nhf/handle.py

@@ -3,59 +3,89 @@ This schematics file contains all designs related to tool handles
 """
 from dataclasses import dataclass
 import cadquery as Cq
+import nhf.metric_threads as NMt
 
 @dataclass(frozen=True)
 class Handle:
     """
     Characteristic of a tool handle
+
+    This assumes the handle segment material does not have threads. Each segment
+    attaches to two insertions, which have threads on the inside. A connector
+    has threads on the outside and joints two insertions.
+
+    Note that all the radial sizes are diameters (in mm).
     """
 
-    # Outer radius for the handle
-    radius: float = 38 / 2
+    # Outer and inner radius for the handle usually come in standard sizes
+    diam: float = 38
+    diam_inner: float = 33
 
-    # Inner radius
-    radius_inner: float = 33 / 2
+    # Major diameter of the internal threads, following ISO metric screw thread
+    # standard. This determines the wall thickness of the insertion.
+    diam_threading: float = 27.0
 
-    # Wall thickness for the connector
-    insertion_thickness: float = 4
+    thread_pitch: float = 3.0
 
-    # The connector goes in the insertion
-    connector_thickness: float = 4
+    # Internal cavity diameter. This determines the wall thickness of the connector
+    diam_connector_internal: float = 18.0
+
+    # If set to true, do not generate threads
+    simplify_geometry: bool = True
 
     # Length for the rim on the female connector
     rim_length: float = 5
 
     insertion_length: float = 60
 
+    # Amount by which the connector goes into the segment
     connector_length: float = 60
 
     def __post_init__(self):
-        assert self.radius > self.radius_inner
-        assert self.radius_inner > self.insertion_thickness + self.connector_thickness
+        assert self.diam > self.diam_inner, "Material thickness cannot be <= 0"
+        assert self.diam_inner > self.diam_insertion_internal, "Threading radius is too big"
+        assert self.diam_insertion_internal > self.diam_connector_external
+        assert self.diam_connector_external > self.diam_connector_internal, "Internal diameter is too large"
         assert self.insertion_length > self.rim_length
 
     @property
-    def _r1(self):
-        """
-        Radius of inside of insertion
-        """
-        return self.radius_inner - self.insertion_thickness
+    def diam_insertion_internal(self):
+        r = NMt.metric_thread_major_radius(
+            self.diam_threading,
+            self.thread_pitch,
+            internal=True)
+        return r * 2
+
     @property
-    def _r2(self):
-        """
-        Radius of inside of connector
-        """
-        return self._r1 - self.connector_thickness
+    def diam_connector_external(self):
+        r = NMt.metric_thread_minor_radius(
+            self.diam_threading,
+            self.thread_pitch)
+        return r * 2
 
     def segment(self, length: float):
         result = (
             Cq.Workplane()
-            .cylinder(radius=self.radius, height=length)
+            .cylinder(
+                radius=self.diam / 2,
+                height=length)
         )
         result.faces("<Z").tag("mate1")
         result.faces(">Z").tag("mate2")
         return result
 
+    def _external_thread(self):
+        return NMt.external_metric_thread(
+            self.diam_threading,
+            self.thread_pitch,
+            self.insertion_length,
+            top_lead_in=True)
+    def _internal_thread(self):
+        return NMt.internal_metric_thread(
+            self.diam_threading,
+            self.thread_pitch,
+            self.insertion_length)
+
     def insertion(self):
         """
         This type of joint is used to connect two handlebar pieces. Each handlebar
@@ -69,20 +99,24 @@ class Handle:
         result = (
             Cq.Workplane('XY')
             .cylinder(
-                radius=self.radius_inner,
+                radius=self.diam_inner / 2,
                 height=self.insertion_length - self.rim_length,
                 centered=[True, True, False])
         )
-        result.faces(">Z").tag("lip")
-        result = (
-            result.faces(">Z")
-            .workplane()
-            .circle(self.radius)
-            .extrude(self.rim_length)
-            .faces(">Z")
-            .hole(2 * self._r1)
-        )
+        result.faces(">Z").tag("rim")
+        if self.rim_length > 0:
+            result = (
+                result.faces(">Z")
+                .workplane()
+                .circle(self.diam / 2)
+                .extrude(self.rim_length)
+                .faces(">Z")
+                .hole(self.diam_insertion_internal)
+            )
         result.faces(">Z").tag("mate")
+        if not self.simplify_geometry:
+            thread = self._internal_thread().val()
+            result = result.union(thread)
         return result
 
