def temple_hinge_pockets(temples):
# We're operating in a 90 degree rotated fixture
#l_hinge = poly.rotate_90(temples["left_hinge_contour"])
#r_hinge = poly.rotate_90(temples["right_hinge_contour"])
l_hinge = temples["left_hinge_contour"]
r_hinge = temples["right_hinge_contour"]
if not poly.is_ccw(l_hinge):
l_hinge = poly.reverse(l_hinge)
if not poly.is_ccw(r_hinge):
r_hinge = poly.reverse(r_hinge)
left_hinge_pocket_contours = []
while len(l_hinge) > 0:
l_hinge = poly.erode(1.5875 / 2, l_hinge)
if len(l_hinge) > 0:
l_hinge = l_hinge[0]
left_hinge_pocket_contours.append(l_hinge)
right_hinge_pocket_contours = []
while len(r_hinge) > 0:
r_hinge = poly.erode(1.5875 / 2, r_hinge)
if len(r_hinge) > 0:
r_hinge = r_hinge[0]
right_hinge_pocket_contours.append(r_hinge)
r = [
cam.comment("Hinge Pockets"),
cam.feedrate(750),
cam.change_tool("1/16in endmill"),
cam.start_spindle(15000),
cam.dwell(3),
cam.comment("Right Hinge Pocket"),
cam.pocket(right_hinge_pocket_contours,
-abs(temples['pocket_depth']),
retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Left Hinge Pocket"),
cam.pocket(left_hinge_pocket_contours,
-abs(temples['pocket_depth']),
retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Hinge Holes"),
cam.change_tool("1mm drill"),
cam.start_spindle(4500),
cam.dwell(2),
[
cam.rmp(p + [-8.0], retract=10.0)
for p in temples['right_hinge_holes']
],
[
cam.rmp(p + [-8.0], retract=10.0)
for p in temples['left_hinge_holes']
],
cam.rapid([None, None, 20.0]),
cam.move([None, None, 0]),
cam.contour(poly.rotate_90(temples['left_temple_contour']), True),
cam.contour(poly.rotate_90(temples['right_temple_contour']), True),
]
return r
def face_hinge_pockets(hinge_num, xposition, yposition):
left_hinge = hinges.get_hinge(hinge_num)
right_hinge = hinges.get_hinge(hinge_num, False)
left_translate = [xposition, -yposition]
#left_translate = [xposition, 0]
right_translate = [xposition, yposition]
#right_translate = [xposition, 0]
# Adjust by pocket depth of hinge
pocket_depth = left_hinge['pocket_depth']
left_contour = poly.translate(left_hinge["face_contour"], left_translate[0], left_translate[1])
right_contour = poly.translate(right_hinge["face_contour"], right_translate[0], right_translate[1])
left_holes = poly.translate(left_hinge["face_holes"], left_translate[0], left_translate[1])
right_holes = poly.translate(right_hinge["face_holes"], right_translate[0], right_translate[1])
if not poly.is_ccw(left_contour):
left_contour = poly.reverse(left_contour)
if not poly.is_ccw(right_contour):
right_contour = poly.reverse(right_contour)
left_hinge_pocket_contours = [];
while len(left_contour) > 0:
left_contour = poly.erode(1.5875/2, left_contour)
if len(left_contour) > 0:
left_contour = left_contour[0]
left_hinge_pocket_contours.append(left_contour)
right_hinge_pocket_contours = [];
while len(right_contour) > 0:
right_contour = poly.erode(1.5875/2, right_contour)
if len(right_contour) > 0:
right_contour = right_contour[0]
right_hinge_pocket_contours.append(right_contour)
r = [
cam.comment("Hinge Pockets"),
cam.feedrate(750),
cam.change_tool("1/16in endmill"),
cam.start_spindle(15000),
cam.dwell(3),
cam.comment("Right Hinge Pocket"),
cam.pocket(right_hinge_pocket_contours, -abs(right_hinge['pocket_depth']), retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Left Hinge Pocket"),
cam.pocket(left_hinge_pocket_contours, -abs(left_hinge['pocket_depth']), retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Hinge Holes"),
cam.change_tool("1mm drill"),
cam.start_spindle(4500),
cam.dwell(2),
[cam.rmp(p + [-8.0], retract=10.0) for p in right_holes],
[cam.rmp(p + [-8.0], retract=10.0) for p in left_holes],
cam.rapid([None, None, 20.0]),
]
return r
def mill_temples(outdir, temples, order):
#TODO: Replace with information in materials database
print 'Creating milling program for temples'
top_thickness = 4 # Assume 4mm temple
top_raw = 4
if order.get("temple_material"):
top_raw = order["temple_material"].get("top_raw_thickness") or order["temple_material"].get("top_thickness") or top_thickness
print 'top raw', top_raw
# Automatically determine some surfacing. The bottom thickness
# is a lamination and should be thin. It should be thinned to 1mm.
# The top should be thinned to bring total finished thickness to 6mm or less.
thin_back = 0
if top_raw > top_thickness:
thin_back = top_raw - top_thickness
l_temple = temples['left_temple_contour']
r_temple = temples['right_temple_contour']
offset = frame_offset(l_temple)
# Calculate entry points for bevelling operation
program = [
cam.setup(),
cam.select_fixture("blank_clamp"),
cam.retract_spindle(),
cam.rapid([0,0]),
cam.activate_pin("stock_clamp"),
surface_back(thin_back),
index_holes(top_raw),
# cam.rapid(l_temple[0]+[0]),
# cam.contour(l_temple, True),
# cam.move(l_temple[0]),
# cam.rapid(r_temple[0]),
# cam.contour(r_temple, True),
rough_temple_bevel(l_temple, thin_back),
rough_temple_bevel(r_temple, thin_back),
cam.change_tool("1/16in endmill"),
cam.rapid([0,0]),
temple_hinge_pockets(temples, thin_back),
cam.change_tool("dovetail"),
bevel_temple(l_temple, thin_back),
bevel_temple(r_temple, thin_back),
temple_hinge_clearance(l_temple, thin_back),
temple_hinge_clearance(r_temple, thin_back),
cam.retract_spindle(),
cam.deactivate_pin("stock_clamp"),
cam.change_tool("1/8in endmill"),
cam.end_program()
]
open(outdir + "/temples_milling.ngc", "w").write(to_string(program))
def temple_hinge_pockets(temples):
# We're operating in a 90 degree rotated fixture
#l_hinge = poly.rotate_90(temples["left_hinge_contour"])
#r_hinge = poly.rotate_90(temples["right_hinge_contour"])
l_hinge = temples["left_hinge_contour"]
r_hinge = temples["right_hinge_contour"]
if not poly.is_ccw(l_hinge):
l_hinge = poly.reverse(l_hinge)
if not poly.is_ccw(r_hinge):
r_hinge = poly.reverse(r_hinge)
left_hinge_pocket_contours = [];
while len(l_hinge) > 0:
l_hinge = poly.erode(1.5875/2, l_hinge)
if len(l_hinge) > 0:
l_hinge = l_hinge[0]
left_hinge_pocket_contours.append(l_hinge)
right_hinge_pocket_contours = [];
while len(r_hinge) > 0:
r_hinge = poly.erode(1.5875/2, r_hinge)
if len(r_hinge) > 0:
r_hinge = r_hinge[0]
right_hinge_pocket_contours.append(r_hinge)
r = [
cam.comment("Hinge Pockets"),
cam.feedrate(750),
cam.change_tool("1/16in endmill"),
cam.start_spindle(15000),
cam.dwell(3),
cam.comment("Right Hinge Pocket"),
cam.pocket(right_hinge_pocket_contours, -abs(temples['pocket_depth']), retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Left Hinge Pocket"),
cam.pocket(left_hinge_pocket_contours, -abs(temples['pocket_depth']), retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Hinge Holes"),
cam.change_tool("1mm drill"),
cam.start_spindle(4500),
cam.dwell(2),
[cam.rmp(p + [-8.0], retract=10.0) for p in temples['right_hinge_holes']],
[cam.rmp(p + [-8.0], retract=10.0) for p in temples['left_hinge_holes']],
cam.rapid([None, None, 20.0]),
cam.move([None, None, 0]),
cam.contour(poly.rotate_90(temples['left_temple_contour']), True),
cam.contour(poly.rotate_90(temples['right_temple_contour']), True),
]
return r
def index_holes(contours, thickness):
# We put the index holes 1/2 between top and bottom, 160mm apart
# log(str(poly.right(face_c)))
# log(str(poly.left(face_c)))
# log(str(poly.right(face_c) - poly.left(face_c)))
# log(str((poly.right(face_c) - poly.left(face_c))/2))
# log(str(poly.right(face_c) - (poly.right(face_c) - poly.left(face_c))/2))
rightmost = -1000000
leftmost = 1000000
for contour in contours:
right = poly.right(contour)
left = poly.left(contour)
rightmost = max(right, rightmost)
leftmost = min(left, leftmost)
# x_offset = poly.right(face_c) - (poly.right(face_c) - poly.left(face_c))/2
x_offset = rightmost - (rightmost - leftmost) / 2
hole_radius = 4.85 / 2 # Measured from dowel pin
tool_radius = 3.175 / 2
helix_radius = hole_radius - tool_radius
r_hole = [x_offset, 90]
l_hole = [x_offset, -90]
r = [
cam.comment("Index Holes for secondary operations"),
cam.change_tool("1/8in endmill"),
cam.start_spindle(15000),
cam.feedrate(1000),
cam.dwell(3),
cam.rmh(r_hole + [-thickness - 1.0], helix_radius, 0.5, 1),
cam.rmh(l_hole + [-thickness - 1.0], helix_radius, 0.5, 1),
]
return r
def nose_contour(nose_rad, nose_h, nose_sa, nose_ra, face_con, thickness):
"""Creates the nose contour feature toolpath. Angular arguments are in degrees."""
