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kernel, smlib: a blend larger than its faces is SMLib's refusal; blends take exactly the given edges

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SMLib (fork 68e3086) refuses a blend whose rails leave the faces they roll on with
SMLIB_ERR_NO_ROOM, which the kernel reports as KernelError::TooLarge. The kernel's own
pre-checks go: blend_fit's fit check and the 256-station band check of the variable fillet.
The shim no longer follows tangent chains; the Fillet/Chamfer dialog already expands a pick
to its chain (its Tangent Chain option) and stores every edge in the feature.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_017itGh5fpMEousnZ91cYcVt
This commit is contained in:
jyviko
2026-10-22 08:37:06 -04:00
parent 83d965f308
commit bcbb990051
11 changed files with 33 additions and 714 deletions
Download Patch File Download Diff File Expand all files Collapse all files
crates/kernel/src/blend.rs
+12 -24
View File
@@ -1,12 +1,11 @@
//! Edge fillets and chamfers. SMLib blends the picked edges, each with its tangent chain, in one
//! call ([`crate::blend_smlib`]): the blend faces, the corners where blends meet (a sphere, a
//! patch, a bevel or a mitre, as its fillet corners choose) and the end faces rebuilt round
//! them. Before SMLib runs, a blend that would run past the faces beside its edge into other
//! geometry or into another blend is refused as too large, with the largest size that fits
//! ([`crate::blend_fit`]); after, a result that changed more than the blends can is refused too.
//! Edge fillets and chamfers. SMLib blends exactly the picked edges in one call
//! ([`crate::blend_smlib`]): the blend faces, the corners where blends meet (a sphere, a patch, a
//! bevel or a mitre, as its fillet corners choose) and the end faces rebuilt round them. A blend
//! whose contact lines would leave the faces it rolls on is SMLib's refusal, reported as
//! [`KernelError::TooLarge`]. A tangent chain is the caller's to select.
//!
//! The helpers here read a body's schema 4 record for those checks: planar faces' outward
//! normals, the direction into a face across an edge, an edge's tangent at its ends.
//! The helpers here read a body's schema 4 record: planar faces' outward normals, the direction
//! into a face across an edge, an edge's tangent at its ends.
use std::collections::BTreeSet;
@@ -89,6 +88,7 @@ impl Faces {
}
/// The outward unit normal of face `f` at `p` (a point within `accept` of its surface).
#[cfg(test)]
pub(crate) fn normal_at(&self, f: usize, p: Vec3, accept: f64) -> Option<Vec3> {
let s = SurfaceEval::new(&self.rec.faces.get(f)?.surface).ok()?;
let uv = s.project(p, None, accept)?;
@@ -96,11 +96,6 @@ impl Faces {
Some(su.cross(sv).normalized()? * self.side(f)?)
}
/// The unit natural normal of face `f`'s surface at `p` (a point within `accept` of it).
pub(crate) fn natural_normal_at(&self, f: usize, p: Vec3, accept: f64) -> Option<Vec3> {
Some(self.normal_at(f, p, accept)? * self.side(f)?)
}
/// Every edge use in the face's loops.
pub(crate) fn uses(&self, f: usize) -> impl Iterator<Item = &OrientedEdge> {
self.rec.faces.get(f).into_iter().flat_map(|face| face.loops.iter()).flat_map(|l| match l {
@@ -215,9 +210,7 @@ fn closed(input: &Body, b: Body) -> Result<Body> {
/// largest that works).
pub fn fillet(body: &Body, edges: &[Vec3], radius: f64) -> Result<Body> {
body.require_brep("fillet")?;
crate::blend_fit::fit(body, edges, crate::blend_fit::Size::Round(radius), || {
crate::blend_smlib::fillet(body, edges, radius).and_then(|b| closed(body, b))
})
crate::blend_smlib::fillet(body, edges, radius).and_then(|b| closed(body, b))
}
/// [`fillet`] whose corners where three blended edges meet are G2 patches. SMLib's fillet
@@ -306,7 +299,7 @@ pub fn fillet_max_each(body: &Body, edges: &[Vec3], radius: f64) -> Option<(Vec<
}
/// The fillet of each edge at its own radius (`radii` in `edges`' order), all in one SMLib
/// blend. Each round must fit beside its own edge (#1080).
/// blend.
pub fn fillet_each(body: &Body, edges: &[Vec3], radii: &[f64]) -> Result<Body> {
if radii.len() != edges.len() {
return Err(KernelError::Invalid("one radius per edge".into()));
@@ -315,9 +308,6 @@ pub fn fillet_each(body: &Body, edges: &[Vec3], radii: &[f64]) -> Result<Body> {
return fillet(body, edges, *r);
}
body.require_brep("fillet")?;
for (p, r) in edges.iter().zip(radii) {
crate::blend_fit::check(body, std::slice::from_ref(p), crate::blend_fit::Size::Round(*r))?;
}
crate::blend_smlib::fillet_each(body, edges, radii).and_then(|b| closed(body, b))
}
@@ -369,7 +359,7 @@ pub fn chamfer(body: &Body, edges: &[Vec3], distance: f64) -> Result<Body> {
if edges.is_empty() || edges.len() > 1000 {
return Err(KernelError::Invalid("select 1…1000 edges".into()));
}
crate::blend_fit::fit(body, edges, crate::blend_fit::Size::Chamfer(distance), || crate::blend_smlib::chamfer(body, edges, distance))
crate::blend_smlib::chamfer(body, edges, distance)
}
/// The second side of an unequal chamfer: a distance along the other face, or the angle the
@@ -396,9 +386,7 @@ pub fn chamfer_sides(body: &Body, edges: &[Vec3], d1: f64, side: ChamferSide, fl
if edges.is_empty() || edges.len() > 1000 {
return Err(KernelError::Invalid("select 1…1000 edges".into()));
}
crate::blend_fit::fit(body, edges, crate::blend_fit::Size::Sides(d1, side, flip), || {
crate::blend_smlib::chamfer_sides(body, edges, d1, side, flip)
})
crate::blend_smlib::chamfer_sides(body, edges, d1, side, flip)
}
#[cfg(test)]
crates/kernel/src/blend_fit.rs
-645
View File
@@ -1,645 +0,0 @@
//! Does a fillet or chamfer fit where it is asked for (#1080)? A blend of a straight edge
//! between two planar faces takes away (or, on a concave edge, fills) at most the wedge between
//! the edge and its two setback lines. Any other face of the body inside that wedge means the
//! blend runs past a neighbouring face's boundary into other geometry (a hole, a pocket, an
//! earlier round), and two such wedges overlapping mean two blends cross. Either way the result
//! the operations build is not a blend of those edges, so it is refused with the largest size
//! that does fit. After the build, the volume taken away is checked against the wedges too.
