Kernel rig: perforation cases, square and staggered fields counted hole by hole, a field kept clear of a bend zone, and a pitch refused

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>

tests/kernel-cases/sheet-metal/cov-perforate-keeps-clear-of-a-bend-zone/expected.json

@@ -0,0 +1,20 @@
+{
+ "sources": [],
+ "what": "sheet.perforate, a square field over a 40 x 20 x 1 base with a 10 mm flange on its x = 40 edge: no hole within the margin of the bend zone",
+ "source": "analytic",
+ "method": "T = 1, R = 1, K = 0.5: the flange sets the base back R + T = 2 (flat x 0..38), its bend zone is BA = (pi/2)(R + K*T) = 2.356194 wide (x 38..40.356194), its leg 10 - 2 = 8 (to x 48.356194). 1 mm holes, pitch 4, margin 1 (clear 1.5): rows y 1.5, 5.5, 9.5, 13.5, 17.5 (5); per row x 1.5, 5.5, ..., 45.5 (<= 46.8562) less those within 1.5 of the zone (37.5 and 41.5): 9 on the base, 1 on the flange (45.5): 50 holes",
+ "body_count": 1,
+ "results": [
+  {
+   "step": 8,
+   "json": {
+    "perforations": [
+     {
+      "count": 50,
+      "pattern": "square"
+     }
+    ]
+   }
+  }
+ ]
+}

tests/kernel-cases/sheet-metal/cov-perforate-keeps-clear-of-a-bend-zone/recipe.json

@@ -0,0 +1,72 @@
+{
+ "commands": [
+  {
+   "command": "sheet.manage_rules",
+   "params": {
+    "name": "Steel 1",
+    "thickness": "1 mm",
+    "active": true,
+    "bend_radius": "1 mm",
+    "k_factor": 0.5
+   }
+  },
+  {
+   "command": "sketch.create",
+   "params": {
+    "plane": "XY",
+    "name": "Base"
+   }
+  },
+  {
+   "command": "sketch.rectangle.two_point",
+   "params": {
+    "p0": [
+     0,
+     0
+    ],
+    "p1": [
+     40,
+     20
+    ]
+   }
+  },
+  {
+   "command": "sketch.finish",
+   "params": {}
+  },
+  {
+   "command": "sheet.flange",
+   "params": {
+    "type": "base",
+    "sketch": "Base"
+   }
+  },
+  {
+   "command": "sheet.flange",
+   "params": {
+    "type": "edge",
+    "edges": [
+     [
+      40,
+      10,
+      1
+     ]
+    ],
+    "height": 10
+   }
+  },
+  {
+   "command": "sheet.perforate",
+   "params": {
+    "diameter": "1",
+    "pitch": "4",
+    "margin": "1",
+    "pattern": "square"
+   }
+  },
+  {
+   "command": "sheet.flat_pattern",
+   "params": {}
+  }
+ ]
+}

tests/kernel-cases/sheet-metal/cov-perforate-pitch-no-larger-than-the-hole-refused/expected.json

@@ -0,0 +1,8 @@
+{
+ "sources": [],
+ "what": "sheet.perforate with a pitch equal to the hole's diameter: the holes would touch",
+ "source": "invariants",
+ "method": "holes 2 mm across at a 2 mm pitch leave no web between them; the documented rule is pitch > diameter, so the field is refused",
+ "outcome": "refused",
+ "refusal": "pitch > diameter"
+}

tests/kernel-cases/sheet-metal/cov-perforate-pitch-no-larger-than-the-hole-refused/recipe.json

@@ -0,0 +1,53 @@
+{
+ "commands": [
+  {
+   "command": "sheet.manage_rules",
+   "params": {
+    "name": "Steel 1",
+    "thickness": "1 mm",
+    "active": true,
+    "bend_radius": "1 mm",
+    "k_factor": 0.5
+   }
+  },
+  {
+   "command": "sketch.create",
+   "params": {
+    "plane": "XY",
+    "name": "Base"
+   }
+  },
+  {
+   "command": "sketch.rectangle.two_point",
+   "params": {
+    "p0": [
+     0,
+     0
+    ],
+    "p1": [
+     30,
+     20
+    ]
+   }
+  },
+  {
+   "command": "sketch.finish",
+   "params": {}
+  },
+  {
+   "command": "sheet.flange",
+   "params": {
+    "type": "base",
+    "sketch": "Base"
+   }
+  },
+  {
+   "command": "sheet.perforate",
+   "params": {
+    "diameter": "2",
+    "pitch": "2",
+    "margin": "1"
+   }
+  }
+ ]
+}

tests/kernel-cases/sheet-metal/cov-perforate-square-field-on-a-plate/expected.json