     def connector(self, solid: bool = False):
@@ -93,29 +127,40 @@ class Handle:
         result = (
             Cq.Workplane('XY')
             .cylinder(
-                radius=self.radius,
+                radius=self.diam / 2,
                 height=self.connector_length,
             )
         )
         for (tag, selector) in [("mate1", "<Z"), ("mate2", ">Z")]:
             result.faces(selector).tag(tag)
-            r1 = self.radius_inner
             result = (
                 result
                 .faces(selector)
                 .workplane()
-                .circle(self._r1)
+                .circle(self.diam_connector_external / 2)
                 .extrude(self.insertion_length)
             )
         if not solid:
-            result = result.faces(">Z").hole(2 * self._r2)
+            result = result.faces(">Z").hole(self.diam_connector_internal)
+        if not self.simplify_geometry:
+            thread = self._external_thread().val()
+            result = (
+                result
+                .union(
+                    thread
+                    .moved(Cq.Vector(0, 0, self.connector_length / 2)))
+                .union(
+                    thread
+                    .rotate((0,0,0), (1,0,0), angleDegrees=90)
+                    .moved(Cq.Vector(0, 0, -self.connector_length / 2)))
+            )
         return result
 
     def one_side_connector(self):
         result = (
             Cq.Workplane('XY')
             .cylinder(
-                radius=self.radius,
+                radius=self.diam / 2,
                 height=self.rim_length,
             )
         )
@@ -125,7 +170,7 @@ class Handle:
             result
             .faces("<Z")
             .workplane()
-            .circle(self._r1)
+            .circle(self.diam_connector_external / 2)
             .extrude(self.insertion_length)
         )
         return result

