Boolean nudge: no sliver where a tool only touches a round side (#827, seen in #897) (#941)

* Boolean nudge tried both ways: no sliver where a cut's end touches a round side (#897, #827) Robustness seed 14 cuts a cylinder whose end lies exactly on the apex of the plate's arc side. Since the display tessellation plans (#805) the generator sees the arc's true extent, so the cut's base lands on -10 instead of -10.000000000000002 and the end is tangent to the arc. The direct boolean fails there and the last-resort tool nudge pushed the end into the arc, leaving a planar sliver a tenth of a millimetre wide; shell then picked that sliver and refused it. The 13 October merges were not the cause (the bisect lands on #805). The nudge is now tried both ways and the simpler result (fewer faces) is kept, so the opposite nudge parts the touching faces instead. The same change joins the hinge barrel in #827, whose top lies tangent to the lid's underside where the mounting leaf ends. Each result still passes the same checks as before. Goldens: seeds 14, 26 and 85 now build to the end, 31 and 78 come out with fewer faces. Seeds 6, 43 and 73 still stop at shell: their joins now succeed and shell reaches corners it can't offset (a cusp where a box face touches an arc, coplanar faces facing opposite ways), which is unchanged. Fixes #897 Fixes #827 Co-Authored-By: Claude Opus 5.5 <[email protected]> * Nudge the other way only when the first nudge fails or leaves a sliver Trying both nudges and keeping the one with fewer faces could prefer a result that keeps two pieces joined by a hair over one that separates them (the centred coplanar revolve cut). The opposite nudge now runs only when the first one failed or left a face narrower than 1/200 of the part, and it is taken when it works with fewer of those. Goldens re-recorded on current main: seeds 14, 26 and 85 build to the end, 31 and 78 with fewer faces. The other changed seeds are main's own since its last full record, identical with and without this change. Co-Authored-By: Claude Opus 5.5 <[email protected]> * Nudge the other way only for slivers the nudge made On the sensor enclosure's lid the first nudge left thin faces the operands already had (thin walls, small rounds), so the opposite nudge ran a second boolean for nothing and the press/pull took 79 s against main's 55 s. The opposite nudge now runs only when the first one failed or left more slivers than the operands brought; the press/pull test takes 36 s against 42 s on main (same machine, one after the other). Goldens re-recorded on top of #940. Co-Authored-By: Claude Opus 5.5 <[email protected]> * Goldens on current main: seeds 31, 43 and 78 with the two-way nudge Co-Authored-By: Claude Opus 5.5 <[email protected]> * Keep the hinge and tangent-cut tests beside the #871 fillet test Co-Authored-By: Claude Opus 5.5 <[email protected]> * Goldens: seeds 33 and 91 as main's fillet changes build them Co-Authored-By: Claude Opus 5.5 <[email protected]> * Goldens: keep main's #950 record Co-Authored-By: Claude Opus 5.5 <[email protected]> --------- Co-authored-by: Claude Opus 5.5 <[email protected]>
2026-10-14 02:55:37 -04:00
1 parent ac84491638
commit 18347b3d0d
@@ -32,9 +32,9 @@
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  "29": {"area":6965.599057,"bodies":1,"edges":74,"error":null,"faces":30,"outcome":"ok","rejected":0,"shells":1,"steps":["extruded profile","shell","join cylinder"],"unsupported":0,"volume":3977.885339},
  "30": {"area":853.525389,"bodies":1,"edges":23,"error":null,"faces":10,"outcome":"ok","rejected":0,"shells":1,"steps":["revolved section","chamfer"],"unsupported":0,"volume":1337.14821},
-  "31": {"area":10195.468237,"bodies":3,"edges":75,"error":null,"faces":31,"outcome":"ok","rejected":1,"shells":3,"steps":["box","cut box","fillet","join box","circular pattern","cut box","circular pattern","hole"],"unsupported":1,"volume":56416.134686},
+  "31": {"area":10195.46137,"bodies":3,"edges":69,"error":null,"faces":30,"outcome":"ok","rejected":1,"shells":3,"steps":["box","cut box","fillet","join box","circular pattern","cut box","circular pattern","hole"],"unsupported":1,"volume":56416.127527},
  "32": {"area":3220.802769,"bodies":1,"edges":51,"error":null,"faces":19,"outcome":"ok","rejected":0,"shells":1,"steps":["revolved section","cut sphere","cut box","cut box","join box"],"unsupported":0,"volume":7565.955897},