nr = nose_rad
h = nose_h
sa = math.radians(nose_sa)
ra = math.radians(nose_ra)
xfloor = poly.left(face_con) - 3.175 # bottom most point minus tool radius
xfloor = max(xfloor, -27.0) # miminum safe distance without hitting clamp
nose_tool_radius = 3.175
nextpoly = nose.nose_poly(nr, h, sa, ra, xfloor, nose_tool_radius, 0.0)
r = [
"(Nose Contour)",
cam.change_tool("1/4in ballmill"),
cam.start_spindle(20000),
cam.feedrate(2000),
cam.rmp(nextpoly[0] + [2.0]) # Start near our first contour
]
direction = 1
for i in range(-20, (thickness + 2) * 10):
z = -i / 10.0
# r += cam.move(nextpoly[0])
if (direction < 0):
nextpoly.reverse()
direction = direction * -1
r += cam.contour(nextpoly, False)
r += cam.move([None, None, z])
nextpoly = nose.nose_poly(nr, h, sa, ra, xfloor, nose_tool_radius, z)
return r
def mill_temples(outdir, temples, temple_length):
#TODO: Replace with information in materials database
front_surface_thickness = 0
back_surface_thickness = 4
final_front_thickness = 0
final_back_thickness = 4
thickness = final_front_thickness + final_back_thickness
front_surface_removal = final_front_thickness - front_surface_thickness
back_surface_removal = final_back_thickness - back_surface_thickness
r_temple = poly.rotate_90(temples['right_temple_contour'])
l_temple = poly.rotate_90(temples['left_temple_contour'])
offset = frame_offset(l_temple)
program = [
cam.setup(),
cam.select_fixture("blank_clamp"),
cam.retract_spindle(),
cam.activate_pin("stock_clamp"),
surface_front(front_surface_removal),
surface_back(back_surface_removal),
cam.change_tool("1/16in endmill"),
cam.rapid([0,0]),
cam.temporary_offset(offset),
temple_hinge_pockets(temples),
index_holes([l_temple, r_temple], thickness),
#thin_temples([l_temple, r_temple], temple_length),
]
open(outdir + "/temples_milling.ngc", "w").write(to_string(program))
def rough_temple_bevel(temple, thinning):
p1 = extendLine(temple[-1], temple[-2], 3.175/2 - 0.5)
p2 = extendLine(temple[0], temple[1], 3.175/2 - 0.5)
p3 = extendLine(temple[0], temple[1], 15)
p4 = extendLine(temple[-1], temple[-2], 15) # room for dovetail
# p1 and p2 are just extensions of the temple - move them to the side a bit to
# clearance for when the dovetail cutter comes through
p1 = extendLine(p1, p2, 3)
p2 = extendLine(p2, p1, 3)
p3 = extendLine(p3, p4, 3)
p4 = extendLine(p4, p3, 3)
# Move to the dovetail cutter entry point, helix through stock.
# Cut a circle big enough to admit the dovetail cutter.
# Rough cut the end of the temple
# Clear a return path for the dovetail cutter.
return [
cam.change_tool("1/8in endmill"),
cam.feedrate(1000),
cam.rmh(p4 + [-5-thinning], 1, pitch=1),
cam.move(p1),
cam.move(p2),
cam.move(p3),
cam.move(p4),
cam.rapid(p4 + [10])
]
def index_holes(contours, thickness):
# We put the index holes 1/2 between top and bottom, 160mm apart
# log(str(poly.right(face_c)))
# log(str(poly.left(face_c)))
# log(str(poly.right(face_c) - poly.left(face_c)))
# log(str((poly.right(face_c) - poly.left(face_c))/2))
# log(str(poly.right(face_c) - (poly.right(face_c) - poly.left(face_c))/2))
rightmost = -1000000
leftmost = 1000000
for contour in contours:
right = poly.right(contour)
left = poly.left(contour)
rightmost = max(right, rightmost)
leftmost = min(left, leftmost)
# x_offset = poly.right(face_c) - (poly.right(face_c) - poly.left(face_c))/2
x_offset = rightmost - (rightmost - leftmost)/2
hole_radius = 4.85/2 # Measured from dowel pin
tool_radius = 3.175/2
helix_radius = hole_radius - tool_radius
r_hole = [x_offset, 90]
l_hole = [x_offset, -90]
r = [
cam.comment("Index Holes for secondary operations"),
cam.change_tool("1/8in endmill"),
cam.start_spindle(15000),
cam.feedrate(1000),
cam.dwell(3),
cam.rmh(r_hole + [-thickness - 1.0], helix_radius, 0.5, 1),
cam.rmh(l_hole + [-thickness - 1.0], helix_radius, 0.5, 1),
]
return r
def generic_nose_contour(face_con, thickness, thin_back, centering_shift):
""" Use the tapered endmill to create a nose relief along the curve of the
glasses frame.
First construct a path that is a simple, average shape for a nose: 8 mm nose radius, 34 degree
splay. Compare the curve to the spline of the glasses, if the spline crosses our naive curve, follow
the glasses curve until it crosses the naive curve again, then keep following the naive curve.
"""
curve_offset = 0 # Set so tapered endmill cuts about 1mm from front face of frame
nose_sa = math.radians(34) # Experiment with this
nose_rad = 9
xfloor = -26 # set to avoid hitting clamp
nose_height = 8 # again, experiment
naive_poly = nose.nose_poly(nose_rad, nose_height, nose_sa, nose_sa, xfloor, curve_offset, 0)
# close it
#naive_poly = naive_poly + [naive_poly[0]]
intersect = poly.difference(naive_poly, face_con)
intersect = intersect[1:] + [intersect[0]]
eroded = poly.erode(2, intersect)[0]
finish = poly.erode(1.5, intersect)[0]
hole_radius = 4.85/2 # Measured from dowel pin
tool_radius = 3.175/2
helix_radius = hole_radius - tool_radius
return [
cam.change_tool("tapered"),
cam.start_spindle(20000),
cam.feedrate(1000),
cam.rmh(eroded[0] + [-thickness - 1.0], helix_radius, 0.5, 1),
cam.contour(eroded, False),
cam.contour(finish[::-1], False),
]
def mill_temples(outdir, temples, temple_length):
#TODO: Replace with information in materials database
front_surface_thickness = 0
back_surface_thickness = 4
final_front_thickness = 0
final_back_thickness = 4
thickness = final_front_thickness + final_back_thickness
front_surface_removal = final_front_thickness - front_surface_thickness
back_surface_removal = final_back_thickness - back_surface_thickness
r_temple = poly.rotate_90(temples['right_temple_contour'])
l_temple = poly.rotate_90(temples['left_temple_contour'])
offset = frame_offset(l_temple)
program = [
cam.setup(),
cam.select_fixture("blank_clamp"),
cam.retract_spindle(),
cam.activate_pin("stock_clamp"),
surface_front(front_surface_removal),
surface_back(back_surface_removal),
cam.change_tool("1/16in endmill"),
cam.rapid([0, 0]),
cam.temporary_offset(offset),
temple_hinge_pockets(temples),
index_holes([l_temple, r_temple], thickness),
#thin_temples([l_temple, r_temple], temple_length),
]
open(outdir + "/temples_milling.ngc", "w").write(to_string(program))
def lens_groove(left_c, right_c, height):
"""Generates the toolpath for the lens holes (holes, groove and tabs)."""
print 'Generating lens grooves'
if not poly.is_ccw(left_c):
left_c = poly.reverse(left_c)
if not poly.is_ccw(right_c):
right_c = poly.reverse(right_c)
lgroove = poly.erode(1.8, left_c)[0]
rgroove = poly.erode(1.8, right_c)[0]
left_entry = poly.erode(7.0, left_c)[0][0];
right_entry = poly.erode(7.0, right_c)[0][0];
r = [
"(Lens Grooves)",
cam.change_tool("vgroove"),
cam.start_spindle(20000),
cam.dwell(5),
cam.feedrate(2000),
cam.rmp(right_entry + [height]),
cam.contour(rgroove, True),
cam.move(right_entry), # Get out from under the overhang
cam.rmp(left_entry + [height]),
cam.contour(lgroove, True),
cam.move(left_entry), # Get out from under the overhang
]
return r
def nose_contour(nose_rad, nose_h, nose_sa, nose_ra, face_con, thickness):
"""Creates the nose contour feature toolpath. Angular arguments are in degrees."""
