Multiblock_Die_Calc/diecalc.js

// Some constant variables
// Eventually these might become configuration options if this project gets complex enough
var MC_MAX_HEADS = 5;

// This function gets the reduction of area with two provided sizes, and returns it
function getReduction(startSize, finalSize) {
    var startArea = Math.PI * ((startSize / 2) * (startSize / 2));
    var finalArea = Math.PI * ((finalSize / 2) * (finalSize / 2));

    var reduction = ((startArea - finalArea) / startArea) * 100;

    return reduction;
}

// This function gets the elongation
function getElongation(startSize, finalSize) {
    return (Math.pow(startSize / finalSize, 2) - 1) * 100;
}

// This function will get the average reduction, across a number of dies.
// Used to calculate how many dies we'll need
function getAverageReduction(startSize, finalSize, numDies) {
    return (1 - Math.pow((Math.pow(finalSize / startSize, 2)), (1 / numDies))) * 100;
}


// This function gets us the number of dies we need, and returns it.
function getNumDies(startSize, finalSize) {
    var reduction = getReduction(startSize, finalSize);
    var numDies = 0;

    while (reduction > document.getElementById("machineMaxReduction").value) {
        numDies++;
        reduction = getAverageReduction(startSize, finalSize, numDies);

        if (reduction < document.getElementById("machineMaxReduction").value) {
            if (numDies > MC_MAX_HEADS) {
                numDies--;
                reduction = getAverageReduction(startSize, finalSize, numDies);
                reduction = Math.round(reduction * 100) / 100;
                break;
            }
            reduction = Math.round(reduction * 100) / 100;
        }
    }
    return numDies;
}

// This function calculates the die needed to go before the coiler
// This is the first die calcuated and dictates how the rest of the machine should be setup

function getPreCoilerDie(finalSize) {
    var coilerTarget = document.getElementById("coilerTarget").value;
    var s = 0;  // this variable counts our steps to get a final pre-coiler die
    var reduction = getReduction((finalSize + s), finalSize);

    // Iterate until we pass the maximum allowed
    while (reduction < coilerTarget) {
        s++;
        reduction = getReduction((finalSize + s), finalSize);
    }

    // Once we exceed the max we need to go back one size
    if (reduction > coilerTarget) {
        s--;
        reduction = getReduction((finalSize + s), finalSize);
    }

    // Round it off and display it
    document.getElementById("coilerROA").innerHTML = (Math.round(reduction * 10) / 10).toFixed(1);
    document.getElementById("coilerElong").innerHTML = (Math.round(getElongation(finalSize + s, finalSize) * 10) / 10).toFixed(1);

    return finalSize + s;
}

function getDies() {
    clearScreen(); // "Clear" the screen right away

    // Get our values from the web page
    var startSize = document.getElementById("startSize").value;
    var finalSize = document.getElementById("finalSize").value;
    var maxMachineROA = document.getElementById("machineMaxReduction").value;

    // If mm is selected we convert it to inches
    if (document.getElementById("metric").checked == true) {
        startSize = Math.round((startSize * 1000) / 25.4);
    }

    // Format our numbers to prevent maximum user stupidity
    if (startSize < 1.0 && startSize > 0) {  // If we have a 'proper' number i.e. ".130"
        startSize = startSize * 1000;
    } else {  // re-format the number if it's 'wrong' i.e. "130"
        startSize = Number(startSize);
    }
    if (finalSize < 1.0 && finalSize > 0) {  // If we have a 'proper' number i.e. ".130"
        finalSize = finalSize * 1000;
    } else {  // re-format the number if it's 'wrong' i.e. "130"
        finalSize = Number(finalSize);
    }

    if (finalSize == 0 || finalSize == NaN || startSize == 0 || startSize == NaN) {
        console.log("Zero");
        return;
    }

    // Set our final size based on input
    document.getElementById("coilerDie").innerHTML = "." + finalSize;

    // Get the total Reduction Of Area of the run
    var totalROA = getReduction(startSize, finalSize);

    // Get the total elongation for the run
    var totalElong = getElongation(startSize, finalSize);

    // Get the die we need before the coiler
    var preCoilerDie = getPreCoilerDie(finalSize);

    // Get the rest of the dies...
    // Start by calculating how many we need
    var machineROA = getReduction(startSize, preCoilerDie);
    var numDies = getNumDies(startSize, preCoilerDie);

    if (numDies > MC_MAX_HEADS) {
        // TODO THROW AN ERROR IF WE TRY OVERLOADING THE MACHINE
        numDies = MC_MAX_HEADS;
    }

    var averageReduction = getAverageReduction(startSize, preCoilerDie, numDies);