@@ -0,0 +1,26 @@
+{
+ "sources": [],
+ "what": "sheet.perforate, a square field of 2 mm holes at 5 mm pitch, 1 mm margin, over a 30 x 20 x 1 plate",
+ "source": "analytic",
+ "method": "holes start at margin + radius = 2 from the flat's lower-left corner and step 5: x 2, 7, ..., 27 (6, each <= 30 - 2), y 2, 7, 12, 17 (4): 24 holes, open area 24*pi*1^2. The field is stored, not cut into the B-rep: the body stays the 30 x 20 x 1 plate, V = 600, 6 faces",
+ "body_count": 1,
+ "volume_mm3": 600.0,
+ "faces": 6,
+ "results": [
+  {
+   "step": 7,
+   "json": {
+    "perforations": [
+     {
+      "count": 24,
+      "pattern": "square",
+      "diameter": 2.0,
+      "pitch": 5.0,
+      "margin": 1.0,
+      "open_area_mm2": 75.39822368615503
+     }
+    ]
+   }
+  }
+ ]
+}

tests/kernel-cases/sheet-metal/cov-perforate-square-field-on-a-plate/recipe.json

@@ -0,0 +1,58 @@
+{
+ "commands": [
+  {
+   "command": "sheet.manage_rules",
+   "params": {
+    "name": "Steel 1",
+    "thickness": "1 mm",
+    "active": true,
+    "bend_radius": "1 mm",
+    "k_factor": 0.5
+   }
+  },
+  {
+   "command": "sketch.create",
+   "params": {
+    "plane": "XY",
+    "name": "Base"
+   }
+  },
+  {
+   "command": "sketch.rectangle.two_point",
+   "params": {
+    "p0": [
+     0,
+     0
+    ],
+    "p1": [
+     30,
+     20
+    ]
+   }
+  },
+  {
+   "command": "sketch.finish",
+   "params": {}
+  },
+  {
+   "command": "sheet.flange",
+   "params": {
+    "type": "base",
+    "sketch": "Base"
+   }
+  },
+  {
+   "command": "sheet.perforate",
+   "params": {
+    "diameter": "2",
+    "pitch": "5",
+    "margin": "1",
+    "pattern": "square"
+   }
+  },
+  {
+   "command": "sheet.flat_pattern",
+   "params": {}
+  }
+ ]
+}

tests/kernel-cases/sheet-metal/cov-perforate-staggered-field-on-a-plate/expected.json

@@ -0,0 +1,38 @@
+{
+ "sources": [],
+ "what": "sheet.perforate, a staggered (60 degree) field of 1 mm holes at 3 mm pitch, 1 mm margin, over a 20 x 10 x 1 plate, exported to DXF",
+ "source": "analytic",
+ "method": "clear = radius + margin = 1.5; rows every 3*sqrt(3)/2 = 2.598 from y 1.5: y 1.5, 4.098, 6.696 (9.294 > 8.5); even rows x 1.5, 4.5, ..., 16.5 (6), the odd row shifted 1.5: x 3, ..., 18 (6): 18 holes. In the DXF, 18 circles on layer PERFORATION, length 18*pi*1; the plate's outline 4 lines, 60 long. The B-rep is not cut: V = 200",
+ "body_count": 1,
+ "volume_mm3": 200.0,
+ "faces": 6,
+ "results": [
+  {
+   "step": 7,
+   "json": {
+    "perforations": [
+     {
+      "count": 18,
+      "pattern": "staggered",
+      "open_area_mm2": 14.137166941154069
+     }
+    ]
+   }
+  }
+ ],
+ "files": [
+  {
+   "path": "flat.dxf",
+   "dxf": {
+    "PERFORATION": {
+     "CIRCLE": 18,
+     "length_mm": 56.548667764616276
+    },
+    "OUTLINE": {
+     "LINE": 4,
+     "length_mm": 60.0
+    }
+   }
+  }
+ ]
+}

tests/kernel-cases/sheet-metal/cov-perforate-staggered-field-on-a-plate/recipe.json

@@ -0,0 +1,63 @@
+{
+ "commands": [
+  {
+   "command": "sheet.manage_rules",
+   "params": {
+    "name": "Steel 1",
+    "thickness": "1 mm",
+    "active": true,
+    "bend_radius": "1 mm",
+    "k_factor": 0.5
+   }
+  },
+  {
+   "command": "sketch.create",
+   "params": {
+    "plane": "XY",
+    "name": "Base"
+   }
+  },
+  {
+   "command": "sketch.rectangle.two_point",
+   "params": {
+    "p0": [
+     0,
+     0
+    ],
+    "p1": [
+     20,
+     10
+    ]
+   }
+  },
+  {
+   "command": "sketch.finish",
+   "params": {}
+  },
+  {
+   "command": "sheet.flange",
+   "params": {
+    "type": "base",
+    "sketch": "Base"
+   }
+  },
+  {
+   "command": "sheet.perforate",
+   "params": {
+    "diameter": "1",
+    "pitch": "3",
+    "margin": "1"
+   }
+  },
+  {
+   "command": "sheet.flat_pattern",
+   "params": {}
+  },
+  {
+   "command": "sheet.export_dxf",
+   "params": {
+    "path": "$OUT/flat.dxf"
+   }
+  }
+ ]
+}