nr = nose_rad
h = nose_h
sa = math.radians(nose_sa)
ra = math.radians(nose_ra)
xfloor = poly.left(face_con) - 3.175 # bottom most point minus tool radius
xfloor = max(xfloor, -27.0) # miminum safe distance without hitting clamp
nose_tool_radius = 3.175
nextpoly = nose.nose_poly(nr, h, sa, ra, xfloor, nose_tool_radius, 0.0)
r = [
"(Nose Contour)",
cam.change_tool("1/4in ballmill"),
cam.start_spindle(20000),
cam.feedrate(2000),
cam.rmp(nextpoly[0] + [2.0]) # Start near our first contour
]
direction = 1
for i in range(-20, (thickness+2)*10):
z = -i/10.0
# r += cam.move(nextpoly[0])
if(direction < 0):
nextpoly.reverse()
direction = direction * -1
r += cam.contour(nextpoly, False)
r += cam.move([None, None, z])
nextpoly = nose.nose_poly(nr, h, sa, ra, xfloor, nose_tool_radius, z)
return r
def surface_front(amount):
if amount < 0.1:
print 'Not surfacing front, returning'
return None
print "Surfacing front with amount", amount
surface_amount = min(amount, 4)
surface_heights = []
while surface_amount <= amount:
surface_heights.append(surface_amount)
surface_amount = max(surface_amount+2, amount)
print "surface amounts", surface_heights
program = [
cam.comment("Surface front by %f mm" % amount),
cam.flip_stock(),
cam.change_tool("3/8in endmill"),
cam.spindle_speed(20000),
cam.feedrate(2000),
cam.start_spindle(),]
for height in surface_heights:
program = program + cam.surface_along_y(-40, -110, 40, 110, 4.7625, -height)
program = program + [
cam.stop_spindle(),
cam.retract_spindle(),
cam.flip_stock(),
]
return program
def lens_holes(left_c, right_c, thickness):
"""Generates the toolpath for the lens holes (holes, groove and tabs)."""
if not poly.is_ccw(left_c):
left_c = poly.reverse(left_c)
if not poly.is_ccw(right_c):
right_c = poly.reverse(right_c)
lhole = poly.erode(3.175 / 2.0, left_c)[0]
rhole = poly.erode(3.175 / 2.0, right_c)[0]
right_rough = poly.erode(0.1, rhole)[0]
left_rough = poly.erode(0.1, lhole)[0]
lgroove = poly.erode(0.8, left_c)[0]
rgroove = poly.erode(0.8, right_c)[0]
left_entry = poly.erode(2.0, lhole)[0][0]
right_entry = poly.erode(2.0, rhole)[0][0]
lhole = poly.reverse(lhole)
rhole = poly.reverse(rhole)
r = [
"(Lens Holes)",
cam.change_tool("1/8in endmill"),
cam.start_spindle(20000),
cam.feedrate(2000),
cam.rmh(right_entry + [-thickness - 1.0], 1.5, 0.5, 1.0),
cam.contour(right_rough, True),
cam.contour(rhole, True),
cam.rmh(left_entry + [-thickness - 1.0], 1.5, 0.5, 1.0),
cam.contour(left_rough, True),
cam.contour(lhole, True),
]
return r
def surface_back(amount):
return [
cam.change_tool("1/4in endmill"),
cam.spindle_speed("20000"),
cam.start_spindle(),
cam.surface_along_y(-80, -100, -5, 100, 0.25/2, amount),
cam.stop_spindle(),
cam.retract_spindle(),
cam.dactivate_pin("stock_clamp"),
] if amount > 0 else None
def surface_back(amount):
return [
cam.change_tool("1/4in endmill"),
cam.spindle_speed("20000"),
cam.start_spindle(),
cam.surface_along_y(-80, -100, -5, 100, 0.25 / 2, amount),
cam.stop_spindle(),
cam.retract_spindle(),
cam.dactivate_pin("stock_clamp"),
] if amount > 0 else None
def lens_holes(left_c, right_c, thickness):
"""Generates the toolpath for the lens holes (holes, groove and tabs)."""
print 'Calculating the lens holes'
tool_radius = 3.175
if not poly.is_ccw(left_c):
left_c = poly.reverse(left_c)
if not poly.is_ccw(right_c):
right_c = poly.reverse(right_c)
# drawing = dxf.drawing('test.dxf')
# drawing.add_layer('OUTLINE', color=1)
# polyline = dxf.polyline(layer="OUTLINE")
# polyline.add_vertices(left_c)
# drawing.add(polyline)
lhole = poly.erode(tool_radius/2.0, left_c)[0]
rhole = poly.erode(tool_radius/2.001, right_c);
rhole = rhole[0]
# polyline = dxf.polyline(layer="OUTLINE")
# polyline.add_vertices(lhole)
# drawing.add(polyline)
right_rough = poly.erode((tool_radius + 0.3)/2, right_c)[0]
left_rough = poly.erode((tool_radius+0.3)/2, left_c)[0]
#lgroove = poly.erode(0.8, left_c)[0]
#rgroove = poly.erode(0.8, right_c)[0]
left_entry = poly.erode(5.0, left_c)[0][0];
right_entry = poly.erode(5.0, right_c)[0][0];
lhole = poly.reverse(lhole)
rhole = poly.reverse(rhole)
r = [
"(Lens Holes)",
cam.change_tool("1/8in endmill"),
cam.start_spindle(22000),
cam.feedrate(2000),
cam.rmh(right_entry + [-thickness - 1.0], 1.5, 0.5, 1.0),
cam.contour(right_rough, True),
cam.feedrate(1000),
cam.contour(rhole, True),
cam.feedrate(2000),
cam.rmh(left_entry + [-thickness - 1.0], 1.5, 0.5, 1.0),
cam.contour(left_rough, True),
cam.feedrate(1000),
cam.contour(lhole, True),
]
return r
def surface_back(amount):
if amount < 0.1:
return None
print 'surfacing back with', amount
surface_amount = min(amount, 4)
surface_heights = []
while surface_amount <= amount:
surface_heights.append(surface_amount);
print surface_heights
surface_amount = max(surface_amount+2, amount)
print "surface amounts on back", surface_heights
return [
cam.comment("Surface back by %f mm" % amount),
cam.change_tool("3/8in endmill"),
cam.spindle_speed(15000),
cam.feedrate(1500),
cam.start_spindle(),
cam.dwell(5),
cam.surface_along_y(-40, -110, 40, 110, 4.7625, -amount),
cam.rapid([None, None, 20]),
] if amount > 0 else None
program = [
cam.comment("Surface back by %f mm" % amount),
cam.change_tool("3/8in endmill"),
cam.spindle_speed(20000),
cam.feedrate(2000),
cam.start_spindle(),
cam.dwell(5),
]
for height in surface_heights:
program = program + cam.surface_along_y(-40, -110, 40, 110, 4.7625, -height),
program = program + [
cam.stop_spindle(),
cam.retract_spindle(),
]
return program
def surface_front(amount):
log("Surfacing front with amount %f" % amount)
return [
cam.flip_stock(),
cam.change_tool("1/4in endmill"),
cam.spindle_speed(20000),
cam.feedrate(2000),
cam.start_spindle(),
cam.surface_along_y(-80, -100, -5, 100, 3.175, amount),
cam.stop_spindle(),
cam.retract_spindle(),
cam.flip_stock(),
] if amount < 0 else None
def bevel_entry_hole(temples, thickness):
hole_radius = 8
tool_radius = 3.175/2 # 1/2 inch
helix_radius = hole_radius - tool_radius
r = [
cam.comment("Entry holes for temple bevelling operation"),
cam.change_tool("1/8in endmill"),
cam.start_spindle(22000),
cam.feedrate(800),
cam.dwell(5),
]
def surface_front(amount):
log("Surfacing front with amount %f" % amount)
return [
cam.flip_stock(),
cam.change_tool("1/4in endmill"),
cam.spindle_speed(20000),
cam.feedrate(2000),
cam.start_spindle(),
cam.surface_along_y(-80, -100, -5, 100, 3.175, amount),
cam.stop_spindle(),
cam.retract_spindle(),
cam.flip_stock(),
] if amount < 0 else None
def temple_hinge_clearance(temple, thinning):
# Endpoints for the top bevel
entry = extendLine(temple[-1], temple[-2], 7.5)
p1 = extendLine(temple[0], temple[-1], 1)
p2 = extendLine(temple[-1], temple[0], 1)
return [
cam.change_tool("engraver"),
cam.feedrate(750),
cam.start_spindle(20000),
cam.rmp(entry + [-2 - thinning]),
cam.move(p1),
cam.move(p2),
cam.move(entry),
cam.move(entry + [10]),
]
def nose_contour(nose_rad, nose_h, nose_sa, nose_ra, face_con, thickness, thin_back, centering_shift):
"""Creates the nose contour feature toolpath. Angular arguments are in degrees."""#
print 'Generating nose contour'
