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tools.scad
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tools.scad
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//
// reusable openscad tools
//
// Original work released, year of our lord, 2022
// - Commercial use, copying, altering, re-packaging, with
// or without attribution is encouraged, but not mandatory
//
// $fa - minimum angular division of a round object, resulting in (360/$fa)
// facets. Smaller is smoother. Larger is faster.
$fa = 4;
// $fs - minimum size (in mm) of a facet of a round object.
// If the facet resulting from by $fa is bigger, this value has no effect.
// If the facet is smaller, then the angular $fa value is ignored in favor of
// this dimensional value. The only reason to set $fs seems to be to save
// cycles rendering fine details with unnecessary resolution? Here we override
// the default (2mm?), since that seems a bit coarse.
$fs = 0.5;
// Check if argument is defined
function defined(a) = str(a) != "undef";
// Use default value if argument undefined
function default(a,b) = (defined(a)?a:b);
// constants
function pi() = 3.141592653589793;
function e() = 2.718281828459045;
// imperial to metric
mm_per_in=25.4;
function inToMm(in) = (in * mm_per_in);
// Threads per inch to mm thread pitch
function tpiToTp(tpi) = inToMm(1/tpi);
// overrideable scale factor
pla_shrink_scale=1.008;
//
// account for PLA shrinkage, so final part has expected dimensions
//
module preShrink(shrinkFactor)
{
// if shrinkFactor not specified, use default
factor=default(shrinkFactor,pla_shrink_scale);
scale([factor,factor,factor])
{
children();
}
}
//
// Makes a tube with the given dimensions
//
module tube(tube_outer_diameter, tube_inner_diameter, tube_length)
{
assert(defined(tube_outer_diameter) && defined(tube_inner_diameter) &&
defined(tube_length),
"Usage: tube(tube_outer_diameter, tube_inner_diameter, tube_length)");
assert(tube_inner_diameter < tube_outer_diameter,
"tube_inner_diameter must be less than tube_outer_diameter");
difference()
{
cylinder(h=tube_length,d=tube_outer_diameter,center=true);
cylinder(h=tube_length+1,d=tube_inner_diameter,center=true);
}
}
module outer_chamfer_ring(diameter, distance)
{
chamferAngle = 45;
ring_height = 10;
depth=((ring_height/2.0)/tan(chamferAngle));
rotate_extrude(angle = 360)
{
group()
{
translate([(depth+(diameter/2))-distance, -(ring_height/2), 0])
polygon(
points=
[
[0,0],[0,ring_height],
[(-depth),ring_height/2.0]
],
paths=[[0,1,2,0]]
);
}
}
}
module inner_chamfer_ring(diameter)
{
height=10;
chamferAngle = 45;
ring_height = abs(height);
depth=((ring_height/2.0)/tan(chamferAngle));
rotate_extrude(angle = 360)
{
group()
{
translate([(diameter/2) - (depth/2), -(ring_height/2), 0])
polygon(
points=
[
[0,0],[0,ring_height],
[(depth),ring_height/2.0]
],
paths=[[0,1,2,0]]
);
}
}
}
module chamfer_dome(diameter)
{
difference()
{
difference()
{
sphere(d=diameter + 5);
sphere(d=diameter);
}
translate([0,0,-(diameter)])
cube([diameter*4,diameter*4,diameter*2],center=true);
}
}
//
// creates a donut shape
// extrusion diameter is the path of the midpoint of the extruded circle
// extrusion height is the thickness of the donut
//
module torus(extrusion_diameter, extrusion_height)
{
assert((extrusion_diameter >= extrusion_height), "extrusion_diameter must be >= extrusion_height");
rotate_extrude(angle = 360)
group()
{
translate([extrusion_diameter/2,0,0])
circle(d=extrusion_height);
}
}
//
// draw objects repeated in a circle
// count is how many objects ro repeat
// diameter is the diameter of the cicular path that objects are rotated through
//
module rotational_repeat(diameter, count)
{
for(i=[0:count])
rotate([0,0,(i*(360/count))])
translate([diameter/2,0,0])
rotate ([0, 0, 0])
{
children();
}
}
//
// works like a drill was used at x,y,z
//
module drillHole(diameter, depth, x, y, z)
{
difference()
{
children();
translate([x,y,z-(depth/2)])
cylinder(d=diameter,h=depth,center=true);
}
}
// Through-hole profile, including chamfering.
