Cosplay/nhf/touhou/houjuu_nue/wing.py

"""
This file describes the shapes of the wing shells. The joints are defined in
`__init__.py`.
"""
import math
import cadquery as Cq
from nhf.joints import HirthJoint

def wing_root_profiles(
        base_sweep=150,
        wall_thickness=8,
        base_radius=60,
        middle_offset=30,
        conn_width=40,
        conn_height=100) -> tuple[Cq.Wire, Cq.Wire]:
    assert base_sweep < 180
    assert middle_offset > 0
    theta = math.pi * base_sweep / 180
    c, s = math.cos(theta), math.sin(theta)
    c_1, s_1 = math.cos(theta * 0.75), math.sin(theta * 0.75)
    c_2, s_2 = math.cos(theta / 2), math.sin(theta / 2)
    r1 = base_radius
    r2 = base_radius - wall_thickness
    base = (
        Cq.Sketch()
        .arc(
            (c * r1, s * r1),
            (c_1 * r1, s_1 * r1),
            (c_2 * r1, s_2 * r1),
        )
        .arc(
            (c_2 * r1, s_2 * r1),
            (r1, 0),
            (c_2 * r1, -s_2 * r1),
        )
        .arc(
            (c_2 * r1, -s_2 * r1),
            (c_1 * r1, -s_1 * r1),
            (c * r1, -s * r1),
        )
        .segment(
            (c * r1, -s * r1),
            (c * r2, -s * r2),
        )
        .arc(
            (c * r2, -s * r2),
            (c_1 * r2, -s_1 * r2),
            (c_2 * r2, -s_2 * r2),
        )
        .arc(
            (c_2 * r2, -s_2 * r2),
            (r2, 0),
            (c_2 * r2, s_2 * r2),
        )
        .arc(
            (c_2 * r2, s_2 * r2),
            (c_1 * r2, s_1 * r2),
            (c * r2, s * r2),
        )
        .segment(
            (c * r2, s * r2),
            (c * r1, s * r1),
        )
        .assemble(tag="wire")
        .wires().val()
    )
    assert isinstance(base, Cq.Wire)

    # The interior sweep is given by theta, but the exterior sweep exceeds the
    # interior sweep so the wall does not become thinner towards the edges.
    # If the exterior sweep is theta', it has to satisfy
    #
    # sin(theta) * r2 + wall_thickness = sin(theta') * r1
    x, y = conn_width / 2, conn_height / 2
    t = wall_thickness
    dx = middle_offset
    middle = (
        Cq.Sketch()
        # Interior arc, top point
        .arc(
            (x - t, y - t),
            (x - t + dx, 0),
            (x - t, -y + t),
        )
        .segment(
            (x - t, -y + t),
            (-x, -y+t)
        )
        .segment((-x, -y))
        .segment((x, -y))
        # Outer arc, bottom point
        .arc(
            (x, -y),
            (x + dx, 0),
            (x, y),
        )
        .segment(
            (x, y),
            (-x, y)
        )
        .segment((-x, y-t))
        #.segment((x2, a))
        .close()
        .assemble(tag="wire")
        .wires().val()
    )
    assert isinstance(middle, Cq.Wire)

    x, y = conn_width / 2, conn_height / 2
    t = wall_thickness
    tip = (
        Cq.Sketch()
        .segment((-x, y), (x, y))
        .segment((x, -y))
        .segment((-x, -y))
        .segment((-x, -y+t))
        .segment((x-t, -y+t))
        .segment((x-t, y-t))
        .segment((-x, y-t))
        .close()
        .assemble(tag="wire")
        .wires().val()
    )
    return base, middle, tip


def wing_root(joint: HirthJoint,
              bolt_diam: int = 12):
    """
    Generate the contiguous components of the root wing segment
    """
    root_profile, middle_profile, tip_profile = wing_root_profiles()

    rotate_centre = Cq.Vector(-200, 0, -25)
    rotate_axis = Cq.Vector(0, 1, 0)
    terminal_offset = Cq.Vector(-80, 0, 80)
    terminal_rotate = Cq.Vector(0, -45, 0)

    #middle_profile = middle_profile.moved(Cq.Location((0, 0, -100)))
    #tip_profile = tip_profile.moved(Cq.Location((0, 0, -200)))
    middle_profile = middle_profile.rotate(
        startVector=rotate_centre,
        endVector=rotate_centre + rotate_axis,
        angleDegrees = 30,
    )
    antetip_profile = tip_profile.rotate(
        startVector=rotate_centre,
        endVector=rotate_centre + rotate_axis,
        angleDegrees = 60,
    )
    tip_profile = tip_profile.rotate(
        startVector=rotate_centre,
        endVector=rotate_centre + rotate_axis,
        angleDegrees = 90,
    )
    seg1 = (
        Cq.Workplane('XY')
        .add(root_profile)
        .toPending()
        .transformed(
            offset=terminal_offset,
            rotate=terminal_rotate)
        #.add(middle_profile.moved(Cq.Location((-15, 0, 15))))
        .add(middle_profile)
        .toPending()
        .loft()
    )
    seg2 = (
        Cq.Workplane('XY')
        .add(middle_profile)
        .toPending()
        .workplane()
        .add(antetip_profile)
        .toPending()
        .loft()
    )
    seg3 = (
        Cq.Workplane('XY')
        .add(antetip_profile)
        .toPending()
        .workplane()
        .add(tip_profile)
        .toPending()
        .loft()
    )
    result = seg1.union(seg2).union(seg3)
    result.faces("<Z").tag("base")
    result.faces(">X").tag("conn")

    j = (
        joint.generate(is_mated=True)
        .faces("<Z")
        .hole(bolt_diam)
    )
    result = (
        result
        .union(j.translate((0, 0, -10)))
        #.union(Cq.Solid.makeCylinder(57, 5).moved(Cq.Location((0, 0, -10))))
        .union(Cq.Solid.makeCylinder(20, 5).moved(Cq.Location((0, 0, -10))))
        .clean()
    )
    return result