nr = nose_rad
nose_tool_radius = 3.175
# We're cutting with a ball-end mill. Where it actually cuts is dependent on the
# ridge angle. If you draw a line at the ridge angle and put it tangent to the ball mill,
# that is the cutting line. The angle between the center of the ball mill and the intersection
# of the cutting line and the surface is 1/2 of the ridge angle. From that and the radius
# of the ball mill we can figure out the offset.
cutter_offset = (nose_tool_radius)*math.tan(math.radians(nose_ra/2))
sa = math.radians(nose_sa)
ra = math.radians(nose_ra)
h = nose_h + centering_shift
print 'centering shift', centering_shift
# h = nose_h
xfloor = poly.left(face_con) - 3.175 # bottom most point minus tool radius
xfloor = max(xfloor, -27.0) # miminum safe distance without hitting clamp
z_depth = -thin_back # Start a bit above the surface of the glasses
nextpoly = nose.nose_poly(nr, h, sa, ra, xfloor, cutter_offset, z_depth)
r = [
"(Nose Contour)",
cam.change_tool("1/4in ballmill"),
cam.start_spindle(20000),
cam.feedrate(4000),
cam.rmp(nextpoly[0] + [2.0]), # Start near our first contour
]
direction = 1
z_start = int((z_depth)*10) # We have to use integers for the range, also step in 1/10 mm steps
for i in range(-z_start, int(((thickness)+3)*10)):
z = -i/10.0
# r += cam.move(nextpoly[0])
if(direction < 0):
nextpoly.reverse()
direction = direction * -1
r += cam.move([None, None, z-thin_back]) # Z adjusted for any surfacing that happened
r += cam.contour(nextpoly, False)
nextpoly = nose.nose_poly(nr, h, sa, ra, xfloor, cutter_offset, z)
return r
def index_holes(thickness):
# We put the index holes 1/2 between top and bottom, 160mm apart
hole_radius = 4.85/2 # Measured from dowel pin
tool_radius = 3.175/2
helix_radius = hole_radius - tool_radius
r = [
cam.comment("Index holes for secondary operations"),
cam.change_tool("1/8in endmill"),
cam.start_spindle(22000),
cam.feedrate(1000),
cam.dwell(5),
# Index holes should be at 90, -90 but are shifted a bit to compensate
# for inaccuracy on laser fixture
cam.rmh([0, 85.00, -thickness - 1.0], helix_radius, 0.5, 1),
cam.rmh([0, -85.00, -thickness - 1.0], helix_radius, 0.5, 1),
]
return r
def rough_nose_contour(nose_rad, nose_h, nose_sa, nose_ra, face_con, thickness, thin_back, centering_shift):
sa = math.radians(nose_sa)
ra = math.radians(nose_ra)
h = nose_h + centering_shift
h = nose_h
xfloor = poly.left(face_con) - 3.175 # bottom most point minus tool radius
xfloor = max(xfloor, -27.0) # miminum safe distance without hitting clamp
cutter_offset = 1.5875 # radius of 1/8" cutter
nosepoly = nose.nose_poly(nose_rad, h, sa, ra, xfloor, cutter_offset, thickness+thin_back)
return [
"(Rough nose contour)",
cam.change_tool("1/8in endmill"),
cam.start_spindle(20000),
cam.feedrate(2000),
cam.rmp(nosepoly[0] + [1.0]),
cam.rmh([0, 85.00, -thickness - 1.0], helix_radius, 0.5, 1),
]
def bevel_temple(temple, thinning):
# Assume a 20 degree dovetail cutter, cutting 5mm from bottom
dovetail_offset = 9.52/2 - 1.82
entry = extendLine(temple[-1], temple[-2], 7.5)
# Endpoints for the undercut
p1 = extendLine(temple[-1], temple[-2], dovetail_offset)
p2 = extendLine(temple[0], temple[1], dovetail_offset)
p2 = extendLine(p2, p1, 2)
return [
cam.change_tool("dovetail"),
cam.feedrate(750),
cam.start_spindle(20000),
cam.rmp(entry + [-5-thinning]),
cam.move(p1),
cam.move(p2),
cam.move(entry),
cam.move(entry + [10]),
]
def bevel_temple_ends(path1, path2, thinning):
depth = -4 - thinning
# Assume a 14 degree dovetail cutter, cutting 5mm from bottom
dovetail_offset = 12.35/2 - 1.25
return [
cam.comment("Bevel temple ends"),
cam.change_tool("dovetail"),
cam.start_spindle(20000),
cam.feedrate(750),
cam.rapid(path1[0]),
cam.rapid([None, None, depth]),
cam.move(path1[1]),
cam.move(path1[2]),
cam.move(path1[0]),
cam.rapid([None, None, 10]),
cam.rapid(path2[0]),
cam.rapid([None, None, depth]),
cam.move(path2[1]),
cam.move(path2[2]),
cam.move(path2[0]),
cam.move([None, None, 20])
]
def lens_holes(left_c, right_c, thickness):
"""Generates the toolpath for the lens holes (holes, groove and tabs)."""
if not poly.is_ccw(left_c):
left_c = poly.reverse(left_c)
if not poly.is_ccw(right_c):
right_c = poly.reverse(right_c)
lhole = poly.erode(3.175/2.0, left_c)[0]
rhole = poly.erode(3.175/2.0, right_c)[0]
right_rough = poly.erode(0.1, rhole)[0]
left_rough = poly.erode(0.1, lhole)[0]
lgroove = poly.erode(0.8, left_c)[0]
rgroove = poly.erode(0.8, right_c)[0]
left_entry = poly.erode(2.0, lhole)[0][0];
right_entry = poly.erode(2.0, rhole)[0][0];
lhole = poly.reverse(lhole)
rhole = poly.reverse(rhole)
r = [
"(Lens Holes)",
cam.change_tool("1/8in endmill"),
cam.start_spindle(20000),
cam.feedrate(2000),
cam.rmh(right_entry + [-thickness - 1.0], 1.5, 0.5, 1.0),
cam.contour(right_rough, True),
cam.contour(rhole, True),
cam.rmh(left_entry + [-thickness - 1.0], 1.5, 0.5, 1.0),
cam.contour(left_rough, True),
cam.contour(lhole, True),
]
return r
def mill_fronts(outdir, order):
"""Creates the g-code for the first milling operation. The
first milling operation is done on an unregistered plastic blank,
so includes creating registration holes for subsequent operations."""
# Initial thickness of the forward-facing lamination. 0 if no lamination.
top_thickness = 6
bottom_thickness = 0
top_raw = 6
bottom_raw = 0
if order.get("face_material"):
top_thickness = order["face_material"].get("top_thickness")
bottom_thickness = order["face_material"].get("bottom_thickness") or 0
top_raw = order["face_material"].get("top_raw_thickness") or top_thickness
bottom_raw = order["face_material"].get("bottom_raw_thickness") or bottom_thickness
frame_thickness = top_thickness + bottom_thickness
machining_z_offset = bottom_raw - bottom_thickness
# top_thickness = 6
# bottom_thickness = 0
# total_thickness = 6
# top_raw = 0
# Automatically determine some surfacing. The bottom thickness
# is a lamination and should be thin. It should be thinned to 1mm.
# The top should be thinned to bring total finished thickness to 6mm or less.
thin_back = 0
if bottom_raw > bottom_thickness:
thin_back = bottom_raw - bottom_thickness
thin_front = 0
if top_raw > top_thickness:
thin_front = top_raw - top_thickness
# The machine has the stock clamp oriented 90 degrees to the way the
# software creates the contours.
face_c = poly.rotate_90(order["face_con"])
left_lens_c = poly.rotate_90(order["lhole_con"])
right_lens_c = poly.mirror_y(left_lens_c, True)
face_c = face_c + poly.reverse(poly.mirror_y(face_c, False))[1:]
temple_height = abs(order["ltemple_con"][0][1] - order["ltemple_con"][-1][1])
msg = check_frame_size(left_lens_c)
if msg:
print msg
sys.exit(1)
# Instead of offset, we'll make sure this thing is centered on the stock
offset = frame_offset(face_c)
top = poly.top(face_c)
bottom = poly.bottom(face_c)
left = poly.left(face_c)
right = poly.right(face_c)
print 'frame bounding box: ', top, bottom, left, right
y_shift = (top + bottom)/2
x_shift = (left + right)/2
print 'x and y shift', x_shift, y_shift
face_c = poly.translate(face_c, -x_shift, -y_shift)
left_lens_c = poly.translate(left_lens_c, -x_shift, -y_shift)
right_lens_c = poly.translate(right_lens_c, -x_shift, -y_shift)
# Groove for lenses is 2/3 of the distance from back to front.
# Here we're calculating the actual cutting depth so we need to add
# back the material that we surfaced away from the back.
groove_depth = -(float(machining_z_offset) + (2.0/3)*float(frame_thickness))
hinge_loc = order["ltemple_con"][0][1] - (order["ltemple_con"][0][1] - order["ltemple_con"][-1][1])/2
size_info = order.get('size_info')
if not size_info and order.get('usersizes'):
# Legacy order
size_info = order.get('usersizes')
size_info["noseradius"] = size_info["nose_radius"]
size_info["noseheight"] = size_info["nose_height"]
size_info["splayangle"] = size_info["nose_splayangle"]
size_info["ridgeangle"] = size_info["nose_ridgeangle"]
generic = not size_info or len(size_info) == 0
generic = True # TESTING
program = [
cam.setup(),
cam.select_fixture("blank_clamp"),
cam.retract_spindle(),
cam.activate_pin("stock_clamp"),
cam.rapid([0,0]),
surface_front(thin_front),
surface_back(thin_back),
cam.change_tool("1/8in endmill"),
cam.rapid([0, 0]),
# Note that X and Y parameters in the order are switched from our system
#TODO: replace the thickness offset with the thickness of the TEMPLE, not the fronts.
