "Safety Factor"]
-        y_stress = [stress, material_strength, safety_factor]
-
-        # Create a combined graph
-        fig, ax = plt.subplots()
-        ax.plot(x, y_stress, marker='o', label="Simulation Parameters")
-        ax.axhline(y=1, color='red', linestyle='--', label="Critical Safety Factor (1)")
-        ax.set_ylabel("Value")
-        ax.set_title("Stress Analysis Parameters")
-        ax.legend()
-        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
-def stress_analysis_interface(force, die_width, die_height, material_strength, simulation_tool):
-    if simulation_tool == "Python":
-        # Python-based stress analysis with combined graph
-        safety_factor, fig = stress_analysis(force, die_width, die_height, material_strength)
-        data = {"stress": force / (die_width * die_height), "safety_factor": safety_factor}
-        pdf_filename = generate_pdf_report(data)
-        return safety_factor, fig, pdf_filename
-
-    elif simulation_tool == "ANSYS":
-        # Run ANSYS-based simulation
-        result = run_ansys_simulation(force, die_width, die_height, material_strength)
-        return result, None, None
-
-    elif simulation_tool == "SolidWorks":
-        # Run SolidWorks-based simulation
-        result = solidworks_stress_analysis(force, die_width, die_height, material_strength)
-        return result, None, None
-
-    else:
-        return "Invalid simulation tool selected", None, None
-
-
-        with gr.Tab("Tool Optimization"):
-            gr.Markdown("### Enter Machining Parameters for Tool Optimization")
-            speed = gr.Number(label="Cutting Speed (m/min)", value=100)
-            feed_rate = gr.Number(label="Feed Rate (mm/rev)", value=0.2)
-            depth_of_cut = gr.Number(label="Depth of Cut (mm)", value=1.0)
-            material = gr.Dropdown(choices=["Steel", "Aluminum", "Titanium"], label="Material", value="Steel")
-            optimization_results = gr.JSON(label="Optimization Results")
-            optimize_button = gr.Button("Optimize Tool")
-            optimize_button.click(
-                optimize_tool,
-                inputs=[speed, feed_rate, depth_of_cut, material],
-                outputs=optimization_results,
-            )
 
 # Launch the app
 app.launch()