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Ladder generator: cases.py writes the values committed by hand for 05/007, 06/017, 07/016 and 11/003

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The tap maker's 6.8 mm M8 drill, the chamfered tip's ISO 724 d3 with tip: both, and 07/016's
refusal reason were edited into the cases' JSON but not into cases.py, so running it undid them.
Its output now matches the committed cases (to the last rounding digit of two volumes).

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
This commit is contained in:
jyviko
2026-10-29 17:39:59 -04:00
committed by Irakli Kourtis
parent 9fecf7709e
commit 22cd8e74f6
1 changed files with 12 additions and 13 deletions
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tools/kernel-ladder/cases.py
+12 -13
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@@ -530,11 +530,11 @@ case(T5, "005-countersink", "a countersunk hole: d6.6 through, d12 x 90 deg coun
case(T5, "006-tapped-m6-through", "an M6 tapped hole through: the tap drill d5 (major - pitch), cosmetic thread",
[H(position=top, thread="M6")],
{"body_count": 1, "volume_mm3": VB - PI * 6.25 * 20, "faces": 7}, "M6 coarse pitch 1: tap drill 6 - 1 = 5; removed pi 2.5^2 20; the cosmetic thread adds no geometry", base=B1)
ch8 = 3.375 / math.tan(math.radians(59))
ch8 = 3.4 / math.tan(math.radians(59))
case(T5, "007-tapped-m8-blind", "an M8 tapped blind hole 12 deep with a 118 deg drill point",
[H(position=top, thread="M8", depth=12, type="drilled", tip_angle=118)],
{"body_count": 1, "volume_mm3": VB - PI * 3.375 ** 2 * 12 - PI * 3.375 ** 2 * ch8 / 3, "faces": 8},
"M8 coarse pitch 1.25: tap drill (major - pitch) 6.75; removed pi r^2 12 to the shoulder + the point cone pi r^2 (r/tan59)/3", base=B1)
{"body_count": 1, "volume_mm3": VB - PI * 3.4 ** 2 * 12 - PI * 3.4 ** 2 * ch8 / 3, "faces": 8},
"M8 coarse pitch 1.25: the tap maker's drill 6.8 (Yamawa YEU23 p.704); removed pi r^2 12 to the shoulder + the point cone pi r^2 (r/tan59)/3", base=B1)
r, Rc = 2.1, 20
vint = quad(lambda y: 2 * math.sqrt(max(r * r - y * y, 0)) * 2 * math.sqrt(Rc * Rc - y * y), -r, r, 128)
case(T5, "008-tapped-m5-into-curved-face", "an M5 tapped hole drilled radially through a cylinder r20 lying along X",
@@ -568,7 +568,6 @@ case(T5, "013-part-holes", "the running part: an M6 tapped through hole, an M5 t
{"body_count": 1, "volume_mm3": V5, "faces": 20},
"removed pi 2.5^2 20 (M6, tap drill 5) + pi 2.1^2 8 (M5, tap drill 4.2, flat) + pi 1.65^2 35; faces +1 +2 +1", base=C4)
C5 = up(T5, "013-part-holes")
# ---------------------------------------------------------------- 06 threads
def thr(face, **p):
return C("solid.thread", face=face, modeled=True, **p)
@@ -759,14 +758,14 @@ case(T6, "019-external-tr40x14-p7-two-start", "a modelled two-start trapezoidal
"groove of pitch 7 would: over 42 mm (three leads, six pitches) between free ends") + "ISO 2904 for P 7: 30 deg, H1 = P/2, crest flat 0.366 P, "
"ac = 0.5 (P 6..12), external minor d3 = d - 2 (H1 + ac) = 32")
rf10 = 5 - 5 * math.sqrt(3) / 2 * 1.5 / 8
case(T6, "017-external-m10-chamfered-tip", "001's modelled M10 thread with ISO 4753's chamfered end at both free ends: a 45 deg cone down to the minor diameter, cut after the groove",
cylT + [thr([5, 0, 15], designation="M10", tip="chamfer")],
rf10 = 5 - 17 / 24 * math.sqrt(3) / 2 * 1.5 # ISO 724: d3 = d - 2 (17/24) H
case(T6, "017-external-m10-chamfered-tip", "001's modelled M10 thread with ISO 4753's chamfered end at both free ends: a 45 deg cone down to the external minor diameter d3, cut after the groove",
cylT + [thr([5, 0, 15], designation="M10", tip="both")],
{"body_count": 1, "volume_mm3": ext_volume(10, 1.5, [(0, 5 - rf10, lambda z: rf10 + z), (5 - rf10, 25 + rf10, lambda z: 5), (25 + rf10, 30, lambda z: rf10 + 30 - z)]),
"tolerance": {"rel": 1e-4}},
TMETH.replace("Tolerance 0.5%: solid.thread cuts faceted by design (chords within P/200 on the body, P/100 on the tool)", "Tolerance 0.01%: SMLib's exact screw sweep") +
"; the chamfer is axisymmetric and cut after the groove, so it only lowers the stock's outer radius: r <= d_f/2 + distance from the end (45 deg), d_f the minor diameter d - 5H/4 = 8.376 "
"(ISO 4753 chamfered end: the end's diameter at most the minor diameter)")