index_holes(frame_thickness+machining_z_offset),
lens_holes(left_lens_c, right_lens_c, frame_thickness + machining_z_offset),
lens_groove(left_lens_c, right_lens_c, groove_depth),
# rough_nose_contour(
# float(size_info["noseradius"]),
# float(size_info["noseheight"]),
# float(size_info["splayangle"]),
# float(size_info["ridgeangle"]),
# face_c, frame_thickness, machining_z_offset, -x_shift ),
face_hinge_pockets(order.get("lhinge") or 1, hinge_loc, order["ltemple_x"], (-x_shift, -y_shift), machining_z_offset),
#nose_pads(order, thickness),
nose_contour(
float(size_info["noseradius"]),
float(size_info["noseheight"]),
float(size_info["splayangle"]),
float(size_info["ridgeangle"]),
face_c, frame_thickness, machining_z_offset, -x_shift ),
# nose_contour(
# 7.0, 8.0, 30.0, 32.0, face_c, frame_thickness, machining_z_offset, -x_shift),
#generic_nose_contour(face_c, frame_thickness, machining_z_offset, -x_shift),
cam.retract_spindle(),
cam.deactivate_pin("stock_clamp"),
cam.change_tool("1/8in endmill"),
# cam.rapid([face_c[0][0], face_c[0][1], -thin_back] ),
# cam.contour(face_c, True),
cam.end_program(),
]
print 'Writing face milling program to ', outdir + "/face_stange1.ngc"
open(outdir + "/face_stage1.ngc", "w").write(to_string(program))
def mill_fronts(outdir, order):
"""Creates the g-code for the first milling operation. The
first milling operation is done on an unregistered plastic blank,
so includes creating registration holes for subsequent operations."""
#TODO: Replace with information in materials database
# Initial thickness of the forward-facing lamination. 0 if no lamination.
front_surface_thickness = 0
# The final desired thickness of the fronto facing lamination. Must
# be equal to or less than the front_surface_thickness.
final_front_thickness = 0
# Initial thickness of the face side lamination. Use this thickness only if
# stock is solid
back_surface_thickness = 4
# The final thickness of the left and right extremes of the frame where the
# hinge will go. Must be equal to or less than back_surface_thickness.
hinge_thickness = 4
# The thickness of the highest point of the nosepad
nosepad_thickness = 4
# Final thickness of the main part of the frame. Must be equal to or less than
# the back_surface_thickness.
final_back_thickness = 4
thickness = final_front_thickness + final_back_thickness
front_surface_removal = final_front_thickness - front_surface_thickness
back_surface_removal = final_back_thickness - back_surface_thickness
# The machine has the stock clamp oriented 90 degrees to the way the
# software creates the contours.
face_c = poly.rotate_90(order["face_con"])
left_lens_c = poly.rotate_90(order["lhole_con"])
right_lens_c = poly.rotate_90(order["rhole_con"])
temple_height = abs(order["ltemple_con"][0][1] -
order["ltemple_con"][-1][1])
msg = check_frame_size(face_c)
if msg:
print msg
sys.exit(0)
print 'milling front with hinge', order['lhinge'], order['rhinge']
offset = frame_offset(face_c)
groove_height = back_surface_removal + (thickness / 2)
print 'groove', groove_height, back_surface_removal, (thickness / 2)
program = [
cam.setup(),
cam.select_fixture("blank_clamp"),
cam.retract_spindle(),
cam.activate_pin("stock_clamp"),
surface_front(front_surface_removal),
# surface_back(back_surface_removal),
cam.change_tool("1/8in endmill"),
cam.rapid([0, 0]),
cam.temporary_offset(offset),
# Note that X and Y parameters in the order are switched from our system
#TODO: replace the thickness offset with the thickness of the TEMPLE, not the fronts.
index_holes([face_c], back_surface_thickness),
lens_holes(left_lens_c, right_lens_c, back_surface_thickness),
lens_groove(left_lens_c, right_lens_c,
back_surface_removal - (thickness / 2)),
# contour_face(
# back_surface_removal,
# back_surface_thickness - hinge_thickness,
# back_surface_thickness - nosepad_thickness,
# temple_height,
# face_c, left_lens_c, order['lhinge_y']),
face_hinge_pockets(order["lhinge"], order["lhinge_y"],
order["ltemple_x"]),
# nose_pads(order, thickness),
nose_contour(order["nose_rad"], order["nose_h"], order["nose_sa"],
order["nose_ra"], face_c, back_surface_thickness),
cam.retract_spindle(),
cam.deactivate_pin("stock_clamp"),
cam.end_program(),
]
open(outdir + "/face_stage1.ngc", "w").write(to_string(program))
def mill_fronts(outdir, order):
"""Creates the g-code for the first milling operation. The
first milling operation is done on an unregistered plastic blank,
so includes creating registration holes for subsequent operations."""
#TODO: Replace with information in materials database
# Initial thickness of the forward-facing lamination. 0 if no lamination.
front_surface_thickness = 0
# The final desired thickness of the fronto facing lamination. Must
# be equal to or less than the front_surface_thickness.
final_front_thickness = 0
# Initial thickness of the face side lamination. Use this thickness only if
# stock is solid
back_surface_thickness = 4
# The final thickness of the left and right extremes of the frame where the
# hinge will go. Must be equal to or less than back_surface_thickness.
hinge_thickness = 4
# The thickness of the highest point of the nosepad
nosepad_thickness = 4
# Final thickness of the main part of the frame. Must be equal to or less than
# the back_surface_thickness.
final_back_thickness =4
thickness = final_front_thickness + final_back_thickness
front_surface_removal = final_front_thickness - front_surface_thickness
back_surface_removal = final_back_thickness - back_surface_thickness
# The machine has the stock clamp oriented 90 degrees to the way the
# software creates the contours.
face_c = poly.rotate_90(order["face_con"])
left_lens_c = poly.rotate_90(order["lhole_con"])
right_lens_c = poly.rotate_90(order["rhole_con"])
temple_height = abs(order["ltemple_con"][0][1] - order["ltemple_con"][-1][1])
msg = check_frame_size(face_c)
if msg:
print msg
sys.exit(0)
print 'milling front with hinge', order['lhinge'], order['rhinge']
offset = frame_offset(face_c)
groove_height = back_surface_removal + (thickness/2)
print 'groove', groove_height, back_surface_removal, (thickness/2)
program = [
cam.setup(),
cam.select_fixture("blank_clamp"),
cam.retract_spindle(),
cam.activate_pin("stock_clamp"),
surface_front(front_surface_removal),
# surface_back(back_surface_removal),
cam.change_tool("1/8in endmill"),
cam.rapid([0, 0]),
cam.temporary_offset(offset),
# Note that X and Y parameters in the order are switched from our system
#TODO: replace the thickness offset with the thickness of the TEMPLE, not the fronts.
