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 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 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 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 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 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