nhf/metric_threads.py

@@ -0,0 +1,422 @@
+# Copyright (c) 2020-2024, Nerius Anthony Landys.  All rights reserved.
+#   neri-engineering 'at' protonmail.com
+#   https://svn.code.sf.net/p/nl10/code/cq-code/common/metric_threads.py
+# This file is public domain.  Use it for any purpose, including commercial
+# applications.  Attribution would be nice, but is not required.  There is no
+# warranty of any kind, including its correctness, usefulness, or safety.
+#
+# Simple code example to create meshing M3x0.5 threads:
+###############################################################################
+#
+#     male   = external_metric_thread(3.0, 0.5, 4.0, z_start= -0.85,
+#                                     top_lead_in=True)
+#
+#     # Please note that the female thread is meant for a hole which has
+#     # radius equal to metric_thread_major_radius(3.0, 0.5, internal=True),
+#     # which is in fact very slightly larger than a 3.0 diameter hole.
+#
+#     female = internal_metric_thread(3.0, 0.5, 1.5,
+#                                     bottom_chamfer=True, base_tube_od= 4.5)
+#
+###############################################################################
+# Left hand threads can be created by employing one of the "mirror" operations.
+# Thanks for taking the time to understand and use this code!
+
+import math
+import cadquery as cq
+
+###############################################################################
+# The functions which have names preceded by '__' are not meant to be called
+# externally; the remaining functions are written with the intention that they
+# will be called by external code.  The first section of code consists of
+# lightweight helper functions; the meat and potatoes of this library is last.
+###############################################################################
+
+# Return value is in degrees, and currently it's fixed at 30.  Essentially this
+# results in a typical 60 degree equilateral triangle cutting bit for threads.
+def metric_thread_angle():
+    return 30
+
+# Helper func. to make code more intuitive and succinct.  Degrees --> radians.
+def __deg2rad(degrees):
+    return degrees * math.pi / 180
+
+# In the absence of flat thread valley and flattened thread tip, returns the
+# amount by which the thread "triangle" protrudes outwards (radially) from base
+# cylinder in the case of external thread, or the amount by which the thread
+# "triangle" protrudes inwards from base tube in the case of internal thread.
+def metric_thread_perfect_height(pitch):
+    return pitch / (2 * math.tan(__deg2rad(metric_thread_angle())))
+
+# Up the radii of internal (female) thread in order to provide a little bit of
+# wiggle room around male thread.  Right now input parameter 'diameter' is
+# ignored.  This function is only used for internal/female threads.  Currently
+# there is no practical way to adjust the male/female thread clearance besides
+# to manually edit this function.  This design route was chosen for the sake of
+# code simplicity.
+def __metric_thread_internal_radius_increase(diameter, pitch):
+    return 0.1 * metric_thread_perfect_height(pitch)
+
+# Returns the major radius of thread, which is always the greater of the two.
+def metric_thread_major_radius(diameter, pitch, internal=False):
+    return (__metric_thread_internal_radius_increase(diameter, pitch) if
+            internal else 0.0) + (diameter / 2)
+
+# What portion of the total pitch is taken up by the angled thread section (and
+# not the squared off valley and tip).  The remaining portion (1 minus ratio)
+# will be divided equally between the flattened valley and flattened tip.
+def __metric_thread_effective_ratio():
+    return 0.7
+
+# Returns the minor radius of thread, which is always the lesser of the two.
+def metric_thread_minor_radius(diameter, pitch, internal=False):
+    return (metric_thread_major_radius(diameter, pitch, internal)
+            - (__metric_thread_effective_ratio() *
+               metric_thread_perfect_height(pitch)))
+
+# What the major radius would be if the cuts were perfectly triangular, without
+# flat spots in the valleys and without flattened tips.
+def metric_thread_perfect_major_radius(diameter, pitch, internal=False):
+    return (metric_thread_major_radius(diameter, pitch, internal)
+            + ((1.0 - __metric_thread_effective_ratio()) *
+               metric_thread_perfect_height(pitch) / 2))
+