index_holes([face_c], back_surface_thickness),
lens_holes(left_lens_c, right_lens_c, back_surface_thickness),
lens_groove(left_lens_c, right_lens_c, back_surface_removal - (thickness/2)),
# contour_face(
# back_surface_removal,
# back_surface_thickness - hinge_thickness,
# back_surface_thickness - nosepad_thickness,
# temple_height,
# face_c, left_lens_c, order['lhinge_y']),
face_hinge_pockets(order["lhinge"], order["lhinge_y"], order["ltemple_x"]),
# nose_pads(order, thickness),
nose_contour(order["nose_rad"], order["nose_h"], order["nose_sa"], order["nose_ra"], face_c, back_surface_thickness),
cam.retract_spindle(),
cam.deactivate_pin("stock_clamp"),
cam.end_program(),
]
open(outdir + "/face_stage1.ngc", "w").write(to_string(program))
def temple_hinge_pockets(temples, thinned):
# We're operating in a 90 degree rotated fixture
#l_hinge = poly.rotate_90(temples["left_hinge_contour"])
#r_hinge = poly.rotate_90(temples["right_hinge_contour"])
print 'Generating temple hinge pockets'
l_hinge = temples["left_hinge_contour"]
r_hinge = temples["right_hinge_contour"]
if not poly.is_ccw(l_hinge):
l_hinge = poly.reverse(l_hinge)
if not poly.is_ccw(r_hinge):
r_hinge = poly.reverse(r_hinge)
#pocket_depth = temples['pocket_depth'] + thinned
pocket_depth = 1 + thinned;
def pocket_contours(contour):
contours = []
erode = poly.erode(1.5875/2, contour)
making_progress = True
while len(erode) > 0 and making_progress:
making_progress = False
for path in erode:
if len(path) > 5:
making_progress = True
contours.append(path)
erode = poly.erode(1.5875/2, contours[-1])
return contours
left_hinge_pocket_contours = pocket_contours(l_hinge)
right_hinge_pocket_contours = pocket_contours(r_hinge)
# left_hinge_pocket_contours = [];
# while len(l_hinge) > 0:
# l_hinge = poly.erode(1.5875/2, l_hinge)
# if len(l_hinge) > 0:
# l_hinge = l_hinge[0]
# left_hinge_pocket_contours.append(l_hinge)
# right_hinge_pocket_contours = [];
# while len(r_hinge) > 0:
# r_hinge = poly.erode(1.5875/2, r_hinge)
# if len(rhinge_) == 1:
# right_hinge_pocket
# if len(r_hinge) > 0:
# r_hinge = r_hinge[0]
# right_hinge_pocket_contours.append(r_hinge)
r = [
cam.comment("Hinge Pockets"),
cam.feedrate(750),
cam.change_tool("1/16in endmill"),
cam.start_spindle(22000),
cam.dwell(5),
cam.comment("Right Hinge Pocket"),
cam.pocket(right_hinge_pocket_contours, -abs(pocket_depth), retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Left Hinge Pocket"),
cam.pocket(left_hinge_pocket_contours, -abs(pocket_depth), retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Hinge Holes"),
cam.change_tool("1mm drill"),
cam.start_spindle(5000),
cam.dwell(2),
[cam.rmp(p + [-8.0], retract=10.0) for p in temples['right_hinge_holes']],
[cam.rmp(p + [-8.0], retract=10.0) for p in temples['left_hinge_holes']],
cam.rapid([None, None, 20.0]),
]
return r
def contour_face(body_removal, hinge_removal, nosepad_removal, temple_height,
face_c, lens_c, x_pos):
''' Create the heightmap of the frame, surfacing the back and adding thickness for the
hinge location and the nosepads. '''
if body_removal == hinge_removal == nosepad_removal == 0:
return [] # Nothing to do
cutter_radius = 6.35 / 2 # 3/4 inch cutter
entry_point = [x_pos, 110, 0]
facing_contour = poly.dilate(0.05, lens_c)
# Reshape the facing contour so the first point is near the hinge
center_y = poly.bottom(facing_contour) + (poly.top(facing_contour) -
poly.bottom(facing_contour)) / 2
center_x = poly.right(facing_contour) + (poly.left(facing_contour) -
poly.right(facing_contour)) / 2
split_idx = -1
for idx, pt in enumerate(facing_contour):
if pt[1] > center_y and (idx + 1) < len(facing_contour):
if (pt[0] < x_pos and facing_contour[idx + 1][0] > x_pos) or (
pt[0] > x_pos and facing_contour[idx + 1][0] < x_pos):
split_idx = idx
break
if split_idx < 0:
print 'Error contouring back of frame: could not locate entry point for surfacing cut'
return []
facing_contour = poly.new_start(facing_contour, split_idx)
# Ensure we're going clockwise, i.e. starting at the hinge and moving up over the frame
if poly.is_ccw(facing_contour):
facing_contour = poly.reverse(facing_contour)
# Calculate the Z values
# We'll need a few helper values. nosepad_start is the inflection point of the nose bridge.
nosepad_start = max([pt[0] for pt in face_c if pt[1] == 0]) + cutter_radius
hinge_rampdown_start_x = x_pos + temple_height / 2 + cutter_radius
hinge_rampdown_start_y = facing_contour[0][1] - cutter_radius
hinge_rampup_start_x = x_pos - temple_height / 2 - cutter_radius
hinge_rampup_start_y = facing_contour[0][1] - cutter_radius
print nosepad_start, hinge_rampdown_start_x, hinge_rampdown_start_y, hinge_rampup_start_x, hinge_rampup_start_y
'''
Arbitrary heuristic, adjusted for aesthetics.
1. If we're past the center point of the lens hole, we're either on the body
of the frame or over the raised hinge point.
2. If we're before the center point we're either on the body or over the nosepiece.
1a. If we're above the cutter-radius-adjusted top of the temple, we're ramping down
1b. If we're below the cutter-radius-adjusted bottom of the temple, we're ramping up
1c. Otherwise we're at body thickness
2a. If we're above the top of the nose cutout, we're at body thickness
2b. When we reach nose cutout, we do a s-curve over 3 mm to nosepad height
2c. Continue for length of cutter diameter to get rear of cutter over highest point
2d. Continue for 10mm
2e. S-curve down over 10mm
'''
print hinge_removal, body_removal
def add_hinge_heights(contour):
heightmap = []
over_hinge = True # Start over hinge
items_to_skip = 0 # for fast-forwarding enumeration
for idx, pt in enumerate(contour):
if items_to_skip > 0:
items_to_skip = items_to_skip - 1
if items_to_skip == 0:
print 'first post ramp point', contour[idx + 1]
continue
if pt[1] < center_y:
heightmap = heightmap + [pt]
# Going up and around: start ramping down when we're clear of X or Y
elif pt[0] > x_pos:
if pt[0] > hinge_rampdown_start_x or pt[
1] < hinge_rampdown_start_y:
if (over_hinge): # starting transition
transition_length = poly.polyline_length(
contour[:(idx + 1)], False)
ramp_segment = poly.segment(contour, transition_length,
transition_length + 5,
False)
ramp_segment = poly.ramp(ramp_segment, hinge_removal,
body_removal, False)
heightmap = heightmap + ramp_segment[:-1]
items_to_skip = len(ramp_segment)
print 'last ramp segment', ramp_segment[-1]
over_hinge = False
else: # past transition but still on hinge side of lens hole
heightmap = heightmap + [pt + [body_removal]]
else: # We're on the top part but haven't reached the transition yet
heightmap = heightmap + [pt + [hinge_removal]]
# Coming back up to the hinge: start ramping up if we encroach on both x and y
elif pt[0] < x_pos and (pt[0] > hinge_rampup_start_x
and pt[1] > hinge_rampdown_start_y):
if (not over_hinge): # starting transition
print pt, x_pos, hinge_rampup_start_x, hinge_rampdown_start_y, idx
transition_length = poly.polyline_length(
contour[:(idx + 1)], False)
ramp_segment = poly.segment(contour, transition_length,
transition_length + 5, False)
ramp_segment = poly.ramp(ramp_segment, body_removal,
hinge_removal, False)
heightmap = heightmap + ramp_segment
items_to_skip = len(ramp_segment)
over_hinge = True
else: # Over flat hinge area
heightmap = heightmap + [pt + [hinge_removal]]
else: # We're over the body area but back on the hinge side
heightmap = heightmap + [pt + [body_removal]]
return heightmap
def add_nosepad_heights(contour):
heightmap = []
over_nosepad = False
past_nosepad = False
nosepad_flat_idx = -1
items_to_skip = 0 # for fast-forwarding the enumeration
for idx, pt in enumerate(contour):
if items_to_skip > 0:
items_to_skip = items_to_skip - 1
continue
if pt[1] >= center_y:
heightmap = heightmap + [pt]
elif not over_nosepad and not past_nosepad:
if pt[0] < nosepad_start: # Transition
transition_length = poly.polyline_length(
contour[:(idx + 1)], False)
ramp_segment = poly.segment(contour, transition_length,
transition_length + 5, False)
ramp_segment = poly.ramp(ramp_segment, body_removal,
nosepad_removal, False)
heightmap = heightmap + ramp_segment[:-1]
items_to_skip = len(ramp_segment)
nosepad_flat_idx = idx + items_to_skip # we'll need this to go down
over_nosepad = True
else: # we're past the nosepad
heightmap = heightmap + [pt + [body_removal]]
elif over_nosepad and not past_nosepad:
if nosepad_flat_idx < 0:
print "ERROR! I think I'm on the nosepad but have not transitioned yet"
return []
# We'll be cutting the far side with the back of the cutter, so need to move at
# least the diameter to get any flat at all
flat_length = poly.polyline_length(
contour[nosepad_flat_idx:(idx + 1)],
False) - (cutter_radius * 2)
if flat_length < 5:
heightmap = heightmap + [pt + [nosepad_removal]]
else: # ramp down
transition_length = poly.polyline_length(
contour[:(idx + 1)], False)
ramp_segment = poly.segment(contour, transition_length,
transition_length + 5, False)
ramp_segment = poly.ramp(ramp_segment, nosepad_removal,
body_removal, False)