//
// - Chamfering avoids fit problems caused by "elephant's foot".
// - Good for wheel hubs.
// - Assumes material is centered on the x/y plane.
// - Depth of zero is equivalent to no chamfer.
// - Depth is the length of a side of the 45 degree triangle,
// desribing the profile of the material that would be removed.
//
// | D |
// - _ _ _ _ _
// |_| .
// D | .
// _ |.
// |
//
module chamferedThroughHole(holeDiameter, materialThickness, chamferDepth)
{
module upInnerCone(diameter,chamferDepth,startZ)
{
coneDiameter=diameter*3;
coneHeight=coneDiameter/2;
translate([0,0,-(coneHeight/2)+((diameter+chamferDepth)/2)+startZ])
cylinder(d1=coneDiameter,d2=0.01,h=coneHeight,center=true, $fs = 2);
}
module downInnerCone(diameter,chamferDepth,startZ)
{
coneDiameter=diameter*3;
coneHeight=coneDiameter/2;
translate([0,0,(coneHeight/2)-((diameter+chamferDepth)/2)+startZ])
cylinder(d2=coneDiameter,d1=0.01,h=coneHeight,center=true, $fs = 2);
}
difference()
{
children();
group()
{
downInnerCone(holeDiameter,chamferDepth,(materialThickness/2));
cylinder(d=holeDiameter,h=materialThickness*2,center=true);
upInnerCone(holeDiameter,chamferDepth,-(materialThickness/2));
}
}
}
// / \ ? / \
// / \ / \
//
default_thread_angle=60;
// |--?--|
// / \ / \
// / \ / \
//
default_thread_pitch=1.5;
// _
// | |___
// |-| VVVVVV\ _
// | | ||||||| _?
// |-|___AAAAAA/
// |_|
//
default_minor_diameter=4;
// _
// | |___ _ _
// |-| VVVVVV\ |
// | | ||||||| ?
// |-|___AAAAAA/ _|_
// |_|
//
default_major_diameter=5;
// |--- ? ---|
// _
// | |___
// |-| VVVVVV\
// | | |||||||
// |-|___AAAAAA/
// |_|
//
default_fastener_length=15;
// _ |- ? -|
// | |___
// |-| VVVVVV\
// | | |||||||
// |-|___AAAAAA/
// |_|
//
default_thread_length=15;
// |?|
// _
// | |___
// |-| VVVVVV\
// | | |||||||
// |-|___AAAAAA/
// |_|
//
default_head_height=3;
// _ ___
// | |___| | _
// |-| |---|V\ - ?
// | | | |||
// |-|___|---|A/
// |_| |___|
//
// (value of total addtional gap)
default_inner_thread_gap = 1.25;
// | ? |
// _ ___
// | |___| |
// |-| |---|V\
// | | | |||
// |-|___|---|A/
// |_| |___|
//
default_nut_height = 4;
//
// /\?
// _
// | |___ ||
// |-| VV||VV\
// | | |||||||
// |-|___AA||AA/
// |_| ||
//
default_washer_thickness=1;
// _
// | |___ ------ -
// |-| VVVVVV\ - ?