+# What the minor radius would be if the cuts were perfectly triangular, without
+# flat spots in the valleys and without flattened tips.
+def metric_thread_perfect_minor_radius(diameter, pitch, internal=False):
+    return (metric_thread_perfect_major_radius(diameter, pitch, internal)
+            - metric_thread_perfect_height(pitch))
+
+# Returns the lead-in and/or chamfer distance along the z axis of rotation.
+# The lead-in/chamfer only depends on the pitch and is made with the same angle
+# as the thread, that being 30 degrees offset from radial.
+def metric_thread_lead_in(pitch, internal=False):
+    return (math.tan(__deg2rad(metric_thread_angle()))
+            * (metric_thread_major_radius(256.0, pitch, internal)
+               - metric_thread_minor_radius(256.0, pitch, internal)))
+
+# Returns the width of the flat spot in thread valley of a standard thread.
+# This is also equal to the width of the flat spot on thread tip, on a standard
+# thread.
+def metric_thread_relief(pitch):
+    return (1.0 - __metric_thread_effective_ratio()) * pitch / 2
+
+
+###############################################################################
+# A few words on modules external_metric_thread() and internal_metric_thread().
+# The parameter 'z_start' is added as a convenience in order to make the male
+# and female threads align perfectly.  When male and female threads are created
+# having the same diameter, pitch, and n_starts (usually 1), then so long as
+# they are not translated or rotated (or so long as they are subjected to the
+# same exact translation and rotation), they will intermesh perfectly,
+# regardless of the value of 'z_start' used on each.  This is in order that
+# assemblies be able to depict perfectly aligning threads.
+
+# Generates threads with base cylinder unless 'base_cylinder' is overridden.
+# Please note that 'use_epsilon' is activated by default, which causes a slight
+# budge in the minor radius, inwards, so that overlaps would be created with
+# inner cylinders.  (Does not affect thread profile outside of cylinder.)
+###############################################################################
+def external_metric_thread(diameter,  # Required parameter, e.g. 3.0 for M3x0.5
+                           pitch,     # Required parameter, e.g. 0.5 for M3x0.5
+                           length,    # Required parameter, e.g. 2.0
+                           z_start=0.0,
+                           n_starts=1,
+                           bottom_lead_in=False, # Lead-in is at same angle as
+                           top_lead_in   =False, # thread, namely 30 degrees.
+                           bottom_relief=False, # Add relief groove to start or
+                           top_relief   =False, # end of threads (shorten).
+                           force_outer_radius=-1.0, # Set close to diameter/2.
+                           use_epsilon=True, # For inner cylinder overlap.
+                           base_cylinder=True, # Whether to include base cyl.
+                           cyl_extend_bottom=-1.0,
+                           cyl_extend_top=-1.0,
+                           envelope=False): # Draw only envelope, don't cut.
+
+    cyl_extend_bottom = max(0.0, cyl_extend_bottom)
+    cyl_extend_top    = max(0.0, cyl_extend_top)
+
+    z_off             = (1.0 - __metric_thread_effective_ratio()) * pitch / 4
+    t_start           = z_start
+    t_length          = length
+    if bottom_relief:
+        t_start       = t_start  + (2 * z_off)
+        t_length      = t_length - (2 * z_off)
+    if top_relief:
+        t_length      = t_length - (2 * z_off)
+    outer_r           = (force_outer_radius if (force_outer_radius > 0.0) else
+                         metric_thread_major_radius(diameter,pitch))
+    inner_r           = metric_thread_minor_radius(diameter,pitch)
+    epsilon           = 0
+    inner_r_adj       = inner_r
+    inner_z_budge     = 0
+    if use_epsilon:
+        epsilon       = (z_off/3) / math.tan(__deg2rad(metric_thread_angle()))
+        inner_r_adj   = inner_r - epsilon
+        inner_z_budge = math.tan(__deg2rad(metric_thread_angle())) * epsilon
+
+    if envelope:
+        threads = cq.Workplane("XZ")
+        threads = threads.moveTo(inner_r_adj, -pitch)
+        threads = threads.lineTo(outer_r, -pitch)
+        threads = threads.lineTo(outer_r, t_length + pitch)
+        threads = threads.lineTo(inner_r_adj, t_length + pitch)