use solidcraft_geom::Vec3;
use crate::blend::{ChamferSide, Faces};
use crate::body::Body;
use crate::{KernelError, Result};
/// What is asked for on every edge.
#[derive(Clone, Copy, Debug)]
pub(crate) enum Size {
/// A round of this radius.
Round(f64),
/// An equal-distance chamfer.
Chamfer(f64),
/// A chamfer with a second distance or an angle (see [`crate::chamfer_sides`]).
Sides(f64, ChamferSide, bool),
}
impl Size {
fn scaled(self, k: f64) -> Size {
match self {
Size::Round(r) => Size::Round(r * k),
Size::Chamfer(s) => Size::Chamfer(s * k),
Size::Sides(d, ChamferSide::Distance(d2), f) => Size::Sides(d * k, ChamferSide::Distance(d2 * k), f),
Size::Sides(d, a, f) => Size::Sides(d * k, a, f),
}
}
fn value(self) -> f64 {
match self {
Size::Round(v) | Size::Chamfer(v) | Size::Sides(v, _, _) => v,
}
}
fn what(self) -> &'static str {
match self {
Size::Round(_) => "fillet",
_ => "chamfer",
}
}
}
/// A straight edge between two planar faces: its ends, the unit directions into each face
/// (perpendicular to the edge) and the faces' outward normals.
struct Frame {
p0: Vec3,
p1: Vec3,
/// Into face a and face b, from the edge.
ta: Vec3,
tb: Vec3,
na: Vec3,
nb: Vec3,
/// The faces (indices in the body's face order) the blend may meet: the two beside the
/// edge and every face at its ends.
allowed: Vec<usize>,
ends: [u32; 2],
/// Another edge of the two faces runs on from an end tangentially: the blend runs on along
/// that chain past this edge.
chained: bool,
}
/// One edge's region: the triangle edge, setback on face a, setback on face b, swept along the
/// edge, as half-spaces `n·x <= c` and as its five boundary polygons.
struct Wedge {
planes: [(Vec3, f64); 5],
faces: Vec<Vec<Vec3>>,
/// Cross-section area times length: the most a blend of the edge takes away or fills.
volume: f64,
}
impl Frame {
/// The setbacks along face a and face b for `size`; `None` where the faces are (nearly)
/// tangent or the size doesn't make a blend.
fn setbacks(&self, size: Size) -> Option<(f64, f64)> {
let cos = self.ta.dot(self.tb).clamp(-1.0, 1.0);
let phi = cos.acos();
if !(1e-3..std::f64::consts::PI - 1e-3).contains(&phi) {
return None;
}
match size {
// The round touches each face at r / tan(φ/2) from the edge.
Size::Round(r) => {
let t = r / (phi * 0.5).tan();
Some((t, t))
}
Size::Chamfer(s) => Some((s, s)),
Size::Sides(d1, side, flip) => {
// As `chamfer_tool_sides`: side 1 is the face facing up most, unless flipped.
let up = Vec3::new(1e-6, 1e-3, 1.0);
let a_is_first = (self.na.dot(up) >= self.nb.dot(up)) != flip;
let d2 = match side {
ChamferSide::Distance(d) => d,
ChamferSide::Angle(a) => {
let den = (phi + a).sin();
if den <= 1e-9 {
return None;
}
d1 * a.sin() / den
}
};
Some(if a_is_first { (d1, d2) } else { (d2, d1) })
}
}
}
fn wedge(&self, size: Size) -> Option<Wedge> {
let (sa, sb) = self.setbacks(size)?;
if !(sa.is_finite() && sb.is_finite() && sa > 0.0 && sb > 0.0) {
return None;
}
self.prism(self.ta * sa, self.tb * sb)
}
/// For a round, the arc of its cross-section from the setback on face a to the one on face
/// b, in [`ARC_PIECES`] pieces, as offsets from the edge; `None` for a chamfer.
fn arc(&self, size: Size) -> Option<Vec<Vec3>> {
let Size::Round(r) = size else { return None };
let (sa, sb) = self.setbacks(size)?;
let half = 0.5 * self.ta.dot(self.tb).clamp(-1.0, 1.0).acos();
// The ball's centre, on the bisector, `r` from both faces.
let centre = (self.ta + self.tb).normalized()? * (r / half.sin());
let (a, b) = (self.ta * sa - centre, self.tb * sb - centre);
(0..=ARC_PIECES).map(|k| Some(centre + (a + (b - a) * (k as f64 / ARC_PIECES as f64)).normalized()? * r)).collect()
}
/// What a blend of the edge at `size` changes, within the wedge: for a round, the fan of
/// prisms from the edge to the pieces of its arc (between the edge and the arc lies all it
/// takes away or fills; the ball's side of the arc is left as it is), for a chamfer the
/// wedge itself.