heightmap = heightmap + ramp_segment[:-1]
items_to_skip = len(ramp_segment)
nosepad_flat_idx = idx + items_to_skip # we'll need this to go down
over_nosepad = False
past_nosepad = True
else:
heightmap = heightmap + [pt + [body_removal]]
return heightmap
facing_contour = add_hinge_heights(facing_contour)
facing_contour = add_nosepad_heights(facing_contour)
facing_contour = poly.reverse(facing_contour)
right_facing = poly.mirror_y(facing_contour, True)
passes = [1]
heights = [p[2] for p in facing_contour]
r = [
cam.change_tool("1/4in ballmill"),
cam.spindle_speed(22000),
cam.feedrate(1000),
cam.start_spindle(),
cam.rmp(entry_point),
cam.contour(facing_contour, True),
]
for dilate in passes:
dilated = poly.reverse(poly.dilate(dilate, facing_contour))
# dilated = add_hinge_heights(dilated)
dilated = add_nosepad_heights(dilated)
r = r + [
cam.contour(dilated, True),
]
return r
def face_hinge_pockets(hinge_num, hinge_height, temple_position, centering_shift, thin_back):
print 'Generating face hinge pockets', hinge_num
xposition = hinge_height;
yposition = temple_position+3.0; # 4mm for the temple, but less 1mm for temple hinge pocket
print 'Position is ', xposition, yposition
left_hinge = hinges.get_hinge(hinge_num)
print 'Got left hinge'
right_hinge = hinges.get_hinge(hinge_num, False)
print 'Retrieved hinge contours'
left_translate = [xposition, yposition]
right_translate = [xposition, -yposition]
print 'Calculated hinge translations'
#right_translate = [xposition, 0]
# Adjust by pocket depth of hinge
#pocket_depth = left_hinge['pocket_depth']+thin_back
pocket_depth = 1 + thin_back
drill_depth = -thin_back - 2.0
left_contour = poly.mirror_x(poly.rotate_90(left_hinge["face_contour"]), False)
right_contour = poly.mirror_x(poly.rotate_90(right_hinge["face_contour"]), False)
left_holes = poly.mirror_x(poly.rotate_90(left_hinge["face_holes"]), False)
right_holes = poly.mirror_x(poly.rotate_90(right_hinge["face_holes"]), False)
left_contour = poly.translate(left_contour, left_translate[0], -left_translate[1])
right_contour = poly.translate(right_contour, right_translate[0], -right_translate[1])
left_holes = poly.translate(left_holes, left_translate[0], -left_translate[1])
right_holes = poly.translate(right_holes, right_translate[0], -right_translate[1])
# Now center everything on the stock
left_contour = poly.translate(left_contour, centering_shift[0], -centering_shift[1])
right_contour = poly.translate(right_contour, centering_shift[0], -centering_shift[1])
left_holes = poly.translate(left_holes, centering_shift[0], -centering_shift[1])
right_holes = poly.translate(right_holes, centering_shift[0], -centering_shift[1])
if not poly.is_ccw(left_contour):
left_contour = poly.reverse(left_contour)
if not poly.is_ccw(right_contour):
right_contour = poly.reverse(right_contour)
left_hinge_pocket_contours = [];
while len(left_contour) > 0:
left_contour = poly.erode(1.5875/2, left_contour)
if len(left_contour) > 0:
left_contour = left_contour[0]
left_hinge_pocket_contours.append(left_contour)
right_hinge_pocket_contours = [];
while len(right_contour) > 0:
right_contour = poly.erode(1.5875/2, right_contour)
if len(right_contour) > 0:
right_contour = right_contour[0]
right_hinge_pocket_contours.append(right_contour)
r = [
cam.comment("Hinge Pockets"),
cam.feedrate(750),
cam.change_tool("1/16in endmill"),
cam.start_spindle(20000),
cam.dwell(3),
cam.comment("Right Hinge Pocket"),
cam.pocket(right_hinge_pocket_contours, -abs(pocket_depth), retract=-abs(pocket_depth)),
cam.rapid([None, None, 20.0]),
cam.comment("Left Hinge Pocket"),
cam.pocket(left_hinge_pocket_contours, -abs(pocket_depth), retract=-abs(pocket_depth)),
cam.rapid([None, None, 20.0]),
cam.comment("Hinge Holes"),
cam.change_tool("1mm drill"),
cam.start_spindle(5000),
cam.dwell(2),
[cam.rmp(p + [drill_depth], retract=10.0) for p in right_holes],
[cam.rmp(p + [drill_depth], retract=10.0) for p in left_holes],
cam.rapid([None, None, 20.0]),
]
return r
def face_hinge_pockets(hinge_num, xposition, yposition):
left_hinge = hinges.get_hinge(hinge_num)
right_hinge = hinges.get_hinge(hinge_num, False)
left_translate = [xposition, -yposition]
#left_translate = [xposition, 0]
right_translate = [xposition, yposition]
#right_translate = [xposition, 0]
# Adjust by pocket depth of hinge
pocket_depth = left_hinge['pocket_depth']
left_contour = poly.translate(left_hinge["face_contour"],
left_translate[0], left_translate[1])
right_contour = poly.translate(right_hinge["face_contour"],
right_translate[0], right_translate[1])
left_holes = poly.translate(left_hinge["face_holes"], left_translate[0],
left_translate[1])
right_holes = poly.translate(right_hinge["face_holes"], right_translate[0],
right_translate[1])
if not poly.is_ccw(left_contour):
left_contour = poly.reverse(left_contour)
if not poly.is_ccw(right_contour):
right_contour = poly.reverse(right_contour)
left_hinge_pocket_contours = []
while len(left_contour) > 0:
left_contour = poly.erode(1.5875 / 2, left_contour)
if len(left_contour) > 0:
left_contour = left_contour[0]
left_hinge_pocket_contours.append(left_contour)
right_hinge_pocket_contours = []
while len(right_contour) > 0:
right_contour = poly.erode(1.5875 / 2, right_contour)
if len(right_contour) > 0:
right_contour = right_contour[0]
right_hinge_pocket_contours.append(right_contour)
r = [
cam.comment("Hinge Pockets"),
cam.feedrate(750),
cam.change_tool("1/16in endmill"),
cam.start_spindle(15000),
cam.dwell(3),
cam.comment("Right Hinge Pocket"),
cam.pocket(right_hinge_pocket_contours,
-abs(right_hinge['pocket_depth']),
retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Left Hinge Pocket"),
cam.pocket(left_hinge_pocket_contours,
-abs(left_hinge['pocket_depth']),
retract=0),
cam.rapid([None, None, 20.0]),
cam.comment("Hinge Holes"),
cam.change_tool("1mm drill"),
cam.start_spindle(4500),
cam.dwell(2),
[cam.rmp(p + [-8.0], retract=10.0) for p in right_holes],
[cam.rmp(p + [-8.0], retract=10.0) for p in left_holes],
cam.rapid([None, None, 20.0]),
]
return r
def mill_lenses(outdir, order):
def to_polar(polyline):
return [[-math.sqrt(p[0]**2 + p[1]**2), math.degrees(math.atan2(p[1],p[0])) + 180] for p in polyline]
""" Creates g-code for milling the left and right lenses for the frames."""
lens = g.Polygon(order['lhole_con'])
x = lens.bounding_box()
box = lens.bounding_box()
center = g.Point((box.p2.x+box.p1.x)/2, (box.p2.y+box.p1.y)/2)
shift_to_origin = g.Vector(-center.x, -center.y)
lens = g.translate_polygon(lens, shift_to_origin)
polar = g.polygon_to_uniform_polar(lens, 1500)
# Inflate the polar form by 1/2 the diameter of the cutter, and convert
# the angles to degrees
tau = math.pi * 2
conv = 360/tau
roughing = [(pt.theta*conv, pt.r+4.77) for pt in polar]
# Expand for the roughing cut
# left_lens_rough = poly.dilate(4.77, left_lens)
# Convert to polar coordinates
# left_lens_roughing_polar = to_polar(left_lens_rough)
# Start the cut from 0 degrees
# angle_list = [p[1] for p in left_lens_roughing_polar]
# zero_idx = angle_list.index(min(angle_list))
# left_lens_roughing_polar = left_lens_roughing_polar[zero_idx:] + left_lens_roughing_polar[:zero_idx]
# Cut it down to every 0.2 degrees
# coarse = []
# for idx, pt in enumerate(left_lens_roughing_polar):
# if idx == 0 or (pt[1]-coarse[-1][1]) >= 0.2:
# coarse.append(pt)
# The polar distances aren't correct quite. That's because the conversion assumed a flat
# surface, but we'll actually be bending that contour around a sphere. The lens is already
# spherical. So we need to adjust inwards a bit to account for the x distance actually being an arc
# distance.
# The radius of the sphere is 88mm (base 6 lens). ArcLength = Radius * angle, and chord
# length is sin(angle) * radius.
roughing = [(p[0], math.sin(-p[1]/88) * 88) for p in roughing]
roughing.sort(key=lambda pt: pt[0])
closest = max([p[1] for p in roughing])
if abs(closest) < 22.5:
print "Error! Cannot cut lens, it's too small.", closest
roughing_reversed = [[-1*(math.degrees(-math.radians(p[1]))+360), p[1]] for p in roughing]
program = [
cam.setup(),
cam.select_fixture("lens_clamp"),
cam.retract_spindle(),
cam.change_tool("1/4in endmill"),
cam.start_spindle(20000),
cam.rapid([-50, 0]),
["G1 Z0 F500"],
cam.polar_contour(roughing),
["G1 X-50"],
["G1 A0"],
cam.stop_spindle(),
cam.retract_spindle(),
cam.end_program(),
]
open(outdir + "/left_lens.ngc", "w").write(to_string(program))
program = [
cam.setup(),
cam.select_fixture("lens_clamp"),
cam.retract_spindle(),
cam.change_tool("1/4in endmill"),
cam.start_spindle(20000),
cam.rapid([-50, 0]),
["G1 Z0 F500"],
cam.polar_contour(roughing_reversed),
["G1 X-50"],
["G1 A0"],
cam.stop_spindle(),
cam.retract_spindle(),
cam.end_program(),
]
open(outdir + "/right_lens.ngc", "w").write(to_string(program))
def mill_hinges(outdir):
"""Creates the g-code for the first milling operation. The
first milling operation is done on an unregistered plastic blank,
so includes creating registration holes for subsequent operations."""