// | | |||||||
// |-|___AAAAAA/
// |_| ------
//
// (value of total addtional gap)
default_bolt_gap=0.3;
// /\ /\
// / \ / \
// / \/ \
//
THREAD_TYPE_STANDARD=1;
// __ __
// / \ / \
// / \__/ \
//
THREAD_TYPE_ACME=2;
default_thread_type=THREAD_TYPE_STANDARD;
module spacer(innerDiameter, spacerHeight, bolt_gap, customOuterDiameter)
{
// if custom not specified, use nearest aesthetic size
outerDiameter=default(customOuterDiameter,floor((innerDiameter*2.12)+0.5));
tube(outerDiameter, innerDiameter + bolt_gap, spacerHeight);
}
module washer(innerDiameter, washer_thickness, bolt_gap, customOuterDiameter)
{
// if custom not specified, use nearest aesthetic size
outerDiameter=default(customOuterDiameter,floor((innerDiameter*2.12)+0.5));
tube(outerDiameter, innerDiameter + bolt_gap, washer_thickness);
}
module threaded_insert(major_diameter, thread_length, thread_pitch, thread_angle, thread_type, inner_thread_gap)
{
insertDiameter=floor(major_diameter+2.5);
echo ("Threaded Insert height: ", thread_length);
echo ("Diameter: ", insertDiameter);
thread_depth=thread_length*1.3;
difference()
{
// stock to be tapped
cylinder(h=thread_length,d=insertDiameter,center=true);
// negative thread sized a little bit bigger than threaded fastener
difference()
{
group()
{
cylinder(d=major_diameter+inner_thread_gap, h=thread_depth, center=true);
}
group()
{
translate([0,0,(thread_depth/2)+thread_pitch/2])
thread(major_diameter+inner_thread_gap, thread_pitch, thread_depth, thread_angle, thread_type);
}
}
}
}
module nut(major_diameter, thread_length, thread_pitch, thread_angle, thread_type, inner_thread_gap)
{
difference()
{
// shape (insert/nut)
translate([0,0,thread_length/2])
hexHead(major_diameter, thread_length);
// negative thread sized a little bit bigger than threaded fastener
translate([0,0,-((thread_length*1.2)/2)])
difference()
{
group()
{
// cylindrical stock for threading
cylinder(d=major_diameter+inner_thread_gap, h=thread_length*1.2);
}
group()
{
// subtract threads
translate([0,0,(thread_length*1.2)+(thread_pitch/2)])
thread(major_diameter+inner_thread_gap, thread_pitch, thread_length*1.2, thread_angle, thread_type);
}
}
}
}
module wingnut(major_diameter, thread_length, thread_pitch, thread_angle, thread_type, inner_thread_gap)
{
nut(major_diameter, thread_length, thread_pitch, thread_angle, thread_type, inner_thread_gap);
wing_thickness=3;
wing_diameter=thread_length*1.25;
translate([((major_diameter+wing_diameter)/2)+thread_pitch/2,0,abs((thread_length-wing_diameter)/2)])
group()
{
rotate([90,0,0])
cylinder(d=wing_diameter,h=wing_thickness,center=true);
translate([-(wing_diameter/4),0,-(wing_diameter/4)])
cube([wing_diameter/2,wing_thickness,wing_diameter/2],center=true);
}
translate([-(((major_diameter+wing_diameter)/2)+thread_pitch/2),0,abs((thread_length-wing_diameter)/2)])
group()
{
rotate([90,0,0])
cylinder(d=wing_diameter,h=wing_thickness,center=true);
translate([(wing_diameter/4),0,-(wing_diameter/4)])
cube([wing_diameter/2,wing_thickness,wing_diameter/2],center=true);
}
}
module screw(major_diameter, thread_pitch, thread_angle, thread_type, fastener_length, thread_length, head_height)
{
threadedFastener(major_diameter, thread_pitch, thread_angle, thread_type, fastener_length, thread_length, head_height);
screwHead(major_diameter, head_height);
}
module bolt(major_diameter, thread_pitch, thread_angle, thread_type, fastener_length, thread_length, head_height)
{
threadedFastener(major_diameter, thread_pitch, thread_angle, thread_type, fastener_length, thread_length, head_height);