+        threads = threads.close()
+        threads = threads.revolve()
+
+    else: # Not envelope, cut the threads.
+        wire = cq.Wire.makeHelix(pitch=pitch*n_starts,
+                                 height=t_length+pitch,
+                                 radius=inner_r)
+        wire = wire.translate((0,0,-pitch/2))
+        wire = wire.rotate(startVector=(0,0,0), endVector=(0,0,1),
+                           angleDegrees=360*(-pitch/2)/(pitch*n_starts))
+        d_mid = ((metric_thread_major_radius(diameter,pitch) - outer_r)
+                 * math.tan(__deg2rad(metric_thread_angle())))
+        thread = cq.Workplane("XZ")
+        thread = thread.moveTo(inner_r_adj, -pitch/2 + z_off - inner_z_budge)
+        thread = thread.lineTo(outer_r, -(z_off + d_mid))
+        thread = thread.lineTo(outer_r, z_off + d_mid)
+        thread = thread.lineTo(inner_r_adj, pitch/2 - z_off + inner_z_budge)
+        thread = thread.close()
+        thread = thread.sweep(wire, isFrenet=True)
+        threads = thread
+        for addl_start in range(1, n_starts):
+            # TODO: Incremental/cumulative rotation may not be as accurate as
+            #       keeping 'thread' intact and rotating it by correct amount
+            #       on each iteration.  However, changing the code in that
+            #       regard may disrupt the delicate nature of workarounds
+            #       with repsect to quirks in the underlying B-rep library.
+            thread = thread.rotate(axisStartPoint=(0,0,0),
+                                   axisEndPoint=(0,0,1),
+                                   angleDegrees=360/n_starts)
+            threads = threads.union(thread)
+
+    square_shave = cq.Workplane("XY")
+    square_shave = square_shave.box(length=outer_r*3, width=outer_r*3,
+                                    height=pitch*2, centered=True)
+    square_shave = square_shave.translate((0,0,-pitch)) # Because centered.
+    # Always cut the top and bottom square.  Otherwise things don't play nice.
+    threads = threads.cut(square_shave)
+
+    if bottom_lead_in:
+        delta_r = outer_r - inner_r
+        rise = math.tan(__deg2rad(metric_thread_angle())) * delta_r
+        lead_in = cq.Workplane("XZ")
+        lead_in = lead_in.moveTo(inner_r - delta_r, -rise)
+        lead_in = lead_in.lineTo(outer_r + delta_r, 2 * rise)
+        lead_in = lead_in.lineTo(outer_r + delta_r, -pitch - rise)
+        lead_in = lead_in.lineTo(inner_r - delta_r, -pitch - rise)
+        lead_in = lead_in.close()
+        lead_in = lead_in.revolve()
+        threads = threads.cut(lead_in)
+
+    # This was originally a workaround to the anomalous B-rep computation where
+    # the top of base cylinder is flush with top of threads, without the use of
+    # lead-in.  It turns out that preferring the use of the 'render_cyl_early'
+    # strategy alleviates other problems as well.
+    render_cyl_early = (base_cylinder and ((not top_relief) and
+                                           (not (cyl_extend_top > 0.0)) and
+                                           (not envelope)))
+    render_cyl_late = (base_cylinder and (not render_cyl_early))
+    if render_cyl_early:
+        cyl = cq.Workplane("XY")
+        cyl = cyl.circle(radius=inner_r)
+        cyl = cyl.extrude(until=length+pitch+cyl_extend_bottom)
+        # Make rotation of cylinder consistent with non-workaround case.
+        cyl = cyl.rotate(axisStartPoint=(0,0,0), axisEndPoint=(0,0,1),
+                         angleDegrees=-(360*t_start/(pitch*n_starts)))
+        cyl = cyl.translate((0,0,-t_start+(z_start-cyl_extend_bottom)))
+        threads = threads.union(cyl)
+
+    # Next, make cuts at the top.
+    square_shave = square_shave.translate((0,0,pitch*2+t_length))
+    threads = threads.cut(square_shave)
+
+    if top_lead_in:
+        delta_r = outer_r - inner_r
+        rise = math.tan(__deg2rad(metric_thread_angle())) * delta_r
+        lead_in = cq.Workplane("XZ")
+        lead_in = lead_in.moveTo(inner_r - delta_r, t_length + rise)
+        lead_in = lead_in.lineTo(outer_r + delta_r, t_length - (2 * rise))
+        lead_in = lead_in.lineTo(outer_r + delta_r, t_length + pitch + rise)
+        lead_in = lead_in.lineTo(inner_r - delta_r, t_length + pitch + rise)
+        lead_in = lead_in.close()
+        lead_in = lead_in.revolve()
+        threads = threads.cut(lead_in)
+
+    # Place the threads into position.
+    threads = threads.translate((0,0,t_start))