-  "33": {"area":5269.06481,"bodies":2,"edges":64,"error":null,"faces":29,"outcome":"ok","rejected":0,"shells":3,"steps":["revolved section","fillet","join box","cut cylinder","join box","chamfer","fillet","fillet"],"unsupported":2,"volume":13840.242661},
+  "33": {"area":5285.817318,"bodies":2,"edges":59,"error":null,"faces":27,"outcome":"ok","rejected":0,"shells":3,"steps":["revolved section","fillet","join box","cut cylinder","chamfer","join box","chamfer","fillet"],"unsupported":2,"volume":13859.24945},
  "34": {"area":1086.303472,"bodies":1,"edges":30,"error":null,"faces":14,"outcome":"ok","rejected":0,"shells":1,"steps":["revolved section","cut sphere","hole"],"unsupported":0,"volume":2134.365275},
  "35": {"area":4605.630216,"bodies":1,"edges":26,"error":null,"faces":11,"outcome":"ok","rejected":0,"shells":1,"steps":["box","fillet","join box"],"unsupported":0,"volume":13965.526982},
  "36": {"area":10408.825748,"bodies":1,"edges":60,"error":null,"faces":26,"outcome":"ok","rejected":0,"shells":2,"steps":["revolved section","cut cylinder","join box","fillet","join cylinder"],"unsupported":0,"volume":55729.313103},
@@ -44,7 +44,7 @@
  "40": {"area":15548.516294,"bodies":1,"edges":49,"error":"offset: a corner whose faces don't meet the same way after t","faces":22,"outcome":"failed","rejected":0,"shells":1,"steps":["extruded profile","cut cylinder","shell","cut cylinder","join cylinder","shell"],"unsupported":0,"volume":16543.777532},
  "41": {"area":7611.393446,"bodies":1,"edges":99,"error":null,"faces":35,"outcome":"ok","rejected":1,"shells":1,"steps":["box","cut sphere","shell","fillet","cut cylinder","rectangular pattern","cut sphere","join cylinder"],"unsupported":1,"volume":5973.93328},
  "42": {"area":5486.881252,"bodies":1,"edges":45,"error":null,"faces":17,"outcome":"ok","rejected":0,"shells":1,"steps":["extruded profile","cut box","cut cylinder","rectangular pattern"],"unsupported":0,"volume":19095.110963},
-  "43": {"area":2623.031137,"bodies":1,"edges":72,"error":"boolean Union: the operation failed: no result","faces":26,"outcome":"failed","rejected":2,"shells":1,"steps":["extruded profile","cut cylinder","rectangular pattern","fillet","hole","rectangular pattern","join cylinder"],"unsupported":1,"volume":4325.21806},
+  "43": {"area":3492.988343,"bodies":1,"edges":72,"error":null,"faces":26,"outcome":"ok","rejected":2,"shells":1,"steps":["extruded profile","cut cylinder","rectangular pattern","fillet","hole","rectangular pattern","join cylinder"],"unsupported":1,"volume":7528.548742},
  "44": {"area":7972.435565,"bodies":1,"edges":36,"error":null,"faces":15,"outcome":"ok","rejected":0,"shells":1,"steps":["extruded profile","shell","cut sphere"],"unsupported":0,"volume":7622.184369},
  "45": {"area":14416.876392,"bodies":2,"edges":62,"error":"boolean Union: implausible result volume ","faces":29,"outcome":"failed","rejected":0,"shells":3,"steps":["revolved section","join cylinder","fillet","shell","cut box","join box"],"unsupported":1,"volume":14286.791174},
  "46": {"area":3445.162934,"bodies":1,"edges":99,"error":null,"faces":31,"outcome":"ok","rejected":0,"shells":1,"steps":["extruded profile","join cylinder","hole","cut cylinder","rectangular pattern","cut box","cut cylinder"],"unsupported":0,"volume":6232.317935},
@@ -79,7 +79,7 @@
  "75": {"area":7893.117931,"bodies":1,"edges":27,"error":null,"faces":11,"outcome":"ok","rejected":0,"shells":1,"steps":["revolved section","cut cylinder","chamfer","rectangular pattern","rectangular pattern","cut box"],"unsupported":0,"volume":38757.62083},
  "76": {"area":899.010133,"bodies":1,"edges":29,"error":null,"faces":13,"outcome":"ok","rejected":1,"shells":1,"steps":["revolved section","fillet","cut cylinder"],"unsupported":0,"volume":1745.3677},
  "77": {"area":12157.059928,"bodies":1,"edges":126,"error":null,"faces":54,"outcome":"ok","rejected":1,"shells":1,"steps":["revolved section","hole","circular pattern","rectangular pattern","circular pattern","join cylinder"],"unsupported":0,"volume":64306.616746},
-  "78": {"area":2423.343796,"bodies":1,"edges":39,"error":"offset: a corner whose faces don't meet the same way after t","faces":15,"outcome":"failed","rejected":0,"shells":1,"steps":["revolved section","cut cylinder","cut box","shell"],"unsupported":0,"volume":3707.45435},