fn pieces(&self, size: Size) -> Option<Vec<Wedge>> {
match self.arc(size) {
Some(arc) => arc.windows(2).map(|w| self.prism(*w.first()?, *w.get(1)?)).collect(),
None => Some(vec![self.wedge(size)?]),
}
}
/// The blend's own surface at `size`, as polygons: the strips between its arc's pieces, or
/// the chamfer's face.
fn surface(&self, size: Size) -> Option<Vec<Vec<Vec3>>> {
match self.arc(size) {
Some(arc) => arc
.windows(2)
.map(|w| {
let (u, v) = (*w.first()?, *w.get(1)?);
Some(vec![self.p0 + u, self.p0 + v, self.p1 + v, self.p1 + u])
})
.collect(),
None => Some(vec![self.wedge(size)?.faces.get(2)?.clone()]),
}
}
/// The triangle between the edge and the offsets `u` and `w` across it, swept along the edge.
fn prism(&self, u: Vec3, w: Vec3) -> Option<Wedge> {
let d = (self.p1 - self.p0).normalized()?;
let (a0, b0) = (self.p0 + u, self.p0 + w);
let (a1, b1) = (self.p1 + u, self.p1 + w);
// Each side's plane, facing away from the triangle's third corner.
let side = |p: Vec3, q: Vec3, opposite: Vec3| -> Option<(Vec3, f64)> {
let mut n = d.cross(q - p).normalized()?;
if n.dot(opposite - p) > 0.0 {
n = -n;
}
Some((n, n.dot(p)))
};
let planes = [side(self.p0, a0, b0)?, side(self.p0, b0, a0)?, side(a0, b0, self.p0)?, (-d, -d.dot(self.p0)), (d, d.dot(self.p1))];
let faces =
vec![vec![self.p0, a0, a1, self.p1], vec![self.p0, b0, b1, self.p1], vec![a0, b0, b1, a1], vec![self.p0, a0, b0], vec![self.p1, a1, b1]];
let area = 0.5 * u.cross(w).len();
Some(Wedge { planes, faces, volume: area * self.p0.dist(self.p1) })
}
}
/// Pieces a round's arc is divided into for [`Frame::pieces`] and [`Frame::surface`]: each
/// chord sags under 0.5 % of the radius.
const ARC_PIECES: usize = 8;
/// `poly` clipped to the half-spaces `n·x <= c`, each moved `eps` inwards (empty when nothing
/// is left).
fn clip(poly: &[Vec3], planes: &[(Vec3, f64)], eps: f64) -> Vec<Vec3> {
let mut cur: Vec<Vec3> = poly.to_vec();
for (n, c) in planes {
let c = c - eps;
let mut next = Vec::with_capacity(cur.len() + 2);
for (i, p) in cur.iter().enumerate() {
let Some(q) = cur.get((i + 1) % cur.len()) else { continue };
let (dp, dq) = (n.dot(*p) - c, n.dot(*q) - c);
if dp <= 0.0 {
next.push(*p);
}
if (dp < 0.0 && dq > 0.0) || (dp > 0.0 && dq < 0.0) {
next.push(*p + (*q - *p) * (dp / (dp - dq)));
}
}
if next.is_empty() {
return next;
}
cur = next;
}
cur
}
/// `poly` clipped to the half-spaces, each moved `eps` inwards: is anything left?
fn reaches_inside(poly: &[Vec3], planes: &[(Vec3, f64)], eps: f64) -> bool {
!clip(poly, planes, eps).is_empty()
}
/// Most polygons [`reaches_inside_beyond`] clips before it gives up and answers yes.
const MAX_CLIPS: usize = 4096;
/// Whether the part of `poly` outside every one of the wedges `trimmed` (by more than `out`)
/// reaches inside `planes` (by `eps`). A face beside or at the end of another edge the same
/// feature blends is trimmed back to that blend, so its part inside that edge's wedge is gone
/// (#1668).
fn reaches_inside_beyond(poly: &[Vec3], planes: &[(Vec3, f64)], eps: f64, trimmed: &[&Wedge], out: f64) -> bool {
let mut parts = vec![poly.to_vec()];
for w in trimmed {
// Outside a convex wedge is outside one of its planes (pieces may overlap: only
// whether anything is left counts).
let mut next = Vec::new();
for part in &parts {
for (n, c) in &w.planes {
let piece = clip(part, &[(-*n, -*c)], out);
if !piece.is_empty() {
next.push(piece);
}
}
if next.len() > MAX_CLIPS {
return true;
}
}
parts = next;
}
parts.iter().any(|p| reaches_inside(p, planes, eps))
}
/// Whether two sets of convex prisms overlap (by more than `eps`): a face of one reaches
/// inside the other.
fn overlap(a: &[Wedge], b: &[Wedge], eps: f64) -> bool {
a.iter().any(|x| {
b.iter().any(|y| y.faces.iter().any(|p| reaches_inside(p, &x.planes, eps)) || x.faces.iter().any(|p| reaches_inside(p, &y.planes, eps)))
})
}
/// The body's straight edges between planar faces nearest the points (each once; `None` for a
/// point whose edge is something else, which the check leaves alone).
struct Selection {
frames: Vec<Option<Frame>>,
/// The body's triangles, with their face and whether that face is planar.
tris: Vec<([Vec3; 3], usize)>,
planar: Vec<bool>,
size: f64,
chord: f64,
/// The body's volume and area from that mesh.
coarse: (f64, f64),
}
/// The selection on `body` as SMLib blends it: its record's faces and edges, in their order (the
/// mesh's edges and faces are in the same order).
fn select(body: &Body, pts: &[Vec3]) -> Result<Selection> {
let size = body.size();
let chord = (size * 1e-3).max(1e-4);
let mesh = body.mesh(&crate::MeshTolerance::chord(chord))?;
let rec = Faces::of(body)?;
let planar: Vec<bool> = (0..rec.rec.faces.len()).map(|f| rec.plane_normal(f).is_some()).collect();
let mut taken: Vec<usize> = Vec::new();
let mut frames = Vec::new();
for p in pts {
// The edge nearest the point, as the blends pick it.