hexHead(major_diameter, head_height);
}
module hexHead(major_diameter, head_height, customSize)
{
// if custom not specified, use nearest aesthetic integer head size
size=default(customSize,floor((major_diameter*1.6)+0.5));
// low-res cylinder hack to get hexagon
// 30,60,90 triangle math to get to desired wrench size
translate([0,0,-(head_height/2.0)])
cylinder(d=(2*(size/sqrt(3))), h=head_height, $fn=6, center=true);
}
module screwHead(major_diameter, head_height, customSize)
{
// if custom not specified, use nearest aesthetic integer head size
size=default(customSize,floor((major_diameter*1.6)+0.5));
translate([0,0,-(head_height/2)])
difference()
{
cylinder(d=size, h=head_height, center=true);
translate([0,0,-(head_height/2)])
cube([1,size*2,2],center=true);
}
}
module thumbScrew(major_diameter, head_height, customSize)
{
// if custom not specified, use an aesthetic size
size=default(customSize,floor((major_diameter*2.5)+0.5));
translate([0,0,-(head_height/2)])
difference()
{
group()
{
cylinder(d=size, h=head_height, center=true);
}
group()
{
translate([0,0,(head_height/2)])
outer_chamfer_ring(size, 0.5);
translate([0,0,-(head_height/2)])
outer_chamfer_ring(size,0.5);
// calculate number of grooves to be even/alternating
circumference=size*pi();
groove_width = 0.5;
number_of_grooves = (circumference/2)/groove_width;
// do knurling
rotational_repeat(size, number_of_grooves)
cube([1,groove_width,head_height*1.5],center=true);
// decorative circle
rotate_extrude(angle = 360)
{
group()
{
translate([(size/2)-3,-((head_height)-1),0])
polygon(
points=
[
[0,0],[0,1],[0.5,1],[0.5,0]
],
paths=[[0,1,2,3,0]]
);
}
}
}
}
}
module threadedFastener(major_diameter, thread_pitch, thread_angle, thread_type, fastener_length, thread_length, head_height)
{
difference()
{
group()
{
// cylindrical stock for threading
cylinder(d=major_diameter, h=fastener_length);
}
group()
{
// subtract threads
translate([0,0,fastener_length+(thread_pitch/2)])
thread(major_diameter, thread_pitch, thread_length, thread_angle, thread_type);
// round chamfer end for easy threading
translate([0,0,fastener_length-(major_diameter*0.35)])
chamfer_dome(major_diameter);
}
}
}
//
// Extrudes a 2-d cutter shape in a helical path around a cylinder body.
// Openscad does not go to any effort to make this easy or efficient.
// Attempted at being efficient by extruding arc segments and translating/rotating
// to fit the helical path.
//
module thread(major_diameter, thread_pitch, thread_length, thread_angle, thread_type)
{
circumference=major_diameter*pi();
segments=8;
overlap_degrees=2; // prevent gaps
angular_segment=(360/segments);
segment_width=circumference/segments;
angle=(atan((thread_pitch/segments)/segment_width));
// the +1 gives it another turn that seems to be required
for(j=[0:((thread_length+1) / thread_pitch)])
translate([0,0,-thread_pitch*j])
for(i=[0:segments])
translate([0,0,-(thread_pitch/segments)*i])
rotate([0,0,-angular_segment*i])
rotate([angle,0,0])
rotate_extrude(angle = angular_segment+overlap_degrees)
{
group()
{
if(thread_type == THREAD_TYPE_STANDARD)
{
standard_cutter(thread_pitch, thread_angle, major_diameter);
}
else if(thread_type == THREAD_TYPE_ACME)
{
acme_cutter(thread_pitch, thread_angle, major_diameter);
}
}
}
}
module acme_cutter(thread_pitch, thread_angle, major_diameter)
{
// depth it would be if this were not an acme thread
// \
// /
// /
// \
// \
// /
// |-d-|
ideal_depth=((thread_pitch/2.0)/tan(thread_angle/2.0));
// acme thread depth (ideally 1/3 ?)