+    if (not envelope):
+        threads = threads.rotate(axisStartPoint=(0,0,0), axisEndPoint=(0,0,1),
+                                 angleDegrees=360*t_start/(pitch*n_starts))
+
+    if render_cyl_late:
+        cyl = cq.Workplane("XY")
+        cyl = cyl.circle(radius=inner_r)
+        cyl = cyl.extrude(until=length+cyl_extend_bottom+cyl_extend_top)
+        cyl = cyl.translate((0,0,z_start-cyl_extend_bottom))
+        threads = threads.union(cyl)
+
+    return threads
+
+
+###############################################################################
+# Generates female threads without a base tube, unless 'base_tube_od' is set to
+# something which is sufficiently greater than 'diameter' parameter.  Please
+# note that 'use_epsilon' is activated by default, which causes a slight budge
+# in the major radius, outwards, so that overlaps would be created with outer
+# tubes.  (Does not affect thread profile inside of tube or beyond extents.)
+###############################################################################
+def internal_metric_thread(diameter,  # Required parameter, e.g. 3.0 for M3x0.5
+                           pitch,     # Required parameter, e.g. 0.5 for M3x0.5
+                           length,    # Required parameter, e.g. 2.0.
+                           z_start=0.0,
+                           n_starts=1,
+                           bottom_chamfer=False, # Chamfer is at same angle as
+                           top_chamfer   =False, # thread, namely 30 degrees.
+                           bottom_relief=False, # Add relief groove to start or
+                           top_relief   =False, # end of threads (shorten).
+                           use_epsilon=True, # For outer cylinder overlap.
+                           # The base tube outer diameter must be sufficiently
+                           # large for tube to be rendered.  Otherwise ignored.
+                           base_tube_od=-1.0,
+                           tube_extend_bottom=-1.0,
+                           tube_extend_top=-1.0,
+                           envelope=False): # Draw only envelope, don't cut.
+
+    tube_extend_bottom = max(0.0, tube_extend_bottom)
+    tube_extend_top    = max(0.0, tube_extend_top)
+
+    z_off              = (1.0 - __metric_thread_effective_ratio()) * pitch / 4
+    t_start            = z_start
+    t_length           = length
+    if bottom_relief:
+        t_start        = t_start  + (2 * z_off)
+        t_length       = t_length - (2 * z_off)
+    if top_relief:
+        t_length       = t_length - (2 * z_off)
+    outer_r            = metric_thread_major_radius(diameter,pitch,
+                                                    internal=True)
+    inner_r            = metric_thread_minor_radius(diameter,pitch,
+                                                    internal=True)
+    epsilon            = 0
+    outer_r_adj        = outer_r
+    outer_z_budge      = 0
+    if use_epsilon:
+        # High values of 'epsilon' sometimes cause entire starts to disappear.
+        epsilon        = (z_off/5) / math.tan(__deg2rad(metric_thread_angle()))
+        outer_r_adj    = outer_r + epsilon
+        outer_z_budge  = math.tan(__deg2rad(metric_thread_angle())) * epsilon
+
+    if envelope:
+        threads = cq.Workplane("XZ")
+        threads = threads.moveTo(outer_r_adj, -pitch)
+        threads = threads.lineTo(inner_r, -pitch)
+        threads = threads.lineTo(inner_r, t_length + pitch)
+        threads = threads.lineTo(outer_r_adj, t_length + pitch)
+        threads = threads.close()
+        threads = threads.revolve()
+
+    else: # Not envelope, cut the threads.
+        wire = cq.Wire.makeHelix(pitch=pitch*n_starts,
+                                 height=t_length+pitch,
+                                 radius=inner_r)
+        wire = wire.translate((0,0,-pitch/2))
+        wire = wire.rotate(startVector=(0,0,0), endVector=(0,0,1),
+                           angleDegrees=360*(-pitch/2)/(pitch*n_starts))
+        thread = cq.Workplane("XZ")
+        thread = thread.moveTo(outer_r_adj, -pitch/2 + z_off - outer_z_budge)
+        thread = thread.lineTo(inner_r, -z_off)
+        thread = thread.lineTo(inner_r, z_off)
+        thread = thread.lineTo(outer_r_adj, pitch/2 - z_off + outer_z_budge)
+        thread = thread.close()
+        thread = thread.sweep(wire, isFrenet=True)
+        threads = thread
