From b310512e93aecfa8c4f1761d5e052d8b5bfb46ea Mon Sep 17 00:00:00 2001
From: jyviko <2501648+jyviko@users.noreply.github.com>
Date: Mon, 26 Oct 2026 11:18:53 -0400
Subject: [PATCH] kernel-ladder: tier 11 threaded parts grade their geometry

003 and 004 passed on one valid body alone. 003 is now the flange less
its M30 groove (stopped clear of the root round, run out through the
chamfer) and three M8 tap drills; 004 is 10/008 less the M16 groove on
the shelled boss, which cuts the wall only. With bboxes. Both hold on
SMLib (worst 1.4e-7 relative).

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
---
 .../003-threaded-flange/expected.json         | 22 ++++++++++++++++---
 .../004-housing/expected.json                 | 22 ++++++++++++++++---
 tools/kernel-ladder/cases.py                  | 15 ++++++++++---
 3 files changed, 50 insertions(+), 9 deletions(-)

diff --git a/tests/kernel-cases/ladder/11-cumulative-parts/003-threaded-flange/expected.json b/tests/kernel-cases/ladder/11-cumulative-parts/003-threaded-flange/expected.json
index ee716837de..9e742b7d52 100644
--- a/tests/kernel-cases/ladder/11-cumulative-parts/003-threaded-flange/expected.json
+++ b/tests/kernel-cases/ladder/11-cumulative-parts/003-threaded-flange/expected.json
@@ -1,7 +1,23 @@
 {
  "sources": [],
  "what": "the flange with a modelled M30 thread on its hub, between the round and the chamfer, and M8 tapped holes in the disk",
- "source": "invariants",
- "method": "a thread meeting a round and a chamfer, tapped holes; one valid body",
- "body_count": 1
+ "source": "analytic",
+ "method": "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 = 1.632286 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",
+ "body_count": 1,
+ "volume_mm3": 52978.060766654,
+ "bbox": {
+  "min": [
+   -40,
+   -40,
+   0
+  ],
+  "max": [
+   40,
+   40,
+   30
+  ]
+ },
+ "tolerance": {
+  "rel": 0.0001
+ }
 }
diff --git a/tests/kernel-cases/ladder/11-cumulative-parts/004-housing/expected.json b/tests/kernel-cases/ladder/11-cumulative-parts/004-housing/expected.json
index 86d052e430..c5cc3e2c26 100644
--- a/tests/kernel-cases/ladder/11-cumulative-parts/004-housing/expected.json
+++ b/tests/kernel-cases/ladder/11-cumulative-parts/004-housing/expected.json
@@ -1,7 +1,23 @@
 {
  "sources": [],
  "what": "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",
- "source": "invariants",
- "method": "the last case carries every tier; one valid body",
- "body_count": 1
+ "source": "analytic",
+ "method": "10/008 less the M16 groove on the boss: its cylinder runs from the r1 root round (z 21, a shoulder: the groove stops w = 0.932735 clear of it) to the 1 mm top chamfer (z 29, run out through it, a free end); the groove's root r 6.917 stays outside the boss's 1.5 wall's inside (r 6.5), so it cuts the wall only. Bbox: the part's",
+ "body_count": 1,
+ "volume_mm3": 15138.532607554,
+ "bbox": {
+  "min": [
+   0,
+   0,
+   0
+  ],
+  "max": [
+   60,
+   40,
+   35
+  ]
+ },
+ "tolerance": {
+  "rel": 0.0001
+ }
 }
diff --git a/tools/kernel-ladder/cases.py b/tools/kernel-ladder/cases.py
index 95db394807..17b835b00c 100644
--- a/tools/kernel-ladder/cases.py
+++ b/tools/kernel-ladder/cases.py
@@ -1090,12 +1090,21 @@ FL = sketch(vplane([0, 0, 0]), line([[8, 0], [40, 0], [40, 10], [15, 10], [15, 3
 case(T11, "002-flange", "a revolved flange and hub with a bore, six bolt holes, a hub chamfer and a hub-root round", FL,
      {"body_count": 1, "volume_mm3": Vf, "faces": 14},
      "pi((40^2-8^2)10 + (15^2-8^2)20) - 6 pi 4^2 10 - 1.125 * 2 pi 14.5 (chamfer, Pappus) + (1-pi/4) 9 * 2 pi (15 + 3(10-3pi)/(12-3pi)) (concave round)")
+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}, "a thread meeting a round and a chamfer, tapped holes; one valid body", base=up(T11, "002-flange"), source="invariants")
+     {"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,
+      "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"))
 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},
-     "the last case carries every tier; one valid body", base=C10, source="invariants")
+     [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))]),
+      "bbox": {"min": [0, 0, 0], "max": [60, 40, 35]}, "tolerance": {"rel": 1e-4}},
+     "10/008 less the M16 groove on the boss: its cylinder runs from the r1 root round (z 21, a shoulder: the groove stops w = %.6f clear of it) to the 1 mm top chamfer "
+     "(z 29, run out through it, a free end); the groove's root r 6.917 stays outside the boss's 1.5 wall's inside (r 6.5), so it cuts the wall only. Bbox: the part's" % w16, base=C10)
 
 # manifest: tiers in order, cases in authoring order until --record sorts them by time
 WHAT = {