let best = mesh
.edges
.iter()
.enumerate()
.map(|(i, poly)| (i, poly.windows(2).filter_map(|w| Some(p.dist_to_segment(*w.first()?, *w.get(1)?))).fold(f64::INFINITY, f64::min)))
.min_by(|a, b| a.1.total_cmp(&b.1));
// Points on the same edge count once.
let frame = match best.filter(|(i, dist)| *i < rec.rec.edges.len() && *dist <= size * 0.05 + 1e-3) {
Some((e, _)) if taken.contains(&e) => continue,
Some((e, _)) => {
taken.push(e);
frame(&rec, e)
}
None => None,
};
frames.push(frame);
}
let m = mesh.measure();
let coarse = (m.volume, m.area);
let tris = mesh.triangles.iter().zip(&mesh.tri_face).filter_map(|(t, f)| Some((mesh.tri(t)?, *f as usize))).collect();
Ok(Selection { frames, tris, planar, size, chord, coarse })
}
fn frame(rec: &Faces, e: usize) -> Option<Frame> {
if !rec.straight(e) {
return None;
}
let ends = rec.rec.edges.get(e)?.vertices;
let (p0, p1) = rec.ends(e)?;
let d = (p1 - p0).normalized()?;
// Each face along the edge: its outward normal and the direction into it (the face lies to
// the left of its loop seen from its surface's natural normal).
let mut beside = Vec::new();
let mut allowed = Vec::new();
let mut chained = false;
for i in 0..rec.rec.faces.len() {
let at_end = rec.uses(i).any(|x| rec.rec.edges.get(x.edge as usize).is_some_and(|y| y.vertices.iter().any(|v| ends.contains(v))));
if at_end {
allowed.push(i);
}
let mut uses: Vec<_> = rec.uses(i).filter(|x| x.edge as usize == e).collect();
if uses.is_empty() {
continue;
}
let n = rec.plane_normal(i)?;
let u = uses.pop()?;
if !uses.is_empty() {
return None;
}
beside.push((n, rec.direction_into_face(i, u)?));
chained |= rec.uses(i).filter(|x| x.edge as usize != e).any(|x| {
let Some(other) = rec.rec.edges.get(x.edge as usize) else { return false };
let [a, b] = other.vertices;
let x = x.edge as usize;
(ends.contains(&a) && rec.tangent(x, false).is_some_and(|t| t.dot(d).abs() > 1.0 - 1e-6))
|| (ends.contains(&b) && rec.tangent(x, true).is_some_and(|t| t.dot(d).abs() > 1.0 - 1e-6))
});
}
let [(na, ta), (nb, tb)] = beside[..] else { return None };
// Both directions perpendicular to the edge, within their faces.
if ta.dot(d).abs() > 1e-6 || tb.dot(d).abs() > 1e-6 {
return None;
}
Some(Frame { p0, p1, ta, tb, na, nb, allowed, ends, chained })
}
/// What a blend that doesn't fit runs into.
enum Clash {
Face,
Blend,
}
/// What a blend at `size` runs into first, if anything. Curved faces are meshed to within the
/// chord: they count when their mesh reaches into a wedge by more than twice the chord, or, when
/// `strict`, when it comes within the chord of one (the surface may then be inside it).
fn first_clash(sel: &Selection, size: Size, strict: bool) -> Option<Clash> {
let wedges: Vec<Option<Wedge>> = sel.frames.iter().map(|f| f.as_ref().and_then(|f| f.wedge(size))).collect();
// What each blend changes: for a round only the fan between its edge and its arc, a part of
// the wedge. A face inside the wedge but beyond the arc (the inside round of a wall, when the
// outside one is a concentric round) is on the ball's side, left as it is.
let changes: Vec<Option<Vec<Wedge>>> = sel.frames.iter().map(|f| f.as_ref().and_then(|f| f.pieces(size))).collect();
// Planar faces are exact in the mesh; curved ones are within the chord.
let flat = (sel.size * 1e-7).max(1e-9);
let curved = if strict { -sel.chord } else { sel.chord * 2.0 };
// Planar faces beside an edge lie in its wedge's side planes: outside it means further.
let out = (sel.size * 1e-6).max(1e-8);
for (i, ((f, w), changed)) in sel.frames.iter().zip(&wedges).zip(&changes).enumerate() {
let (Some(f), Some(w)) = (f, w) else { continue };
// Without its pieces (or for a chamfer, whose one piece is the wedge) the wedge counts.
let changed = changed.as_deref().unwrap_or_default();
let hit = sel.tris.iter().filter(|(_, face)| !f.allowed.contains(face)).any(|(t, face)| {
let eps = if sel.planar.get(*face).copied().unwrap_or(false) { flat } else { curved };
// The other blended edges this face runs along or ends them trim it back.
let trimmed: Vec<&Wedge> = sel
.frames
.iter()
.zip(&wedges)
.enumerate()
.filter(|(j, (fj, _))| *j != i && fj.as_ref().is_some_and(|fj| fj.allowed.contains(face)))
.filter_map(|(_, (_, wj))| wj.as_ref())
.collect();
// The pieces near the arc's ends are thin: a curved face only goes clear of them
// when its mesh stays a chord outside, or a sliver into the round is missed (#324).
let fan = if sel.planar.get(*face).copied().unwrap_or(false) { flat } else { -sel.chord };
reaches_inside_beyond(t, &w.planes, eps, &trimmed, out)
&& (changed.len() <= 1 || changed.iter().any(|p| reaches_inside_beyond(t, &p.planes, fan, &trimmed, out)))
});
if hit {
return Some(Clash::Face);
}
}
// Two blends whose edges don't meet must not overlap (those meeting at a vertex mitre).