// \
// |
// /
// |
// \
// |
// /
// |-d-|
acme_depth=ideal_depth/3;
// distance between ideal peak and flat top of acme thread
//
// /
// /|
// < |
// \|
// \
// |d|
flat_offset = (ideal_depth-acme_depth)/2;
// calculate y position for inner thread edge
c_y=tan(thread_angle/2) * ((ideal_depth-flat_offset)-flat_offset);
translate([major_diameter/2.0, 0, 0])
polygon(
// Here we alter the ideal (non-acme) profile
//
// B + - + A
// / |
// C + |
// \ |
// D + - + E
//
// shifting the cutter by (flat_offset) so the stock surface
// becomes the outer flat top of the thread
//
// ---->
//
// then blunting the cutter, creating 2 new points,
// c1 and c2, defining the inner flat bottom of the thread
//
// B + - + A
// / |
// C1 + |
// C2 + |
// \ |
// D + - + E
//
points=
[
[(thread_pitch/2)+(flat_offset),thread_pitch/2.0], // A
[0+(flat_offset),thread_pitch/2.0], // B
[(-((ideal_depth - flat_offset)-flat_offset)),+(c_y)],// C1
[(-((ideal_depth - flat_offset)-flat_offset)),-(c_y)],// C2
[0+(flat_offset),-(thread_pitch/2.0)], // D
[(thread_pitch/2)+(flat_offset),-(thread_pitch/2.0)] // E
],
paths=[[0,1,2,3,4,5,0]]
);
}
module standard_cutter(thread_pitch, thread_angle, major_diameter)
{
depth=((thread_pitch/2.0)/tan(thread_angle/2.0));
translate([major_diameter/2.0, 0, 0])
polygon(
// D + - + C
// / |
// E + |
// \ |
// A + - + B
//
// threads are not quite flush, so added the reverse protrusion to
// ensure cutting path gets all the material
points=
[
[0,-(thread_pitch/2.0)], // A
[(thread_pitch/2),-(thread_pitch/2.0)], // B (reverse protrusion)
[(thread_pitch/2),thread_pitch/2.0], // C (reverse protrusion)
[0,thread_pitch/2.0], // D
[(-depth),0] // E
],
paths=[[0,1,2,3,4,0]]
);
}
module gear(tooth_count, gear_module, pressure_angle, thickness)
{
pitch = pi() * gear_module;
pitch_circumference = pitch*tooth_count;
pitch_diameter=pitch_circumference/pi();
pitch_radius=pitch_diameter/2;
undercut_distance=1.25*gear_module;
cutter_tooth_height=gear_module+undercut_distance;
stock_radius=pitch_radius+undercut_distance;
stock_diameter=stock_radius*2;
difference()
{
cylinder(h=thickness,d=stock_diameter,center=true);
rotational_repeat(pitch_diameter, tooth_count)
gear_cutter(cutter_tooth_height, gear_module, pitch, pressure_angle, thickness);
}
}
module gear_cutter(cutter_tooth_height, gear_module, pitch, pressure_angle, thickness)
{
// GEAR CUTTER SHAPE
// __ _
// / \ 1.25 M |
// /----\ | C_T_H
// __/ \__ M |
// |- pitch -| -
//| P/2 |
// _ _ _
// /| \ |
// / | \ | C_T_H
// _/__| \_ |
// |TB| -
//| | HHSZ
// | | HHSZ
triangle_bottom=tan(20)*cutter_tooth_height;
half_horiz_size=((pitch/2) - triangle_bottom)/2;
p1x = -(triangle_bottom+half_horiz_size);
// rotate the cutter through this many degrees to simulate
// the motion of a wheel rolling over a rack profile
cutter_rotation_degrees=10;
// adust orientation
rotate([0,0,90])
for(i=[-(cutter_rotation_degrees/2):(cutter_rotation_degrees/2)])
rotate([0,0,i*2])
linear_extrude(thickness*2,center=true)
polygon(
points=
[
[0,-cutter_tooth_height],
[-((pitch/2)+half_horiz_size+half_horiz_size), -gear_module],
[p1x, -gear_module],
[-half_horiz_size, 1.25 * gear_module],
[half_horiz_size, 1.25 * gear_module],
[-p1x, -gear_module],
[((pitch/2)+half_horiz_size+half_horiz_size), -gear_module]
],
paths=[[0,1,2,3,4,5,6,0]]
);
}
// PLA is more crunchy than cut gears, so give it some additional room
additional_gear_clearance=0.5;
// find the necessay spacing between axles of 2 involute gears
function gearSpacing(tooth_count1, tooth_count2, gear_module)=
((gear_module*tooth_count2)/2) + ((gear_module*tooth_count1)/2) + additional_gear_clearance;
module gearFitFixture(axle_diameter, distance, axle_height)