+  "78": {"area":2510.733756,"bodies":1,"edges":36,"error":"offset: a corner whose faces don't meet the same way after t","faces":14,"outcome":"failed","rejected":0,"shells":1,"steps":["revolved section","cut cylinder","cut box","shell"],"unsupported":0,"volume":3707.416641},
  "79": {"area":13585.252616,"bodies":1,"edges":27,"error":null,"faces":12,"outcome":"ok","rejected":0,"shells":1,"steps":["box","cut cylinder","join cylinder"],"unsupported":0,"volume":104810.763072},
  "80": {"area":8652.533342,"bodies":1,"edges":20,"error":null,"faces":9,"outcome":"ok","rejected":0,"shells":1,"steps":["box","fillet","fillet"],"unsupported":0,"volume":37387.449469},
  "81": {"area":4001.811796,"bodies":2,"edges":75,"error":null,"faces":29,"outcome":"ok","rejected":1,"shells":2,"steps":["revolved section","cut sphere","circular pattern","rectangular pattern","hole","join cylinder","join box","cut sphere"],"unsupported":2,"volume":13139.562065},
@@ -92,7 +92,7 @@
  "88": {"area":3947.799648,"bodies":1,"edges":18,"error":null,"faces":8,"outcome":"ok","rejected":0,"shells":1,"steps":["box","hole"],"unsupported":0,"volume":12788.04706},
  "89": {"area":2512.5,"bodies":1,"edges":12,"error":null,"faces":6,"outcome":"ok","rejected":0,"shells":1,"steps":["box","cut box"],"unsupported":0,"volume":5906.25},
  "90": {"area":9703.747183,"bodies":1,"edges":30,"error":null,"faces":12,"outcome":"ok","rejected":0,"shells":1,"steps":["revolved section","hole"],"unsupported":0,"volume":46947.022876},
-  "91": {"area":4061.429233,"bodies":1,"edges":36,"error":null,"faces":14,"outcome":"ok","rejected":2,"shells":1,"steps":["revolved section","cut cylinder","chamfer"],"unsupported":1,"volume":9885.651549},
+  "91": {"area":3989.788869,"bodies":1,"edges":46,"error":null,"faces":18,"outcome":"ok","rejected":1,"shells":1,"steps":["revolved section","cut cylinder","fillet"],"unsupported":0,"volume":9777.743569},
  "92": {"area":2855.139217,"bodies":1,"edges":30,"error":null,"faces":12,"outcome":"ok","rejected":0,"shells":1,"steps":["revolved section","chamfer","cut sphere"],"unsupported":0,"volume":9814.30292},
  "93": {"area":7266.404017,"bodies":7,"edges":115,"error":null,"faces":51,"outcome":"ok","rejected":0,"shells":7,"steps":["extruded profile","fillet","chamfer","join box","circular pattern","rectangular pattern","cut cylinder"],"unsupported":0,"volume":12734.393171},
  "94": {"area":3504.020666,"bodies":1,"edges":73,"error":null,"faces":27,"outcome":"ok","rejected":1,"shells":1,"steps":["revolved section","cut cylinder","hole","rectangular pattern","cut box","cut box","join box"],"unsupported":1,"volume":5899.986066},
@@ -108,6 +108,8 @@
  {"reason":"#936: fillets and chamfers of smooth seams are refused as invalid picks (rejected) instead of unsupported; nothing else changes","seeds":[10,15,20,21,37,41,50,53,68,81,84,91]},
  {"reason":"#946: small tools in large bodies are traced at their own scale; seeds 26 and 85 now build, 18, 43, 61, 63 and 71 fail with a different message, 19 builds two fewer faces (its fillet pick is also refused as in #936)","seeds":[18,19,26,43,61,63,71,85]},
  {"reason":"#921 with its grid lines kept to display and export meshes (Booleans mesh as before #921): measured volume and area move by about 1e-6 (seed 94 also as in #936)","seeds":[22,78,94]},
-  {"reason":"a hole placed on a face without a direction drills into that face (it took the direction from any face whose plane passed through the point, the last one found, such as a side of a patterned box standing on the point's plane): the holes on these seeds now go straight in (#950)","seeds":[7,21,85]}
+  {"reason":"a hole placed on a face without a direction drills into that face (it took the direction from any face whose plane passed through the point, the last one found, such as a side of a patterned box standing on the point's plane): the holes on these seeds now go straight in (#950)","seeds":[7,21,85]},
+  {"reason":"the last-resort tool nudge is tried the other way when it fails or leaves sliver faces the operands didn't have: seed 43's join builds and the design runs to the end, 31 and 78 come out with fewer faces (#827, #897)","seeds":[31,43,78]},
+  {"reason":"main's fillet changes since the last record (#926, #949) move seeds 33 and 91: a fillet step builds differently or is picked differently","seeds":[33,91]}
 ]
 }