* Fillet: refuse a result with openings in its surface (#871) A fillet on #871's part (radius 1 on a window's edges and on the sides of a block 1.26 mm away) came back closed as topology with every face meshing, but the rounds overlapped and the end faces' boundary loops crossed, so the model showed holes. The constant-radius fillet now checks its result before taking it: the body's mesh, welded within a millionth of its size, must have no edge without as many triangles running the other way along it, except for cracks within the mesh tolerance where fitted curves meet. A result that fails is refused, so the corner build gets its try and the radius search treats it as too large. Body::open_mesh_edges is the check. Kernel tests cover the #871 part (refused at radius 1, closed with a round on every edge at 0.5), and an engine test runs the fillet from the report and leaves the part as it was. All 96 robustness seeds build the same with and without it. Fixes #871 Co-Authored-By: Claude Opus 5.5 <[email protected]> * Check fillets for crossed face boundaries, not free mesh edges Free edges in the mesh also come from cracks where fitted curves meet (corner patches, rounds ending on curved edges), so the mesh test refused good fillets. The check is now on the cause of #871: a planar face whose boundary loops cross each other or themselves has no inside. Body::crossed_face_loops samples each planar face's loops within 1/1000 of the size and counts proper crossings (touching within a millionth doesn't count). The pyramid apex blend and the loft fillets build again. Ten action-matrix fillets stay refused, recorded in the baseline: r = 3 on the 2 mm rim of oracle 09's shelled box (the round runs past the inner wall; the result was 240 mm3 lighter than any round can make it), and the six seam-edge fillets on oracle 60's bolt holes, whose boundary jumps across the hole. Co-Authored-By: Claude Opus 5.5 <[email protected]> --------- Co-authored-by: Claude Opus 5.5 <[email protected]>
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@@ -54,6 +54,44 @@ fn shell_with_a_hole_through_a_curved_side() {
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]));
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}
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/// #871: the fillet from the report (its feature as saved) on a plate with a block on top and
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/// a window through both. Radius 1 on the window's edges and on the block's sides overlaps in
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/// the 1.26 mm wall between them; the result had openings in its end faces and was accepted.
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/// It is refused now, and the part is left as it was.
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#[test]
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fn fillet_that_would_open_the_surface_is_refused() {
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let (a, b) = (12.74437365538526, 22.69275963366936);
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let mut s = script(json!([
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{"command": "solid.box", "params": {"length": 14, "width": 21.5, "height": 10, "corner": [9.5, 8, 0]}},
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{"command": "solid.box", "params": {"length": 14, "width": b - a, "height": 10, "corner": [9.5, a, 10], "operation": "join", "targets": ["Body1"]}},
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{"command": "solid.box", "params": {"length": 14, "width": 5.2, "height": 7.1, "corner": [9.5, 14, 7], "operation": "cut", "targets": ["Body1"]}}
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]));
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let feature = json!({
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"type": "fillet",
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"edges": [
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[23.5, 12.74437365538526, 15.0], [23.5, 10.37218682769263, 10.0], [23.5, 8.0, 5.0], [23.5, 18.75, 0.0],
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[23.5, 29.5, 5.0], [23.5, 26.09637981683468, 10.0], [23.5, 22.69275963366936, 15.0], [23.5, 17.71856664452731, 20.0],
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[23.5, 16.6, 7.0], [23.5, 14.0, 10.55], [23.5, 16.6, 14.100000000000001], [23.5, 19.200000000000003, 10.55],
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[9.5, 17.71856664452731, 20.0], [9.5, 22.69275963366936, 15.0], [9.5, 26.09637981683468, 10.0], [9.5, 29.5, 5.0],
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[9.5, 18.75, 0.0], [9.5, 8.0, 5.0], [9.5, 10.37218682769263, 10.0], [9.5, 12.74437365538526, 15.0],
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[9.5, 19.200000000000003, 10.55], [9.5, 16.6, 14.100000000000001], [9.5, 14.0, 10.55], [9.5, 16.6, 7.0]
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],
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"radius": "1"
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});
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let before = total_volume(&s);
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let result = s.execute("solid.fillet", &json!({"edges": feature["edges"], "radius": feature["radius"]}));
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assert!(result.is_err(), "a fillet with openings in the model was accepted");
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assert!((total_volume(&s) - before).abs() < 1e-9);
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for body in &s.model.state().bodies {
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assert!(body.body.validity().is_empty() && body.body.crossed_face_loops().unwrap() == 0);
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}
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// At half the radius the rounds fit.
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run(&mut s, "solid.fillet", json!({"edges": feature["edges"], "radius": "0.5"}));
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for body in &s.model.state().bodies {
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assert!(body.body.validity().is_empty() && body.body.crossed_face_loops().unwrap() == 0);
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}
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}
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/// Shell of a body in two pieces (a cylinder joined clear of a ring): each piece is shelled.
