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Sheet metal: sew the folded-material guard per piece so adjacent flanges cut (#296) (#355)

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The guard that refuses machining through bends sewed every bend zone and
nonparallel panel into one solid. Two bends meeting at an open corner relief
share only an edge, so that sew failed with "nonmanifold edge contact" and any
cut on the base was refused. Sew and test each piece on its own instead.

Reference case 75-sm-bracket-holes now passes; its known_failure mark is removed.

Fixes #296


Claude-Session: https://claude.ai/code/session_01RjGw4gA5ZvKrU8MQP6sBgT

Co-authored-by: Claude Opus 5.5 <[email protected]>
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bherbruckandClaude Opus 5.5 authored and GitHub committed 2026-10-12 14:27:40 -04:00
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@@ -9,7 +9,7 @@ Where the expected values come from (the **Source** column):
No expected value comes from a commercial CAD product.
**75 / 76 cases pass**; sources: 55 analytic, 21 freecad. 1 known failure(s) tracked in issues; 0 case(s) without expected values yet.
**76 / 76 cases pass**; sources: 55 analytic, 21 freecad. 0 known failure(s) tracked in issues; 0 case(s) without expected values yet.
| Case | Source | Result | Surface distance mm (max / mean) | Method | Notes |
|---|---|---|---|---|---|
@@ -87,7 +87,7 @@ No expected value comes from a commercial CAD product.
| 72-sm-contour-flange | analytic | pass | | contour flange, width 50 along +Y, XZ section: plate x 0..35 z 0..2.5; bend R 2.5..5 about (35, 5) (sketch corner = outer virtual sharp, setback R+t); wall x 37.5..40 z 5..27.5; bend R 2.5..5 about (42.5, 27.5) (sketch corner = inner virtual sharp, setback R); plate x 42.5..70 z 30..32.5 | SolidCraft convention: the sketch lines are the sheet face away from the material (material right of travel); thickness grows to the material side |
| 73-sm-hem | analytic | pass | | 68's part (height 20) plus a flat hem on the flange top edge: 180 deg bend, inner radius = hem gap 0.01, outer 2.51, about (y 2.51, z 20), folded toward +y (inside); hem leg 8 - (0.01 + 2.5) = 5.49: y 2.52..5.02, z 14.51..20; extrusion along x 100 | SolidCraft conventions: hem gap 0.01 mm (rule hem_gap), hem length measured to the outer face of the hem bend (top at z 22.51), hem folds over the flange's inner face. |
| 74-sm-unfold-refold | analytic | pass | | U channel 80x50 (t 2.5, R 2.5, base y 5..45, flanges z 5..20) with the flat-pattern slot x 35..45, y -12..10 refolded: BA = (pi/2)(R + K t) = 5.654866776, so the slot removes base y 5..10, the whole y=0 bend and the flange from z 5 to 5 + (12 - (BA - 5)) = 16.345133224; x-segments 0..35 / 35..45 / 45..80 | unfold/refold maps flat distance through the K-factor neutral layer (K 0.44) |
| 75-sm-bracket-holes | analytic | known failure (#296) | | base x 0..75, y 5..40, z 0..2.5 (trimmed 5 by each flange's setback); bend 1 (R 2.5..5 about y 5, z 5) x 0..75; flange 1 y 0..2.5, z 5..30, x 0..80; bend 2 (R 2.5..5 about x 75, z 5) y 5..40; flange 2 x 77.5..80, z 5..15, y 5..40; minus two d6 through holes at (25,20), (55,20) in the base. A = sum of prism areas - 2 x 4 joint areas (75t, 75t, 35t, 35t) + hole walls - hole discs | step 14 (solid.extrude): invalid input: sew: nonmanifold edge contact; SolidCraft convention: the second flange trims the base under the first bend, so bend 1 stops at x 75 while flange 1's panel runs to x 80 (open corner relief, no fill). |
| 75-sm-bracket-holes | analytic | pass | | base x 0..75, y 5..40, z 0..2.5 (trimmed 5 by each flange's setback); bend 1 (R 2.5..5 about y 5, z 5) x 0..75; flange 1 y 0..2.5, z 5..30, x 0..80; bend 2 (R 2.5..5 about x 75, z 5) y 5..40; flange 2 x 77.5..80, z 5..15, y 5..40; minus two d6 through holes at (25,20), (55,20) in the base. A = sum of prism areas - 2 x 4 joint areas (75t, 75t, 35t, 35t) + hole walls - hole discs | SolidCraft convention: the second flange trims the base under the first bend, so bend 1 stops at x 75 while flange 1's panel runs to x 80 (open corner relief, no fill). |
| 76-sm-thickness-variant | analytic | pass | | final rule thickness 3 (bend radius = Thickness = 3): base y 6..60 x 3; bend annulus R 3..6 about (y 6, z 6); flange y 0..3, z 6..20; extrusion along x 100 | the rule's thickness edits regenerate the whole sheet body; only the final 3 mm state matters |
## Not covered by a reference case