y_offsets = [y*15 for y in range(-5, 6)]
x_offsets = [x*7 for x in range(-3, 4)]
hinge = hinges.get_hinge(2);
contour = hinge['face_contour']
contours = []
erode = poly.erode(1.5875/2, contour)
while len(erode) > 0:
if len(erode) >= 1:
contours.append(erode[0])
else:
break
erode = poly.erode(1.5875/2, contours[-1])
program = [
cam.setup(),
cam.select_fixture("blank_clamp"),
cam.retract_spindle(),
cam.activate_pin("stock_clamp"),
cam.change_tool("1/16in endmill"),
cam.rapid([0,0]),
cam.start_spindle(20000),
cam.dwell(3),
# cam.pocket(contours, -1, -1),
# cam.rapid([None, None, 20.0]),
# cam.change_tool("1mm drill"),
# cam.start_spindle(4500),
# [cam.rmp(p + [-2.5], retract=10.0) for p in hinge['face_holes']],
]
for y_offset in y_offsets:
for x_offset in x_offsets:
program += [
cam.rapid([x_offset, y_offset]),
cam.temporary_offset((0,0)),
cam.pocket(contours, -1.2, -1.2),
cam.rapid([None, None, 20.0]),
cam.remove_temporary_offset(),
]
# program += [
# cam.change_tool("1mm drill"),
# cam.start_spindle(4500),
# ]
# for y_offset in y_offsets:
# for x_offset in x_offsets:
# program += [
# cam.rapid([x_offset, y_offset]),
# cam.temporary_offset((0,0)),
# [cam.rmp(p + [-2.5], retract=10.0) for p in hinge['face_holes']],
# cam.rapid([None, None, 20.0]),
# cam.remove_temporary_offset(),
# ]
program += [
cam.deactivate_pin("stock_clamp"),
cam.end_program(),
]
open(outdir + "/face_stage1.ngc", "w").write(to_string(program))
def contour_face(body_removal, hinge_removal, nosepad_removal, temple_height, face_c, lens_c, x_pos):
''' Create the heightmap of the frame, surfacing the back and adding thickness for the
hinge location and the nosepads. '''
if body_removal == hinge_removal == nosepad_removal == 0:
return [] # Nothing to do
cutter_radius = 6.35/2 # 3/4 inch cutter
entry_point = [x_pos, 110, 0]
facing_contour = poly.dilate(0.05, lens_c)
# Reshape the facing contour so the first point is near the hinge
center_y = poly.bottom(facing_contour) + (poly.top(facing_contour) - poly.bottom(facing_contour))/2
center_x = poly.right(facing_contour) + (poly.left(facing_contour) - poly.right(facing_contour))/2
split_idx = -1
for idx, pt in enumerate(facing_contour):
if pt[1] > center_y and (idx+1) < len(facing_contour):
if (pt[0] < x_pos and facing_contour[idx+1][0] > x_pos) or (pt[0] > x_pos and facing_contour[idx+1][0] < x_pos):
split_idx = idx
break
if split_idx < 0:
print 'Error contouring back of frame: could not locate entry point for surfacing cut'
return []
facing_contour = poly.new_start(facing_contour, split_idx)
# Ensure we're going clockwise, i.e. starting at the hinge and moving up over the frame
if poly.is_ccw(facing_contour):
facing_contour = poly.reverse(facing_contour)
# Calculate the Z values
# We'll need a few helper values. nosepad_start is the inflection point of the nose bridge.
nosepad_start = max([pt[0] for pt in face_c if pt[1] == 0]) + cutter_radius
hinge_rampdown_start_x = x_pos + temple_height/2 + cutter_radius
hinge_rampdown_start_y = facing_contour[0][1] - cutter_radius
hinge_rampup_start_x = x_pos - temple_height/2 - cutter_radius
hinge_rampup_start_y = facing_contour[0][1] - cutter_radius
print nosepad_start, hinge_rampdown_start_x, hinge_rampdown_start_y, hinge_rampup_start_x, hinge_rampup_start_y
'''
Arbitrary heuristic, adjusted for aesthetics.
1. If we're past the center point of the lens hole, we're either on the body
of the frame or over the raised hinge point.
2. If we're before the center point we're either on the body or over the nosepiece.
1a. If we're above the cutter-radius-adjusted top of the temple, we're ramping down
1b. If we're below the cutter-radius-adjusted bottom of the temple, we're ramping up
1c. Otherwise we're at body thickness
2a. If we're above the top of the nose cutout, we're at body thickness
2b. When we reach nose cutout, we do a s-curve over 3 mm to nosepad height
2c. Continue for length of cutter diameter to get rear of cutter over highest point
2d. Continue for 10mm
2e. S-curve down over 10mm
'''
print hinge_removal, body_removal
def add_hinge_heights(contour):
heightmap = []
over_hinge = True # Start over hinge
items_to_skip = 0 # for fast-forwarding enumeration
for idx, pt in enumerate(contour):
if items_to_skip > 0:
items_to_skip = items_to_skip - 1
if items_to_skip == 0:
print 'first post ramp point', contour[idx+1]
continue
if pt[1] < center_y:
heightmap = heightmap + [pt]
# Going up and around: start ramping down when we're clear of X or Y
elif pt[0] > x_pos:
if pt[0] > hinge_rampdown_start_x or pt[1] < hinge_rampdown_start_y:
if(over_hinge): # starting transition
transition_length = poly.polyline_length(contour[:(idx+1)], False)
ramp_segment = poly.segment(contour, transition_length, transition_length+5, False)
ramp_segment = poly.ramp(ramp_segment, hinge_removal, body_removal, False)
heightmap = heightmap + ramp_segment[:-1]
items_to_skip = len(ramp_segment)
print 'last ramp segment', ramp_segment[-1]
over_hinge = False
else: # past transition but still on hinge side of lens hole
heightmap = heightmap + [pt + [body_removal]]
else: # We're on the top part but haven't reached the transition yet
heightmap = heightmap + [pt + [hinge_removal]]
# Coming back up to the hinge: start ramping up if we encroach on both x and y
elif pt[0] < x_pos and (pt[0] > hinge_rampup_start_x and pt[1] > hinge_rampdown_start_y):
if(not over_hinge): # starting transition
print pt, x_pos, hinge_rampup_start_x, hinge_rampdown_start_y, idx
transition_length = poly.polyline_length(contour[:(idx+1)], False)
ramp_segment = poly.segment(contour, transition_length, transition_length+5, False)
ramp_segment = poly.ramp(ramp_segment, body_removal, hinge_removal, False)
heightmap = heightmap + ramp_segment
items_to_skip = len(ramp_segment)
over_hinge = True
else: # Over flat hinge area
heightmap = heightmap + [pt + [hinge_removal]]
else: # We're over the body area but back on the hinge side
heightmap = heightmap + [pt + [body_removal]]
return heightmap
def add_nosepad_heights(contour):
heightmap = []
over_nosepad = False
past_nosepad = False
nosepad_flat_idx = -1
items_to_skip = 0 # for fast-forwarding the enumeration
for idx, pt in enumerate(contour):
if items_to_skip > 0:
items_to_skip = items_to_skip-1
continue
if pt[1] >= center_y:
heightmap = heightmap + [pt]
elif not over_nosepad and not past_nosepad:
if pt[0] < nosepad_start: # Transition
transition_length = poly.polyline_length(contour[:(idx+1)], False)
ramp_segment = poly.segment(contour, transition_length, transition_length+5, False)
ramp_segment = poly.ramp(ramp_segment, body_removal, nosepad_removal, False)
heightmap = heightmap + ramp_segment[:-1]
items_to_skip = len(ramp_segment)
nosepad_flat_idx = idx + items_to_skip # we'll need this to go down
over_nosepad = True
else: # we're past the nosepad
heightmap = heightmap + [pt + [body_removal]]
elif over_nosepad and not past_nosepad:
if nosepad_flat_idx < 0:
print "ERROR! I think I'm on the nosepad but have not transitioned yet"
return []
# We'll be cutting the far side with the back of the cutter, so need to move at
# least the diameter to get any flat at all
flat_length = poly.polyline_length(contour[nosepad_flat_idx:(idx+1)], False) - (cutter_radius*2)
if flat_length < 5:
heightmap = heightmap + [pt + [nosepad_removal]]
else: # ramp down
transition_length = poly.polyline_length(contour[:(idx+1)], False)
ramp_segment = poly.segment(contour, transition_length, transition_length+5, False)
ramp_segment = poly.ramp(ramp_segment, nosepad_removal, body_removal, False)
heightmap = heightmap + ramp_segment[:-1]
items_to_skip = len(ramp_segment)
nosepad_flat_idx = idx + items_to_skip # we'll need this to go down
over_nosepad = False
past_nosepad = True
else:
heightmap = heightmap + [pt + [body_removal]]
return heightmap
facing_contour = add_hinge_heights(facing_contour)
facing_contour = add_nosepad_heights(facing_contour)
facing_contour = poly.reverse(facing_contour)
right_facing = poly.mirror_y(facing_contour, True)
passes = [1]
heights = [p[2] for p in facing_contour]
r = [
cam.change_tool("1/4in ballmill"),
cam.spindle_speed(22000),
cam.feedrate(1000),
cam.start_spindle(),
cam.rmp(entry_point),
cam.contour(facing_contour, True),
]
for dilate in passes:
dilated = poly.reverse(poly.dilate(dilate, facing_contour))
# dilated = add_hinge_heights(dilated)
dilated = add_nosepad_heights(dilated)
r = r + [ cam.contour(dilated, True),]
return r