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#[test]
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fn shell_of_a_body_in_two_pieces() {
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@@ -1623,23 +1623,39 @@ fn loop_split(cur: &Body, pts: &[Vec3]) -> Result<Option<(Vec<Vec<Vec3>>, Vec<Ve
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Ok((!groups.is_empty()).then_some((groups, rest)))
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}
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/// A fillet's result, refused when a face's boundary crosses itself (#871): rounds that
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/// overlap where a wall is thinner than both leave such faces, which the topology checks
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/// don't see but which show as holes in the model. A fillet either closes the solid or is
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/// refused.
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fn closed(b: Body) -> Result<Body> {
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match b.crossed_face_loops()? {
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0 => Ok(b),
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_ => Err(KernelError::Failed(
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"fillet: the rounds would leave openings in the surface (they overlap where a wall or a face is narrower than both)".into(),
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)),
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}
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}
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/// Constant-radius fillet of the edges nearest to the given points. A radius too large for the
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/// faces around the edges is refused with [`KernelError::TooLarge`] ([`fillet_max`] finds the
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/// largest that works).
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pub fn fillet(body: &Body, edges: &[Vec3], radius: f64) -> Result<Body> {
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body.require_brep("fillet")?;
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// Corners the local blends refuse (an earlier round at an edge's end): radius per edge.
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blend(body, edges, radius, Shape::Round, "fillet").or_else(|e| {
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blend(body, edges, radius, Shape::Round, "fillet").and_then(closed).or_else(|e| {
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let sel: Vec<(Vec3, f64)> = edges.iter().map(|p| (*p, radius)).collect();
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// The local blend's refusal, unless only the corner build found the radius too large.
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crate::blend_corner::fillet_radii(body, &sel)
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.and_then(closed)
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.map_err(|e2| match (&e, e2) {
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(KernelError::TooLarge(_), _) => e,
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(_, e2 @ KernelError::TooLarge(_)) => e2,
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_ => e,
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})
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// Three edges at a vertex of any faces end in a sphere.
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.or_else(|e| if edges.len() >= 3 { crate::blend_vertex::fillet_ball_vertices(body, edges, radius).map_err(|_| e) } else { Err(e) })
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.or_else(|e| {
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if edges.len() >= 3 { crate::blend_vertex::fillet_ball_vertices(body, edges, radius).and_then(closed).map_err(|_| e) } else { Err(e) }
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})
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})
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}
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@@ -1726,7 +1742,7 @@ pub fn fillet_each(body: &Body, edges: &[Vec3], radii: &[f64]) -> Result<Body> {
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return fillet(body, edges, *r);
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}
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let sel: Vec<(Vec3, f64)> = edges.iter().copied().zip(radii.iter().copied()).collect();
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if let Ok(b) = crate::blend_corner::fillet_radii(body, &sel) {
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if let Ok(b) = crate::blend_corner::fillet_radii(body, &sel).and_then(closed) {
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return Ok(b);
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}
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let mut by_radius: Vec<(f64, Vec<Vec3>)> = Vec::new();
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@@ -1090,6 +1090,79 @@ impl Body {
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guard("tessellate", || crate::tess::plan(&self.solid, tol, turn).map(|(plan, _)| plan))
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}
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/// Planar faces whose boundary crosses itself: two of its loops crossing each other, or a
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/// loop crossing itself. Such a face has no inside, and its mesh covers what it shouldn't
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/// and leaves openings beside it, while the shell is still closed and every face meshes
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/// (rounds that overlap where a wall is thinner than both, #871). Boundaries that only
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/// touch (at a vertex they share, or within the size's millionth) don't count.
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pub fn crossed_face_loops(&self) -> Result<usize> {
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use mt::{BoundedCurve, ParameterDivision1D};
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if self.is_mesh() {
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return Ok(0);
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}
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const MAX_SEGMENTS: usize = 20_000;
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let size = self.size();
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let tol = (size * 1e-6).max(1e-9);
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let chord = (size * 1e-3).max(1e-4);
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let mut crossed = 0;
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for f in self.solid.face_iter() {
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let mt::Surface::Plane(pl) = f.oriented_surface() else { continue };
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let o = from_p3(pl.origin());
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let (Some(u), Some(n)) = (
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Vec3::new(pl.u_axis().x, pl.u_axis().y, pl.u_axis().z).normalized(),
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Vec3::new(pl.normal().x, pl.normal().y, pl.normal().z).normalized(),
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) else {
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continue;
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};
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let v = n.cross(u);
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let flat = |p: mt::Point3| {
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let d = from_p3(p) - o;
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(d.dot(u), d.dot(v))
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};
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// Each loop's segments, in the face's plane.