let eps = (sel.size * 1e-7).max(1e-9);
for (i, (fi, wi)) in sel.frames.iter().zip(&wedges).enumerate() {
let (Some(fi), Some(wi)) = (fi, wi) else { continue };
for (fj, wj) in sel.frames.iter().zip(&wedges).skip(i + 1) {
let (Some(fj), Some(wj)) = (fj, wj) else { continue };
if fi.ends.iter().any(|v| fj.ends.contains(v)) {
continue;
}
let meet = wj.faces.iter().any(|p| reaches_inside(p, &wi.planes, eps)) || wi.faces.iter().any(|p| reaches_inside(p, &wj.planes, eps));
if meet && blends_cross(fi, wi, fj, wj, size, eps) {
return Some(Clash::Blend);
}
}
}
None
}
/// Two blends whose wedges overlap: do they cross? Rounds on both sides of a wall (the outside
/// round's wedge reaches past the inside corner, which the inside round fills) need not: they
/// cross only where what one changes (between its edge and its arc) overlaps what the other
/// does, or where either's surface runs into the other's wedge (#1668).
fn blends_cross(fi: &Frame, wi: &Wedge, fj: &Frame, wj: &Wedge, size: Size, eps: f64) -> bool {
let (Some(pi), Some(pj), Some(si), Some(sj)) = (fi.pieces(size), fj.pieces(size), fi.surface(size), fj.surface(size)) else { return true };
overlap(&pi, &pj, eps) || sj.iter().any(|p| reaches_inside(p, &wi.planes, eps)) || si.iter().any(|p| reaches_inside(p, &wj.planes, eps))
}
/// The step the largest fitting size is given to: three significant digits.
fn step(v: f64) -> f64 {
10f64.powf(v.log10().floor() - 3.0)
}
/// Why a blend at `size` doesn't fit the selection and the largest size that does (to three
/// significant digits; `None` when not even the smallest step fits), or `None` when it fits or
/// the check can't tell (edges other than straight ones between planar faces).
fn misfit_in(sel: &Selection, size: Size) -> Result<Option<(Clash, Option<f64>)>> {
if sel.frames.iter().all(Option::is_none) || !size.value().is_finite() || size.value() <= 0.0 {
return Ok(None);
}
let Some(clash) = first_clash(sel, size, false) else { return Ok(None) };
// Bisection on the size's steps: `hi` doesn't fit, `lo` does (or is 0). Strictly: a size
// offered as fitting must fit, though a curved face that only touches the wedge at it would
// not be refused (a hole whose rim the round's band just reaches, #324).
let asked = size.value();
let q = step(asked);
let (mut lo, mut hi) = (0u64, (asked / q).ceil() as u64);
for _ in 0..20 {
if hi.saturating_sub(lo) <= 1 {
break;
}
let mid = lo + (hi - lo) / 2;
if first_clash(sel, size.scaled(mid as f64 * q / asked), true).is_none() {
lo = mid;
} else {
hi = mid;
}
}
Ok(Some((clash, (lo > 0).then_some(lo as f64 * q))))
}
/// "; the largest radius that fits is 5 mm", or nothing.
fn fits_note(size: Size, largest: Option<f64>) -> String {
let unit = if matches!(size, Size::Round(_)) { "radius" } else { "size" };
largest.map(|v| format!("; the largest {unit} that fits is {} mm", show(v))).unwrap_or_default()
}
/// Refuse a blend of `edges` at `size` that runs into other faces of `body` or into another of
/// the blends, with [`KernelError::TooLarge`] naming the largest size that fits.
pub(crate) fn check(body: &Body, edges: &[Vec3], size: Size) -> Result<()> {
if body.is_mesh() || edges.is_empty() {
return Ok(());
}
check_in(&select(body, edges)?, size)
}
/// [`check`] on the selection.
fn check_in(sel: &Selection, size: Size) -> Result<()> {
let Some((clash, largest)) = misfit_in(sel, size)? else { return Ok(()) };
let what = size.what();
let into = match clash {
Clash::Face => "it runs past the faces beside the edge into other geometry".to_string(),
Clash::Blend => format!("the {what}s on these edges would cross each other"),
};
Err(KernelError::TooLarge(format!("{} mm is too large for this {what}: {into}{}", show(size.value()), fits_note(size, largest))))
}
/// The blend `build` makes of `edges` at `size` on `input`: refused before it is built when it
/// would not fit ([`check`]), and after when it changes more than the blends can
/// ([`check_volume`]) or goes the wrong way.
pub(crate) fn fit(input: &Body, edges: &[Vec3], size: Size, build: impl FnOnce() -> Result<Body>) -> Result<Body> {
if input.is_mesh() || edges.is_empty() {
return build();
}
let sel = select(input, edges)?;
check_in(&sel, size)?;
let out = build()?;
if out.is_mesh() {
return Ok(out);
}
let out = volume_in(&sel, input, out, size)?;
right_way(input, out, edges, size)
}
/// Whether the edge of `body` nearest `p` is convex (`Some(true)`: a chamfer takes material
/// away) or concave (`Some(false)`: it fills), from the two faces' outward normals and the
/// directions into each face across the edge at `p`. `None` unless that is clear-cut: faces
/// meeting at a few degrees of tangent or of a knife edge, an edge not between two faces.
fn convex_at(body: &Body, p: Vec3) -> Option<bool> {
let tol = (body.size() * 1e-4).max(1e-4);
let (i, _) = body.nearest_edge(p, tol).ok()??;
let rec = Faces::of(body).ok()?;
let edge = rec.rec.edges.get(i)?;
let t = nearest_parameter(&edge.curve, edge.interval, p)?;
let along = crate::blend::curve_tangent(&edge.curve, t)?;
let on = solidcraft_geom::brep::eval::CurveEval::new(&edge.curve).ok()?.point(t)?;
let accept = (body.size() * 1e-3).max(1e-3);
let mut sides = Vec::new();
for f in rec.faces_of(i) {
let f = f as usize;
for u in rec.uses(f).filter(|u| u.edge as usize == i) {
let dir = if u.forward { along } else { along * -1.0 };
// The face lies to the left of its loop seen from its surface's natural normal.