    // Create an array to store our die values
    var dies = [];
    dies.push(preCoilerDie);

    var i = 0;
    while (i < numDies - 1) {
        dies[i + 1] = Math.round(dies[i] / Math.sqrt(1 - (averageReduction / 100)));
        i++;
    }


    // This next section updates the webpage with our values //
    ///////////////////////////////////////////////////////////

    for (var j = 0; j < numDies; j++) {
        var curBlock = MC_MAX_HEADS - j;
        if (numDies < 4) { // This helps formatting, if we have less than 4 blocks running then we need to skip block 5
            curBlock--;
        }
        if (numDies < 3) { // If we only have two blocks running then we need to skip 4 as well as 5
            curBlock--;
        }

        // Working die size
        var htmlID = "block" + curBlock + "Working";
        document.getElementById(htmlID).innerHTML = "." + dies[j];

        // Guide dies
        var htmlID = "block" + curBlock + "Guide";
        if (dies[j + 1]) {
            document.getElementById(htmlID).innerHTML = "." + (dies[j + 1] + 18);
        } else { // This will check to see if it's our first die and change the guide to a pressure die
            var temp = 10 + Math.floor(startSize / 5) * 5;
            document.getElementById(htmlID).innerHTML = "." + temp;
            document.getElementById(htmlID).style.fontWeight = "bold"; // Make our pressure die bold
        }

        // ROA
        htmlID = "block" + curBlock + "ROA";
        if (dies[j + 1]) {
            document.getElementById(htmlID).innerHTML = (Math.round(getReduction(dies[j + 1], dies[j]) * 10) / 10).toFixed(1);
        } else {
            document.getElementById(htmlID).innerHTML = (Math.round(getReduction(startSize, dies[j]) * 10) / 10).toFixed(1);
        }

        // ELONGATION
        htmlID = "block" + curBlock + "Elong";
        if (dies[j + 1]) {
            document.getElementById(htmlID).innerHTML = (Math.round(getElongation(dies[j + 1], dies[j]) * 10) / 10).toFixed(1);
        } else {
            document.getElementById(htmlID).innerHTML = (Math.round(getElongation(startSize, dies[j]) * 10) / 10).toFixed(1);
        }
    }
    // Give the summary of the reduction under the table
    if (document.getElementById("metric").checked == true) { // If metric, convert back to mm
        document.getElementById("setupSummary").innerHTML = ("Generated die setup for " + (Math.round((startSize * 25.4) / 100) / 10) + " mm (." + startSize + "\") &#x1F80A; ." + finalSize + "\"");
    } else { // If our input is imperial/inches then we'll just show it back
        document.getElementById("setupSummary").innerHTML = ("Generated die setup for ." + startSize + "\" (" + (Math.round(((startSize) * 25.4) / 100) / 10) + " mm) &#x1F80A; ." + finalSize + "\"");
    }

    // Write our total ROA and total Elongation for the whole pull
    document.getElementById("totalROAResult").innerHTML = ("Total ROA: " + (Math.round(totalROA * 100) / 100) + "%");
    document.getElementById("totalElongResult").innerHTML = ("Total Elongation: " + (Math.round(totalElong * 100) / 100) + "%");
}

function clearScreen() {
    // This function clears the table back to 'empty' or fresh or whatever you want to call it
    for (var j = 1; j <= MC_MAX_HEADS; j++) {
        var htmlID = "block" + j + "Working";
        document.getElementById(htmlID).innerHTML = ("&nbsp;");
        htmlID = "block" + j + "Guide";
        document.getElementById(htmlID).innerHTML = ("");
        htmlID = "block" + j + "ROA";
        document.getElementById(htmlID).innerHTML = ("");
        htmlID = "block" + j + "Elong";
        document.getElementById(htmlID).innerHTML = ("");
        document.getElementById("coilerDie").innerHTML = ("");
        document.getElementById("coilerROA").innerHTML = ("");
        document.getElementById("coilerElong").innerHTML = ("");
        document.getElementById("totalROAResult").innerHTML = ("Total ROA: 0%");
        document.getElementById("totalElongResult").innerHTML = ("Total Elongation: 0%");
        document.getElementById("setupSummary").innerHTML = ("&nbsp;");
    }
}