{
plate_thickness=2;
plate_width = axle_diameter * 2;
plate_length = axle_diameter + distance + axle_diameter;
cube([plate_width,plate_length,plate_thickness],center=true);
difference()
{
translate([0,distance/2,axle_height/2+plate_thickness/2])
cylinder(h=axle_height,d=axle_diameter,center=true);
translate([0,distance/2,axle_height+plate_thickness/2])
outer_chamfer_ring(axle_diameter, 0.5);
}
difference()
{
translate([0,-(distance/2),axle_height/2+plate_thickness/2])
cylinder(h=axle_height,d=axle_diameter,center=true);
translate([0,-(distance/2),axle_height+plate_thickness/2])
outer_chamfer_ring(axle_diameter, 0.5);
}
}
// get the distance between 2 points in 3D space
function pointDistance(x1,y1,z1,x2,y2,z2)=
sqrt(pow(x2-x1,2) + pow(y2-y1,2) + pow(z2-z1,2));
// user-suppliable factor to lengthen segments, to fill in gaps
// segmentExtendFactor=0.25;
defaultSegmentExtendFactor=0.25;
// extrudes a 2-d shape between two points,
// matching the direction and orientation of
// a line running through them
module extrudeBetween(x1,y1,z1,x2,y2,z2)
{
distance =
pointDistance(x1,y1,z1,x2,y2,z2);
// weak-ass Earth mathematics can't handle divide by zero
x2_diff=((x2-x1)!=0?(x2-x1):0.00001);
y2_diff=((y2-y1)!=0?(y2-y1):0.00001);
z2_diff=((z2-z1)!=0?(z2-z1):0.00001);
extendFactor=(default(segmentExtendFactor, defaultSegmentExtendFactor));
// first, the y rotation gets us to the z height
// of our final position
//
// * initial (H)
// |
// |
// final * * intermediate y rotation
// | / | (O)
// |/ |
// +-----------x
// | (A)
// z
new_opposite = z2_diff;
new_hypotenuse = distance;
raw_y_angle=abs(asin(new_opposite/new_hypotenuse));
// determine the quadrant, so we can rotate by correct angle
x_sign=(x2_diff<0?-1:1);
z_sign=(z2_diff<0?-1:1);
y_sign=(y2_diff<0?-1:1);
y_rot_angle = x_sign * (90 + (raw_y_angle * (z_sign<0?1:-1)) );
// next, the z rotation moves us to the right place on
// the x/y plane
// * final
// /|
// / | y2 (O)
// x-+------* intermediate
// | x2 (A)
// |
// y
raw_z_angle= abs(atan(y2_diff/x2_diff));
// rotate by a different direction and amount depending
// on original y rotation and quadrant
z_rot_angle = (
// x neg + y neg + y rot pos
(x_sign < 0 && y_sign < 0 && y_rot_angle >= 0)?
(180 - raw_z_angle):
// x neg + y pos + y rot pos
(x_sign < 0 && y_sign >= 0 && y_rot_angle >= 0)?
-(180 - raw_z_angle):
// x pos + y neg + y rot pos
(x_sign >= 0 && y_sign < 0 && y_rot_angle >= 0)?
-(raw_z_angle):
// x pos + y pos + y rot pos
(x_sign >= 0 && y_sign >= 0 && y_rot_angle >= 0)?
(raw_z_angle):
// x neg + y neg + y rot neg
(x_sign < 0 && y_sign < 0 && y_rot_angle < 0)?
(raw_z_angle):
// x neg + y pos + y rot neg
(x_sign < 0 && y_sign >= 0 && y_rot_angle < 0)?
-(raw_z_angle):
// x pos + y neg + y rot neg
(x_sign >= 0 && y_sign < 0 && y_rot_angle < 0)?
(180 - raw_z_angle):
// x pos + y pos + y rot neg
(x_sign >= 0 && y_sign >= 0 && y_rot_angle < 0)?
-(180 - raw_z_angle):0
);
// extrude object and
// rotate / translate to
// the desired position
translate([x1,y1,z1])
rotate([0,y_rot_angle,z_rot_angle])
group()
{
translate([0,0,distance/2])
linear_extrude(height = distance*(1+extendFactor), center = true)
children();
}
}
// treat a list of 3D points as a path to extrude a 2D shape over
module extrudePoints(points)
{
for(count=[0:len(points)])
{
if(count-1 > 0)
{
if(
defined(points[count-1][0]) &&
defined(points[count-1][1]) &&
defined(points[count-1][2]) &&
defined(points[count][0]) &&
defined(points[count][1]) &&
defined(points[count][2])
)
{
extrudeBetween(
points[count-1][0],
points[count-1][1],
points[count-1][2],
points[count][0],
points[count][1],
points[count][2]
)
children();
}
}
}
}