let (n, natural) = (rec.normal_at(f, on, accept)?, rec.natural_normal_at(f, on, accept)?);
sides.push((n, natural.cross(dir).normalized()?));
}
}
let [(n1, t1), (n2, t2)] = sides[..] else { return None };
// About 3°: the faces neither nearly tangent nor folded onto each other.
const CLEAR: f64 = 0.05;
if t1.dot(t2) > 1.0 - CLEAR || t1.dot(t2) < -1.0 + CLEAR {
return None;
}
let (a, b) = (n1.dot(t2), n2.dot(t1));
if a < -CLEAR && b < -CLEAR {
Some(true)
} else if a > CLEAR && b > CLEAR {
Some(false)
} else {
None
}
}
/// A chamfer of convex edges takes material away and one of concave edges fills it: a result
/// that went the other way (a chamfer on a curved edge running off a face it skims, which the
/// wedges can't bound) is refused rather than kept. Rounds are left to the wedges: a round
/// rolled along a smooth chain may run on round convex and concave stretches alike.
fn right_way(input: &Body, out: Body, edges: &[Vec3], size: Size) -> Result<Body> {
if matches!(size, Size::Round(_)) {
return Ok(out);
}
let ways: Option<Vec<bool>> = edges.iter().map(|p| convex_at(input, *p)).collect();
let Some(ways) = ways else { return Ok(out) };
let (convex, concave) = (ways.iter().all(|w| *w), ways.iter().all(|w| !*w));
if !(convex || concave) {
return Ok(out);
}
let (Ok(a), Ok(b)) = (crate::measure(input), crate::measure(&out)) else { return Ok(out) };
let slack = a.volume.abs() * 1e-5 + 1e-6;
let grew = b.volume - a.volume;
if (convex && grew > slack) || (concave && grew < -slack) {
return Err(KernelError::TooLarge(format!(
"{} mm is too large for this {}: on {} edge it would {} the part by {} mm³ instead (it runs off a face next to the edge)",
show(size.value()),
size.what(),
if convex { "a convex" } else { "a concave" },
if convex { "grow" } else { "shrink" },
// A fraction of a mm³ is typical here: to the hundredth.
show((grew.abs() * 100.0).round() / 100.0)
)));
}
Ok(out)
}
/// The parameter of the point of `c` within `interval` nearest `p`: the nearest of 33 evenly
/// spaced starts, refined by Gauss-Newton steps on the distance.
fn nearest_parameter(c: &solidcraft_geom::brep::Curve, interval: [f64; 2], p: Vec3) -> Option<f64> {
let e = solidcraft_geom::brep::eval::CurveEval::new(c).ok()?;
let [lo, hi] = interval;
if !(lo.is_finite() && hi.is_finite() && lo < hi) {
return None;
}
let at = |k: usize| lo + (hi - lo) * k as f64 / 32.0;
let mut t = (0..=32).map(at).filter_map(|t| Some((t, e.point(t)?.dist(p)))).min_by(|a, b| a.1.total_cmp(&b.1))?.0;
for _ in 0..32 {
let (q, d) = (e.point(t)?, crate::blend::curve_derivative(c, t)?);
if !(d.len2() > 0.0) {
break;
}
let step = (p - q).dot(d) / d.len2();
t = (t + step).clamp(lo, hi);
if step.abs() <= (hi - lo) * 1e-12 {
break;
}
}
Some(t)
}
/// After a blend of `edges` at `size` turned `input` into `out`: refused when the volume taken
/// away (or added) is more than the blends' wedges hold, which only a result that ran into
/// other geometry does (#871's shelled box lost 240 mm³ more than any round could take).
#[cfg(test)]
pub(crate) fn check_volume(input: &Body, out: Body, edges: &[Vec3], size: Size) -> Result<Body> {
if input.is_mesh() || out.is_mesh() || edges.is_empty() {
return Ok(out);
}
let Ok(sel) = select(input, edges) else { return Ok(out) };
volume_in(&sel, input, out, size)
}
/// [`check_volume`] on the selection.
fn volume_in(sel: &Selection, input: &Body, out: Body, size: Size) -> Result<Body> {
if sel.frames.is_empty() {
return Ok(out);
}
let mut bound = 0.0;
for f in &sel.frames {
// An edge the wedges can't describe: no bound.
let Some(w) = f.as_ref().and_then(|f| f.wedge(size)) else { return Ok(out) };
let Some(f) = f.as_ref().filter(|f| !f.chained) else { return Ok(out) };
// Past an edge's ends a chamfer may still cut under a sloping end face.
let (sa, sb) = f.setbacks(size).unwrap_or((0.0, 0.0));
let len = f.p0.dist(f.p1);
bound += w.volume * (len + 2.0 * sa.max(sb)) / len.max(1e-12);
}
// Well within the bound on the meshes the check made anyway: accepted. Otherwise measured
// finely, as a coarse mesh of a cone or a blend is off by more than a small blend.
if let Ok(m) = out.mesh(&crate::MeshTolerance::chord(sel.chord)).map(|m| m.measure()) {
let (va, aa) = sel.coarse;
// A chord's sag over every face bounds what the meshes miss.
