Thread: a hole too narrow (or a shaft too thick) says so, and what to drill (#2688) (#2853)

An M8 modelled thread in a 6 mm hole, narrower than M8's minor diameter, was
refused as "the face is too far from the thread's diameter". It now says what
is wrong and what fits, as a hole that is too wide already does (#995): "this
6 mm hole is too narrow for a modelled M8 thread (its teeth would fill the
hole); drill 6.75 mm for M8", with the thread that fits this hole when there
is one. A shaft too thick for its thread gets "make the shaft 8 mm for M8".

Fixes #2688

Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
Co-authored-by: bherbruck <brennen.herbruck@gmail.com>

crates/doc/src/eval.rs

@@ -382,7 +382,21 @@ fn thread_groove(t: &ThreadInfo, radius: f64, open: (bool, bool)) -> Result<soli
         (r_root, p / 8.0, r_out, (p / 4.0 + 2.0 * (r_out - r_root) * slope) / 2.0)
     };
     if w0.max(w1) * 2.0 >= p * 0.98 {
-        return Err(DocError::Invalid("the face is too far from the thread's diameter".into()));
+        // The groove would be wider than a pitch: the face is far inside the thread (a hole
+        // narrower than its minor diameter, a shaft thicker than its major one, #2688).
+        let (m, dia) = (&t.designation, 2.0 * radius);
+        let alt = thread_for(dia, t.internal).map(|(n, q)| format_thread(n, q)).filter(|a| a != m);
+        let shown = show_mm(dia);
+        return Err(DocError::Invalid(if t.internal {
+            let alt = alt.map(|a| format!(", or thread this hole {a}")).unwrap_or_default();
+            format!(
+                "this {shown} mm hole is too narrow for a modelled {m} thread (its teeth would fill the hole); drill {} mm for {m}{alt}",
+                show_mm(d - p)
+            )
+        } else {
+            let alt = alt.map(|a| format!(", or thread this shaft {a}")).unwrap_or_default();
+            format!("this {shown} mm shaft is too thick for a modelled {m} thread; make the shaft {} mm for {m}{alt}", show_mm(d))
+        }));
     }
     let k = t.axis;
     let u = k.cross(if k.x.abs() < 0.9 { Vec3::new(1.0, 0.0, 0.0) } else { Vec3::new(0.0, 1.0, 0.0) });

crates/engine/src/thread_tests.rs

@@ -102,6 +102,27 @@ fn a_modelled_thread_that_would_cut_nothing_is_refused() {
     assert!(e.contains("this 17.2 mm shaft") && e.contains("make the shaft 20 mm for M20") && e.contains("thread this shaft M18"), "{e}");
 }
 
+/// Issue 2688: an M8 modelled thread in a 6 mm hole (narrower than its 6.65 mm minor diameter)
+/// was refused as "the face is too far from the thread's diameter". It says what is wrong and
+/// what to drill, as a hole that is too wide does; and the same for a shaft that is too thick.
+#[test]
+fn a_hole_too_narrow_or_a_shaft_too_thick_says_which_and_what_fits() {
+    let mut s = hex_nut(6.0);
+    let before = volume(&mut s, "Nut");
+    let e = s.execute("solid.thread", &json!({"face": [3.0, 0, 2], "designation": "M8", "modeled": true})).err().map(|e| e.to_string());
+    let e = e.unwrap_or_default();
+    assert!(e.contains("this 6 mm hole is too narrow for a modelled M8 thread") && e.contains("drill 6.75 mm for M8"), "{e}");
+    assert!(!e.contains("too far"), "{e}");
+    assert!((volume(&mut s, "Nut") - before).abs() < 1e-9);
+
+    let mut s = Session::default();
+    // 9 mm is close enough to M8 to be offered it, too thick to cut it.
+    run(&mut s, "solid.cylinder", json!({"radius": 4.5, "height": 10, "body_name": "Shaft"}));
+    let e = s.execute("solid.thread", &json!({"face": [4.5, 0, 5], "designation": "M8", "modeled": true})).err().map(|e| e.to_string());
+    let e = e.unwrap_or_default();
+    assert!(e.contains("this 9 mm shaft is too thick for a modelled M8 thread") && e.contains("make the shaft 8 mm for M8"), "{e}");
+}
+
 /// The limit is a quarter of the basic depth 5H/8: a hole up to 4.78 mm for M5 (4.86 mm for
 /// M5x0.5) still takes a modelled thread, a wider one is refused with that pitch's drill.
 #[test]