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 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 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 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 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 thin_temples(temples, temple_length):
left = temples[0]
right = temples[1]
left_side = poly.bottom(left)
right_side = poly.top(left)
halfway = left_side + (right_side - left_side)/2
taperpath = []
for pt in left:
if pt[1] == left_side:
break
elif pt[1] > halfway:
taperpath.append(pt)
print taperpath
# offset the path so our 1/2 mill cuts the whole thing
# TODO: gauge width and make sure we're cutting the whole thing.
flat_begin = left_side + temple_length -10 # 20 mm flat
flat_end = flat_begin + 20
front_slope = -2.0 / (halfway-flat_begin)
print "flat", flat_begin, flat_end
print left_side, right_side, halfway
def calc_thinning_z(pt):
if pt[1] > flat_begin:
print 'Over flat begin', pt
return (abs(pt[1]-halfway) * front_slope)
elif pt[1] > flat_end:
print 'over flat end'
return -4
else:
return -(pt[0]-flat_end)/4 - 4
shiftedpath = []
for idx, pt in enumerate(taperpath):
if idx == 0:
shiftedpath.append([pt[0], pt[1]-3])
else:
lastpt = taperpath[idx-1]
line=[pt[0]-lastpt[0], pt[1]-lastpt[1]]
normal=[-line[1], line[0]]
length = math.sqrt(normal[0]*normal[0]+normal[1]*normal[1])
normal = [6*(x/length) for x in normal]
shiftedpath.append([pt[0]+normal[0], pt[1]+normal[1]])
thinning_contour_left = [[pt[0], pt[1], calc_thinning_z(pt)] for pt in shiftedpath]
#thinning_contour_right = poly.mirror_x(thinning_contour_left)
return [
cam.rmp(thinning_contour_left[0]),
cam.contour(thinning_contour_left, False),
]
def thin_temples(temples, temple_length):
left = temples[0]
right = temples[1]
left_side = poly.bottom(left)
right_side = poly.top(left)
halfway = left_side + (right_side - left_side) / 2
taperpath = []
for pt in left:
if pt[1] == left_side:
break
elif pt[1] > halfway:
taperpath.append(pt)
print taperpath
# offset the path so our 1/2 mill cuts the whole thing
# TODO: gauge width and make sure we're cutting the whole thing.
flat_begin = left_side + temple_length - 10 # 20 mm flat
flat_end = flat_begin + 20
front_slope = -2.0 / (halfway - flat_begin)
print "flat", flat_begin, flat_end
print left_side, right_side, halfway
def calc_thinning_z(pt):
if pt[1] > flat_begin:
print 'Over flat begin', pt
return (abs(pt[1] - halfway) * front_slope)
elif pt[1] > flat_end:
print 'over flat end'
return -4
else:
return -(pt[0] - flat_end) / 4 - 4
shiftedpath = []
for idx, pt in enumerate(taperpath):
if idx == 0:
shiftedpath.append([pt[0], pt[1] - 3])
else:
lastpt = taperpath[idx - 1]
line = [pt[0] - lastpt[0], pt[1] - lastpt[1]]
normal = [-line[1], line[0]]
length = math.sqrt(normal[0] * normal[0] + normal[1] * normal[1])
normal = [6 * (x / length) for x in normal]
shiftedpath.append([pt[0] + normal[0], pt[1] + normal[1]])
thinning_contour_left = [[pt[0], pt[1], calc_thinning_z(pt)]
for pt in shiftedpath]
#thinning_contour_right = poly.mirror_x(thinning_contour_left)
return [
cam.rmp(thinning_contour_left[0]),
cam.contour(thinning_contour_left, False),
]
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 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 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 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 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 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
