Adding sheet metal functionality: make_brake_formed, fillet, offset

examples/ttt_sm_hanger.py

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+"""
+Creation of a complex sheet metal part
+
+name: ttt_sm_hanger.py
+by:   Gumyr
+date: July 17, 2023
+
+desc:
+    This example implements the sheet metal part described in Too Tall Toby's
+    sm_hanger CAD challenge.
+
+    Notably, a BuildLine/Curve object is filleted by providing all the vertices
+    and allowing the fillet operation filter out the end vertices. The 
+    make_brake_formed operation is used both in Algebra and Builder mode to
+    create a sheet metal part from just an outline and some dimensions.
+    license:
+
+    Copyright 2023 Gumyr
+
+    Licensed under the Apache License, Version 2.0 (the "License");
+    you may not use this file except in compliance with the License.
+    You may obtain a copy of the License at
+
+        http://www.apache.org/licenses/LICENSE-2.0
+
+    Unless required by applicable law or agreed to in writing, software
+    distributed under the License is distributed on an "AS IS" BASIS,
+    WITHOUT WARRANTIES OR CONDITIONS OF ANY KIND, either express or implied.
+    See the License for the specific language governing permissions and
+    limitations under the License.
+
+"""
+from build123d import *
+from ocp_vscode import *
+
+sheet_thickness = 4 * MM
+
+# Create the main body from a side profile
+with BuildPart() as side:
+    d = Vector(1, 0, 0).rotate(Axis.Y, 60)
+    with BuildLine(Plane.XZ) as side_line:
+        l1 = Line((0, 65), (170 / 2, 65))
+        l2 = PolarLine(l1 @ 1, length=65, direction=d, length_mode=LengthMode.VERTICAL)
+        l3 = Line(l2 @ 1, (170 / 2, 0))
+        fillet(side_line.vertices(), 7)
+    make_brake_formed(
+        thickness=sheet_thickness,
+        station_widths=[40, 40, 40, 112.52 / 2, 112.52 / 2, 112.52 / 2],
+        side=Side.RIGHT,
+    )
+    fe = side.edges().filter_by(Axis.Z).group_by(Axis.Z)[0].sort_by(Axis.Y)[-1]
+    fillet(fe, radius=7)
+
+# Create the "wings" at the top
+with BuildPart() as wing:
+    with BuildLine(Plane.YZ) as wing_line:
+        l1 = Line((0, 65), (80 / 2 + 1.526 * sheet_thickness, 65))
+        PolarLine(l1 @ 1, 20.371288916, direction=Vector(0, 1, 0).rotate(Axis.X, -75))
+        fillet(wing_line.vertices(), 7)
+    make_brake_formed(
+        thickness=sheet_thickness,
+        station_widths=110 / 2,
+        side=Side.RIGHT,
+    )
+    bottom_edge = wing.edges().group_by(Axis.X)[-1].sort_by(Axis.Z)[0]
+    fillet(bottom_edge, radius=7)
+
+# Create the tab at the top in Algebra mode
+tab_line = Plane.XZ * Polyline(
+    (20, 65 - sheet_thickness), (56 / 2, 65 - sheet_thickness), (56 / 2, 88)
+)
+tab_line = fillet(tab_line.vertices(), 7)
+tab = make_brake_formed(sheet_thickness, 8, tab_line, Side.RIGHT)
+tab = fillet(tab.edges().filter_by(Axis.X).group_by(Axis.Z)[-1].sort_by(Axis.Y)[-1], 5)
+tab -= Pos((0, 0, 80)) * Rot(0, 90, 0) * Hole(5, 100)
+
+# Combine the parts together
+with BuildPart() as sm_hanger:
+    add([side.part, wing.part])
+    mirror(about=Plane.XZ)
+    with BuildSketch(Plane.XY.offset(65)) as h1:
+        with Locations((20, 0)):
+            Rectangle(30, 30, align=(Align.MIN, Align.CENTER))
+            fillet(h1.vertices().group_by(Axis.X)[-1], 7)
+        SlotCenterPoint((154, 0), (154 / 2, 0), 20)
+    extrude(amount=-40, mode=Mode.SUBTRACT)
+    with BuildSketch() as h2:
+        SlotCenterPoint((206, 0), (206 / 2, 0), 20)
+    extrude(amount=40, mode=Mode.SUBTRACT)
+    add(tab)
+    mirror(about=Plane.YZ)
+    mirror(about=Plane.XZ)
+
+# Target 1028g +/- 10g
+print(f"Mass: {sm_hanger.part.volume*7800*1e-6:0.1f} g")  # 1027.7g
+
+show(sm_hanger)