let slack = (aa + m.area) * sel.chord;
if (va - m.volume).abs() + slack <= bound * 1.02 {
return Ok(out);
}
}
let (Ok(ma), Ok(mb)) = (crate::measure(input), crate::measure(&out)) else { return Ok(out) };
let slack = ma.volume.abs() * 1e-4 + (ma.area + mb.area) * sel.size * 1e-5;
let changed = (ma.volume - mb.volume).abs();
if changed > bound * 1.02 + slack {
return Err(KernelError::TooLarge(format!(
"{} mm is too large for this {}: the result changes {} mm³ of the part, more than the {} can (at most {} mm³)",
show(size.value()),
size.what(),
show_rounded(changed),
size.what(),
show_rounded(bound)
)));
}
Ok(out)
}
/// A length in mm, without trailing zeros.
fn show(v: f64) -> String {
let s = format!("{v:.4}");
s.trim_end_matches('0').trim_end_matches('.').to_string()
}
fn show_rounded(v: f64) -> String {
format!("{v:.0}")
}
crates/kernel/src/blend_smlib.rs
+1
View File
@@ -199,6 +199,7 @@ mod imp {
let r = op(&tagged).map_err(|e| match e {
SmError::Unsupported => super::unsupported(&format!("this {what}, which SMLib cannot build exactly")),
SmError::NoEffect => KernelError::Failed(format!("SMLib made no change: the {what} reported success but built no face")),
SmError::NoRoom => KernelError::TooLarge(format!("the {what} is larger than the faces beside its edges allow")),
e => failed(what, "operation", e),
})?;
let check = r.check(CheckLevel::All).map_err(|e| failed(what, "check", e))?;
crates/kernel/src/blend_variable.rs
+2 -12
View File
@@ -198,24 +198,14 @@ pub fn fillet_variable_points(body: &Body, edge_at: Vec3, start: Vec3, points: &
}
/// Fillet one edge with the radius `spline` along it, its positions from the end nearest
/// `start`. One end's radius may be zero. On a straight edge between planar faces a law whose
/// band runs past the faces anywhere along the edge is refused as too large.
/// `start`. One end's radius may be zero. A law whose round would leave the faces beside the
/// edge is SMLib's refusal ([`KernelError::TooLarge`]).
pub fn fillet_variable_spline(body: &Body, edge_at: Vec3, start: Vec3, spline: &RadiusSpline) -> Result<Body> {
body.require_brep("fillet")?;
spline.check()?;
if !(edge_at.is_finite() && start.is_finite()) {
return Err(KernelError::Invalid("the edge pick and the start point must be finite".into()));
}
if let Ok(s) = EdgeSetup::new(body, edge_at) {
// Positions from the end nearest `start` (the edge keeps its own direction).
let law = if s.p1.dist(start) < s.p0.dist(start) { spline.reversed() } else { spline.clone() };
const STATIONS: usize = 256;
let fits =
guard("variable fillet", || Ok((1..STATIONS).all(|k| s.band_fits(k as f64 / STATIONS as f64, law.eval(k as f64 / STATIONS as f64)))))?;
if !fits {
return Err(too_large("the blend is larger than the neighbouring faces"));
}
}
crate::blend_smlib::fillet_variable(body, edge_at, start, spline)
}
crates/kernel/src/issue_1080_tests.rs
-15
View File
@@ -80,21 +80,6 @@ fn chamfers_meeting_at_a_corner_still_build() {
assert!(crate::fillet(&b, &edges, 5.0).is_ok());
}
/// A result that changes more of the part than the blends can is refused (#871's shelled box
/// lost 240 mm³ more than any round of its edge could take).
#[test]
fn a_result_that_removes_more_than_the_blend_is_refused() {
let b = box_solid(Vec3::new(0.0, 0.0, 0.0), Vec3::new(20.0, 20.0, 20.0)).unwrap();
let e = [Vec3::new(10.0, 0.0, 20.0)];
let size = crate::blend_fit::Size::Chamfer(2.0);
let good = crate::chamfer(&b, &e, 2.0).unwrap();
assert!(crate::blend_fit::check_volume(&b, good, &e, size).is_ok());
// A chamfer and a 1 mm slab off the far side as well.
let worse = cut(&crate::chamfer(&b, &e, 2.0).unwrap(), [0.0, 19.0, 0.0], [20.0, 20.0, 20.0]);
let m = too_large(crate::blend_fit::check_volume(&b, worse, &e, size));
assert!(m.contains("more than the chamfer can"), "{m}");
}
/// #1668: a box shelled outward 2 mm, open at the bottom. R5 on its top outer edge alone leaves
/// the sharp inside corner 2 mm away on its ball's side, 0.76 mm inside the round; it reaches
/// the corner only past 2√2 / (√2 - 1) ≈ 6.83 mm. With the inside edge rounded in the same
crates/kernel/src/lib.rs
-1
View File
@@ -15,7 +15,6 @@
mod assemble;
mod blend;
mod blend_corner;
mod blend_fit;
mod blend_smlib;
mod blend_variable;
#[cfg(test)]
crates/kernel/src/plane_fit.rs
-1
View File
@@ -12,4 +12,3 @@ pub(crate) fn loop_area(points: &[Vec3]) -> Vec3 {
}
n * 0.5
}
crates/smlib/src/ffi.rs
+1 -1
View File
@@ -191,8 +191,8 @@ pub mod flat;
pub mod history;
pub mod measure;
pub mod ops;
pub mod split;
pub mod sheets;
pub mod split;
pub mod ssi;
pub mod sweeps;
pub mod trim;
crates/smlib/src/lib.rs
+3 -2
View File
@@ -48,7 +48,8 @@ pub enum Error {
NoMatch { point: usize },
/// Selection point `point` is equally near to two edges (faces).
Ambiguous { point: usize },
/// An inward offset (a shell's wall, faces moved in) leaves no room inside the body.
/// No room for the operation: an inward offset (a shell's wall, faces moved in) leaves none
/// inside the body, or a blend is larger than the faces it rolls on allow.