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let mut loops: Vec<Vec<((f64, f64), (f64, f64))>> = Vec::new();
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let mut total = 0usize;
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for w in f.boundaries() {
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let mut segs = Vec::new();
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for e in w.edge_iter() {
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let pts = guard("face loops", || {
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Ok(match e.curve() {
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mt::Curve::Line(_) => vec![e.front().point(), e.back().point()],
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c => c.parameter_division(c.range_tuple(), chord).1,
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})
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})?;
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segs.extend(pts.windows(2).filter_map(|q| Some((flat(*q.first()?), flat(*q.get(1)?)))));
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}
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total = total.saturating_add(segs.len());
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if total > MAX_SEGMENTS {
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break;
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}
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loops.push(segs);
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}
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if total > MAX_SEGMENTS {
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continue;
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}
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// Proper crossings only: each segment's ends strictly on either side of the other.
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let side = |a: (f64, f64), b: (f64, f64), p: (f64, f64)| {
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let (dx, dy) = (b.0 - a.0, b.1 - a.1);
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let len = (dx * dx + dy * dy).sqrt();
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if len <= tol { 0.0 } else { (dx * (p.1 - a.1) - dy * (p.0 - a.0)) / len }
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};
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let cross = |s: &((f64, f64), (f64, f64)), t: &((f64, f64), (f64, f64))| {
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let (d1, d2) = (side(s.0, s.1, t.0), side(s.0, s.1, t.1));
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let (d3, d4) = (side(t.0, t.1, s.0), side(t.0, t.1, s.1));
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((d1 > tol && d2 < -tol) || (d1 < -tol && d2 > tol)) && ((d3 > tol && d4 < -tol) || (d3 < -tol && d4 > tol))
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};
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let all: Vec<(usize, &((f64, f64), (f64, f64)))> =
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loops.iter().enumerate().flat_map(|(l, segs)| segs.iter().map(move |s| (l, s))).collect();
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let bad = all.iter().enumerate().any(|(i, (_, s))| all.iter().skip(i + 1).any(|(_, t)| cross(s, t)));
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if bad {
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crossed += 1;
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}
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}
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Ok(crossed)
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}
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/// Faces with no triangles in a coarse tessellation (the mesher failed or gave up).
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pub fn unmeshed_faces(&self) -> usize {
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if self.is_mesh() {
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@@ -0,0 +1,60 @@
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//! #871: a fillet that opened holes in the model must be refused, not accepted.
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use solidcraft_geom::Vec3;
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use crate::{Body, BoolOp, build::box_solid, ops::boolean};
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/// The part from #871: a plate with a narrower block on top and a window through both, filleted
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/// at radius 1 along every edge of both end faces.
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fn part() -> Body {
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let (a, b) = (12.74437365538526, 22.69275963366936);
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let base = box_solid(Vec3::new(9.5, 8.0, 0.0), Vec3::new(23.5, 29.5, 10.0)).unwrap();
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let top = box_solid(Vec3::new(9.5, a, 10.0), Vec3::new(23.5, b, 20.0)).unwrap();
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let joined = boolean(&base, &top, BoolOp::Union).unwrap().unwrap();
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let window = box_solid(Vec3::new(9.5, 14.0, 7.0), Vec3::new(23.5, 19.2, 14.1)).unwrap();
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boolean(&joined, &window, BoolOp::Cut).unwrap().unwrap()
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}
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fn edges() -> Vec<Vec3> {
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let yz = [
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(12.74437365538526, 15.0),
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(10.37218682769263, 10.0),
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(8.0, 5.0),
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(18.75, 0.0),
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(29.5, 5.0),
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(26.09637981683468, 10.0),
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(22.69275963366936, 15.0),
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(17.71856664452731, 20.0),
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(16.6, 7.0),
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(14.0, 10.55),
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(16.6, 14.100000000000001),
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(19.200000000000003, 10.55),
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];
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[23.5, 9.5].iter().flat_map(|x| yz.iter().map(move |(y, z)| Vec3::new(*x, *y, *z))).collect()
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}
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/// Radius 1 on both the window's edges and the block's sides: the wall between them is 1.26
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/// mm thick, so the rounds overlap and the end faces' boundaries cross. That result has
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/// openings and is refused.
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#[test]
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fn overlapping_rounds_are_refused() {
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let p = part();
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assert_eq!(p.crossed_face_loops().unwrap(), 0);
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assert!(crate::fillet(&p, &edges(), 1.0).is_err(), "a fillet with openings in its surface was accepted");
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// The corner build makes that body (what #871 got): closed as topology, every face meshes,
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// but the loops of its end faces cross.