+        for addl_start in range(1, n_starts):
+            # TODO: Incremental/cumulative rotation may not be as accurate as
+            #       keeping 'thread' intact and rotating it by correct amount
+            #       on each iteration.  However, changing the code in that
+            #       regard may disrupt the delicate nature of workarounds
+            #       with repsect to quirks in the underlying B-rep library.
+            thread = thread.rotate(axisStartPoint=(0,0,0),
+                                   axisEndPoint=(0,0,1),
+                                   angleDegrees=360/n_starts)
+            threads = threads.union(thread)
+        # Rotate so that the external threads would align.
+        threads = threads.rotate(axisStartPoint=(0,0,0), axisEndPoint=(0,0,1),
+                                 angleDegrees=180/n_starts)
+
+    square_len = max(outer_r*3, base_tube_od*1.125)
+    square_shave = cq.Workplane("XY")
+    square_shave = square_shave.box(length=square_len, width=square_len,
+                                    height=pitch*2, centered=True)
+    square_shave = square_shave.translate((0,0,-pitch)) # Because centered.
+    # Always cut the top and bottom square.  Otherwise things don't play nice.
+    threads = threads.cut(square_shave)
+
+    if bottom_chamfer:
+        delta_r = outer_r - inner_r
+        rise = math.tan(__deg2rad(metric_thread_angle())) * delta_r
+        chamfer = cq.Workplane("XZ")
+        chamfer = chamfer.moveTo(inner_r - delta_r, 2 * rise)
+        chamfer = chamfer.lineTo(outer_r + delta_r, -rise)
+        chamfer = chamfer.lineTo(outer_r + delta_r, -pitch - rise)
+        chamfer = chamfer.lineTo(inner_r - delta_r, -pitch - rise)
+        chamfer = chamfer.close()
+        chamfer = chamfer.revolve()
+        threads = threads.cut(chamfer)
+
+    # This was originally a workaround to the anomalous B-rep computation where
+    # the top of base tube is flush with top of threads w/o the use of chamfer.
+    # This is now being made consistent with the 'render_cyl_early' strategy in
+    # external_metric_thread() whereby we prefer the "render early" plan of
+    # action even in cases where a top chamfer or lead-in is used.
+    render_tube_early = ((base_tube_od > (outer_r * 2)) and
+                         (not top_relief) and
+                         (not (tube_extend_top > 0.0)) and
+                         (not envelope))
+    render_tube_late = ((base_tube_od > (outer_r * 2)) and
+                        (not render_tube_early))
+    if render_tube_early:
+        tube = cq.Workplane("XY")
+        tube = tube.circle(radius=base_tube_od/2)
+        tube = tube.circle(radius=outer_r)
+        tube = tube.extrude(until=length+pitch+tube_extend_bottom)
+        # Make rotation of cylinder consistent with non-workaround case.
+        tube = tube.rotate(axisStartPoint=(0,0,0), axisEndPoint=(0,0,1),
+                           angleDegrees=-(360*t_start/(pitch*n_starts)))
+        tube = tube.translate((0,0,-t_start+(z_start-tube_extend_bottom)))
+        threads = threads.union(tube)
+
+    # Next, make cuts at the top.
+    square_shave = square_shave.translate((0,0,pitch*2+t_length))
+    threads = threads.cut(square_shave)
+
+    if top_chamfer:
+        delta_r = outer_r - inner_r
+        rise = math.tan(__deg2rad(metric_thread_angle())) * delta_r
+        chamfer = cq.Workplane("XZ")
+        chamfer = chamfer.moveTo(inner_r - delta_r, t_length - (2 * rise))
+        chamfer = chamfer.lineTo(outer_r + delta_r, t_length + rise)
+        chamfer = chamfer.lineTo(outer_r + delta_r, t_length + pitch + rise)
+        chamfer = chamfer.lineTo(inner_r - delta_r, t_length + pitch + rise)
+        chamfer = chamfer.close()
+        chamfer = chamfer.revolve()
+        threads = threads.cut(chamfer)
+
+    # Place the threads into position.
+    threads = threads.translate((0,0,t_start))
+    if (not envelope):
+        threads = threads.rotate(axisStartPoint=(0,0,0), axisEndPoint=(0,0,1),
+                                 angleDegrees=360*t_start/(pitch*n_starts))
+
+    if render_tube_late:
+        tube = cq.Workplane("XY")
+        tube = tube.circle(radius=base_tube_od/2)
+        tube = tube.circle(radius=outer_r)
+        tube = tube.extrude(until=length+tube_extend_bottom+tube_extend_top)
+        tube = tube.translate((0,0,z_start-tube_extend_bottom))
+        threads = threads.union(tube)
+
+    return threads