NoRoom,
/// SMLib cannot build this exactly yet (a variable radius whose law has a corner).
Unsupported,
@@ -80,7 +81,7 @@ impl std::fmt::Display for Error {
Error::NotSolid => write!(f, "SMLib's result is not a closed solid"),
Error::NoMatch { point } => write!(f, "selection point {} is not near any edge or face", point + 1),
Error::Ambiguous { point } => write!(f, "selection point {} is equally near to two edges or faces", point + 1),
Error::NoRoom => write!(f, "the offset leaves no room inside the body"),
Error::NoRoom => write!(f, "there is no room for it: an offset leaves none inside the body, or a blend is larger than its faces allow"),
Error::Unsupported => write!(f, "not supported yet: SMLib cannot build this exactly"),
Error::NoEffect => write!(f, "SMLib made no change: it reported success, but the operation did nothing"),
Error::NotExact => write!(f, "SMLib cannot build this exactly in the input's geometry"),
crates/smlib/src/ops.rs
+6 -6
View File
@@ -121,21 +121,21 @@ impl Brep {
ffi::ops::solid_count(&self.0).map(|n| usize::try_from(n).unwrap_or(0)).map_err(error)
}
/// The edges nearest to `edges` (each within `tolerance`), with their tangent chains, rounded
/// The edges nearest to `edges` (each within `tolerance`), exactly those, rounded
/// at `radius`.
pub fn fillet(&self, edges: &[[f64; 3]], tolerance: f64, radius: f64) -> Result<Brep> {
self.pick_op(ffi::ops::Pick::Fillet, edges, tolerance, radius, false)
}
/// The edges nearest to `edges` (each within `tolerance`), with their tangent chains, cut by
/// The edges nearest to `edges` (each within `tolerance`), exactly those, cut by
/// an equal-distance chamfer `distance` back along each face (measured at each edge's
/// midpoint), with bevelled corners.
pub fn chamfer(&self, edges: &[[f64; 3]], tolerance: f64, distance: f64) -> Result<Brep> {
self.pick_op(ffi::ops::Pick::Chamfer, edges, tolerance, distance, false)
}
/// The edges nearest to `edges` (each within `tolerance`), with their tangent chains, blended
/// as `kind`, edge i (and its chain) at `sizes[i]`.
/// The edges nearest to `edges` (each within `tolerance`), exactly those, blended
/// as `kind`, edge i at `sizes[i]`.
pub fn blend(&self, kind: Blend, edges: &[[f64; 3]], sizes: &[f64], tolerance: f64) -> Result<Brep> {
init()?;
if edges.len() > MAX_POINTS || edges.is_empty() || sizes.len() != edges.len() {
@@ -150,7 +150,7 @@ impl Brep {
ffi::ops::blend(kind, &self.0, edges, sizes, tolerance).map(Brep).map_err(pick_error)
}
/// The one edge nearest to `edge` (within `tolerance`, no tangent chain) rounded with a radius
/// The one edge nearest to `edge` (within `tolerance`) rounded with a radius
/// that varies along it: a clamped B-spline of `degree` (1 to 3) with `knots` and control
/// `radii` over the position along the edge, 0 at its end nearest `start` and 1 at the other
/// (the edge curve's parameter scaled to 0..1).
@@ -164,7 +164,7 @@ impl Brep {
})
}
/// The edges nearest to `edges` (each within `tolerance`), with their tangent chains, cut by
/// The edges nearest to `edges` (each within `tolerance`), exactly those, cut by
/// a chamfer `distance` back along the face whose outward normal leans most along `first`,
/// and by `second` on the other, with bevelled corners (setbacks measured at each edge's
/// midpoint).
crates/smlib/src/ops_tests.rs
+8 -7
View File
@@ -163,7 +163,7 @@ fn shell_a_box_open_at_the_top() {
}
#[test]
fn fillet_follows_a_tangent_chain() {
fn fillet_takes_exactly_the_picked_edges() {
// Round the vertical edge x = y = 20 first (r = 5): the top rim is then line, arc, line,
// meeting tangentially.
let c = cube(20.0);
@@ -171,15 +171,16 @@ fn fillet_follows_a_tangent_chain() {
shot(&round, "fillet_one_edge");
let pi = std::f64::consts::PI;
assert_close(volume(&round), 8000.0 - (1.0 - pi / 4.0) * 25.0 * 20.0, 1e-6, "one rounded edge");
// One point on the straight part of the rim rounds the whole chain.
let chain = round.fillet(&[[7.5, 20.0, 20.0]], 0.1, 1.0).unwrap();
shot(&chain, "fillet_tangent_chain");
// One point on the straight part of the rim rounds that edge only; the chain is rounded when
// all of its edges are picked.
let one = round.fillet(&[[7.5, 20.0, 20.0]], 0.1, 1.0).unwrap();
shot(&one, "fillet_one_of_a_chain");
let arc = [15.0 + 5.0 * (pi / 4.0).cos(), 15.0 + 5.0 * (pi / 4.0).sin(), 20.0];
let all = round.fillet(&[[7.5, 20.0, 20.0], arc, [20.0, 7.5, 20.0]], 0.1, 1.0).unwrap();
shot(&all, "fillet_chain_picked");
assert_eq!(chain.counts().unwrap(), all.counts().unwrap(), "one pick = the whole chain");
assert_close(volume(&chain), volume(&all), 1e-9, "one pick = the whole chain");
assert_eq!(chain.counts().unwrap()[0], round.counts().unwrap()[0] + 3, "three rounds on the chain");
assert_eq!(one.counts().unwrap()[0], round.counts().unwrap()[0] + 1, "one round on the picked edge");
assert_eq!(all.counts().unwrap()[0], round.counts().unwrap()[0] + 3, "three rounds on the chain");
assert!(volume(&all) < volume(&one), "the chain takes more than its one edge");
}
#[test]