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let sel: Vec<(Vec3, f64)> = edges().into_iter().map(|e| (e, 1.0)).collect();
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if let Ok(b) = crate::blend_corner::fillet_radii(&p, &sel) {
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assert!(b.validity().is_empty() && b.crossed_face_loops().unwrap() > 0);
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}
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}
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/// Below half the wall the rounds fit: a closed solid with a round on every edge.
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#[test]
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fn rounds_that_fit_are_closed() {
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let p = part();
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let b = crate::fillet(&p, &edges(), 0.5).unwrap();
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assert!(b.validity().is_empty(), "{:?}", b.validity());
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assert_eq!(b.crossed_face_loops().unwrap(), 0);
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assert_eq!(b.face_count(), p.face_count() + edges().len());
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}
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@@ -47,6 +47,8 @@ mod issue_674_tests;
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mod issue_679_tests;
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#[cfg(test)]
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mod issue_851_tests;
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#[cfg(test)]
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mod issue_871_tests;
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mod lip;
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mod loopblend;
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mod measure;
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@@ -3666,20 +3666,20 @@
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"Box/F2:side:l1|F2:side:l4~1": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l1|F2:side:l4~2": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l1|F2:start": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l1|F2:top": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l1|F2:top": "edge.axis edge.chamfer !edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l2": "face.angle_plane face.draft_neutral face.extrude face.hole face.midplane face.offset_plane face.press_pull face.shell face.sketch",
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"Box/F2:side:l2|F2:side:l3~1": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l2|F2:side:l3~2": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l2|F2:start": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l2|F2:top": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l2|F2:top": "edge.axis edge.chamfer !edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l3": "face.angle_plane face.draft_neutral face.extrude face.hole face.midplane face.offset_plane face.press_pull face.shell face.sketch",
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"Box/F2:side:l3|F2:side:l4~1": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l3|F2:side:l4~2": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l3|F2:start": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l3|F2:top": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l3|F2:top": "edge.axis edge.chamfer !edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l4": "face.angle_plane face.draft_neutral face.extrude face.hole face.midplane face.offset_plane face.press_pull face.shell face.sketch",
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"Box/F2:side:l4|F2:start": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l4|F2:top": "edge.axis edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Box/F2:side:l4|F2:top": "edge.axis edge.chamfer !edge.fillet edge.normal_plane edge.project",
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"Box/F2:start": "face.angle_plane face.draft_neutral face.extrude face.hole face.midplane face.offset_plane face.press_pull face.shell face.sketch",
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"Box/F2:top": "face.angle_plane face.draft_neutral face.extrude face.hole face.midplane face.offset_plane face.press_pull face.shell face.sketch",
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"Box/F2:top|F3:inner:F2:side:l1": "edge.axis edge.chamfer !edge.fillet edge.normal_plane edge.project",
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@@ -7698,9 +7698,9 @@
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},
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"oracle/60-pipe-flange": {
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"Flange/F2:side:l1": "face.extrude face.hole face.midplane face.offset_plane face.press_pull face.shell face.sketch",
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"Flange/F2:side:l1|F2:side:l2#1": "edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Flange/F2:side:l1|F2:side:l2#2": "edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Flange/F2:side:l1|F2:side:l2#3": "edge.chamfer edge.fillet edge.normal_plane edge.project",
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"Flange/F2:side:l1|F2:side:l2#1": "edge.chamfer !edge.fillet edge.normal_plane edge.project",
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"Flange/F2:side:l1|F2:side:l2#2": "edge.chamfer !edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l1|F2:side:l2#3": "edge.chamfer !edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l1|F2:side:l6#1": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l1|F2:side:l6#2": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l1|F2:side:l6#3": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
@@ -7721,11 +7721,11 @@
|
||||
"Flange/F2:side:l1|F4:side:[email protected]#1": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l1|F4:side:[email protected]#2": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l2#1": "curved.axis curved.tangent_plane",
|
||||
"Flange/F2:side:l2#1|F2:side:l3": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l2#1|F2:side:l3": "edge.chamfer !edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l2#2": "curved.axis curved.tangent_plane",
|
||||
"Flange/F2:side:l2#2|F2:side:l3": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l2#2|F2:side:l3": "edge.chamfer !edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l2#3": "curved.axis curved.tangent_plane",
|
||||
"Flange/F2:side:l2#3|F2:side:l3": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l2#3|F2:side:l3": "edge.chamfer !edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l3": "face.extrude face.hole face.offset_plane face.press_pull !face.shell face.sketch",
|
||||
"Flange/F2:side:l3|F4:side:c1#1": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
"Flange/F2:side:l3|F4:side:c1#2": "edge.chamfer edge.fillet edge.normal_plane edge.project",
|
||||
|
||||
Reference in new issue
Block a user