nhf/test.py

@@ -2,6 +2,7 @@ import unittest
 import cadquery as Cq
 import nhf.joints
 import nhf.handle
+import nhf.metric_threads as NMt
 
 class TestJoints(unittest.TestCase):
 
@@ -20,8 +21,25 @@ class TestHandle(unittest.TestCase):
 
     def test_handle_assembly(self):
         h = nhf.handle.Handle()
-        h.connector_insertion_assembly()
-        h.connector_one_side_insertion_assembly()
+        assembly = h.connector_insertion_assembly()
+        bbox = assembly.toCompound().BoundingBox()
+        self.assertAlmostEqual(bbox.xlen, h.diam)
+        self.assertAlmostEqual(bbox.ylen, h.diam)
+        assembly = h.connector_one_side_insertion_assembly()
+        bbox = assembly.toCompound().BoundingBox()
+        self.assertAlmostEqual(bbox.xlen, h.diam)
+        self.assertAlmostEqual(bbox.ylen, h.diam)
+
+
+class TestMetricThreads(unittest.TestCase):
+
+    def test_major_radius(self):
+        major = 3.0
+        t = NMt.external_metric_thread(major, 0.5, 4.0, z_start= -0.85, top_lead_in=True)
+        bbox = t.val().BoundingBox()
+        self.assertAlmostEqual(bbox.xlen, major, places=3)
+        self.assertAlmostEqual(bbox.ylen, major, places=3)
+
 
 if __name__ == '__main__':
     unittest.main()

nhf/touhou/houjuu_nue/__init__.py

@@ -89,7 +89,15 @@ class Parameters:
     wing_r2_height = 100
     wing_r3_height = 100
 
-    trident_handle: nhf.handle.Handle = nhf.handle.Handle()
+    trident_handle: nhf.handle.Handle = nhf.handle.Handle(
+        diam=38,
+        diam_inner=33,
+        # M27-3
+        diam_threading=27,
+        thread_pitch=3,
+        diam_connector_internal=18,
+        simplify_geometry=False,
+    )
 
     def __post_init__(self):
         assert self.wing_root_radius > self.hs_joint_radius,\

nhf/touhou/houjuu_nue/trident.py

@@ -15,17 +15,17 @@ def trident_assembly(
         .add(handle.insertion(), name="i0", color=mat_i.color)
         .constrain("i0", "Fixed")
         .add(segment(), name="s1", color=mat_s.color)
-        .constrain("i0?lip", "s1?mate1", "Plane", param=0)
+        .constrain("i0?rim", "s1?mate1", "Plane", param=0)
         .add(handle.insertion(), name="i1", color=mat_i.color)
         .add(handle.connector(), name="c1", color=mat_i.color)
         .add(handle.insertion(), name="i2", color=mat_i.color)
-        .constrain("s1?mate2", "i1?lip", "Plane", param=0)
+        .constrain("s1?mate2", "i1?rim", "Plane", param=0)
         .constrain("i1?mate", "c1?mate1", "Plane")
         .constrain("i2?mate", "c1?mate2", "Plane")
         .add(segment(), name="s2", color=mat_s.color)
-        .constrain("i2?lip", "s2?mate1", "Plane", param=0)
+        .constrain("i2?rim", "s2?mate1", "Plane", param=0)
         .add(handle.insertion(), name="i3", color=mat_i.color)
-        .constrain("s2?mate2", "i3?lip", "Plane", param=0)
+        .constrain("s2?mate2", "i3?rim", "Plane", param=0)
         .add(handle.one_side_connector(), name="head", color=mat_i.color)
         .constrain("i3?mate", "head?mate", "Plane")
     )