"; the chamfer is axisymmetric and cut after the groove, so it only lowers the stock's outer radius: r <= d_f/2 + distance from the end (45 deg), d_f the external minor diameter d3 = d - 1.226869 P = 8.160 "
"(ISO 724; ISO 4753 chamfered end: the end's diameter at most the minor diameter), below the modelled root d1")
# ---------------------------------------------------------------- 07 fillets
F = lambda edges, r, **p: C("solid.fillet", edges=edges, radius=r, **p)
@@ -814,7 +813,7 @@ case(T7, "010-corner-unequal-r7-r3", "an r7 vertical round at a corner, then r3
"Faces: 6 planes + the r7 cylinder + the r3 chain's cylinder, torus, cylinder; edges: 5 round the bottom, 5 round the top, 5 vertical (two r7 tangent lines, the box's "
"three other verticals), the chain's three on the walls and two end arcs, its two seams; vertices from Euler (V - E + F = 2): 14", base=B1)
case(T7, "016-corner-three-sequential-r5-r3-r7", 'rounds r5 and r3 on the two top edges at a corner, then r7 on the vertical edge under them: refused, the r7 cannot exist',
[F([corner[0]], 5), F([corner[1]], 3, tangent_chain=False), F([[60, 40, 8]], 7)], {"outcome": "refused"},
[F([corner[0]], 5), F([corner[1]], 3, tangent_chain=False), F([[60, 40, 8]], 7)], {"outcome": "refused", "refusal": "the fillet is larger than the faces beside its edges allow"},
"the r7 runs on (tangent chain) up the side x=60 along its arc on the r5 round, a circle of radius 5 about the r5 axis: the r7's contact line on that face would be the arc offset 7 towards its centre, radius 5 - 7 < 0, so the blend passes through itself; and along the seam of the r5 and r3 rounds no ball over r3 fits the r3 round. No such round exists, so the right answer is a clean refusal (SMLib: no room for the rolling ball). 018 is the same corner with a radius that fits.", base=B1, source="invariants")
case(T7, "018-corner-three-sequential-r5-r3-r2", 'rounds r5 and r3 on the two top edges at a corner, then r2 on the vertical edge under them, run on up into the corner',
[F([corner[0]], 5), F([corner[1]], 3, tangent_chain=False), F([[60, 40, 8]], 2)], {"body_count": 1, "faces": 11, "bbox": BBOX},
@@ -1119,12 +1118,12 @@ case(T11, "002-flange", "a revolved flange and hub with a bore, six bolt holes,
w30 = ext_half_width(30, 3.5)
case(T11, "003-threaded-flange", "the flange with a modelled M30 thread on its hub, between the round and the chamfer, and M8 tapped holes in the disk",
[thr([15, 0, 20], designation="M30"), H(position=[0, 28, 10], thread="M8", name="Tap"), C("solid.pattern.circular", features=["Tap"], axis="Z", count=3)],
{"body_count": 1, "volume_mm3": Vf - groove(30, 3.5, [(13 + w30, 28.5, lambda z: 15), (28.5, 30, lambda z: 15 - (z - 28.5))]) - 3 * PI * 3.375 ** 2 * 10,
{"body_count": 1, "volume_mm3": Vf - groove(30, 3.5, [(13 + w30, 28.5, lambda z: 15), (28.5, 30, lambda z: 15 - (z - 28.5))]) - 3 * PI * 3.4 ** 2 * 10,
"bbox": {"min": [-40, -40, 0], "max": [40, 40, 30]}, "tolerance": {"rel": 1e-4}},
"the hub's cylinder (r15) runs from the r3 round at its root (z 13) to the 1.5 chamfer at its top (z 28.5): the M30 groove (P 3.5) stops w = %.6f clear of the round, "
"a shoulder (06/007's rule), and runs out through the chamfer, a free end (06/006's): it removes the stock less 2 pi int int r m(r) dr dz over z 13 + w..28.5 at r 15 and the chamfer "
"(r 15 - (z - 28.5)); the bore r8 is inside the root r 13.1. The M8 tap drills (6.75) go through the 10 mm disk at r 28, 90 deg + k 120, clear of the bolt holes (30 deg apart): "
"3 pi 3.375^2 10. Bbox: the flange's" % w30, base=up(T11, "002-flange"))
"(r 15 - (z - 28.5)); the bore r8 is inside the root r 13.1. The M8 tap drills (6.8, the tap maker's) go through the 10 mm disk at r 28, 90 deg + k 120, clear of the bolt holes (30 deg apart): "
"3 pi 3.4^2 10. Bbox: the flange's" % w30, base=up(T11, "002-flange"))
case(T11, "004-housing", "the running part with every tier: back wall, boss, slot, spline window, tapped holes, rounds, chamfers, shell, vents, and a modelled M16 thread on the boss",
[thr([23, 15, 25], designation="M16")],
{"body_count": 1, "volume_mm3": V9 - 4 * PI * 1.5 ** 2 * 1.5 - groove(16, 2, [(21 + w16, 29, lambda z: 8), (29, 30, lambda z: 8 - (z - 29))]),