def check_frame_size(contour):
# We're limited by our stock size and clamp clearances
# We can be about 160mm wide max, and about 65mm high max.
if abs(poly.top(contour)) > 86:
return "Frame is too wide: %f mm" % (poly.top(contour) * 2)
if poly.right(contour) - poly.left(contour) > 60:
return "Frame is too tall: %f mm" % (poly.right(contour) - poly.left(contour))
return None
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 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 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, 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 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 arrange_temple_curves(left_temple_contour, hinge):
# Normalize temple to get origin at 0,0
left_temple_contour = poly.translate(left_temple_contour, -left_temple_contour[0][0], -left_temple_contour[0][1])
right_temple_contour = poly.mirror_x(left_temple_contour, False)
left_hinge = hinges.get_hinge(hinge)
right_hinge = hinges.get_hinge(hinge, False)
hinge_y = (left_temple_contour[0][1]+left_temple_contour[-1][1])/2
left_holes = left_hinge['temple_holes']
right_holes = right_hinge['temple_holes'] # opposite direction. FIX someday
right_hinge_contour = right_hinge['temple_contour']
left_hinge_contour = left_hinge['temple_contour']
# y offset is mucked up because it's calculated from the center of the hinge boxing
# square, not the center of the straight edge
highpoint = poly.top(left_hinge_contour);
lowpoint = poly.bottom(left_hinge_contour);
y_offset = hinge_y-(lowpoint + (highpoint-lowpoint)/2.0) # Distance to move hinge to center it on temple
# strategy for hinge placement. Align corner of
print left_temple_contour[0][0], left_temple_contour[-1][0]
temple_x = left_temple_contour[0][0] - (left_temple_contour[0][0] - left_temple_contour[-1][0]) / 2
x_offset = temple_x - left_hinge_contour[0][0] - 2.5
left_hinge_contour = poly.translate(left_hinge_contour, x_offset, y_offset)
left_holes = poly.translate(left_holes, x_offset, y_offset)
right_hinge_contour = poly.translate(right_hinge_contour, -x_offset, y_offset)
right_holes = poly.translate(right_holes, -x_offset, y_offset)
left_temple_contour = poly.rotate_90(left_temple_contour)
left_hinge_contour = poly.rotate_90(left_hinge_contour)
left_holes = poly.rotate_90(left_holes)
right_temple_contour = poly.rotate(right_temple_contour, 90)
right_hinge_contour = poly.rotate(right_hinge_contour, 90)
right_holes = poly.rotate(right_holes, 90)
# Move them apart so they're not touching
height = poly.right(left_temple_contour) - poly.left(left_temple_contour)+1
left_temple_contour = poly.translate(left_temple_contour, height, 0)
left_holes = poly.translate(left_holes, height, 0)
left_hinge_contour = poly.translate(left_hinge_contour, height, 0)
right_temple_contour = poly.translate(right_temple_contour, -height, 0)
right_holes = poly.translate(right_holes, -height, 0)
right_hinge_contour = poly.translate(right_hinge_contour, -height, 0)
# # Move left one left, right one right to offset them
temple_width = poly.top(left_temple_contour) - poly.bottom(left_temple_contour)
optimization_offset = (160-temple_width)/2.0
print 'optimization offset', optimization_offset, temple_width
left_temple_contour = poly.translate(left_temple_contour, 0, optimization_offset)
left_holes = poly.translate(left_holes, 0, optimization_offset)
left_hinge_contour = poly.translate(left_hinge_contour, 0, optimization_offset)
right_temple_contour = poly.translate(right_temple_contour, 0, -optimization_offset)
right_hinge_contour = poly.translate(right_hinge_contour, 0, -optimization_offset)
right_holes = poly.translate(right_holes, 0, -optimization_offset)
# Make sure they're not intersecting
# translation_step = 2.5
# intersection = poly.intersection(left_temple_contour, right_temple_contour)
# while(len(intersection) > 0):
# left_temple_contour = poly.translate(left_temple_contour, translation_step, 0)
# left_holes = poly.translate(left_holes, translation_step, 0)
# left_hinge_contour = poly.translate(left_hinge_contour, translation_step, 0)
# right_temple_contour = poly.translate(right_temple_contour, -translation_step, 0)
# right_holes = poly.translate(right_holes, -translation_step, 0)
# right_hinge_contour = poly.translate(right_hinge_contour, -translation_step, 0)
# intersection = poly.intersection(left_temple_contour, right_temple_contour)
# Move them together until they touch (may will not have moved at all above because they are far)
# then back off.
#smaller translation step (was 1.0)
translation_step = 0.1
intersection = []
while(len(intersection) == 0):
print "still intersecting", len(intersection)
left_temple_contour = poly.translate(left_temple_contour, -translation_step, 0)
left_holes = poly.translate(left_holes, -translation_step, 0)
left_hinge_contour = poly.translate(left_hinge_contour, -translation_step, 0)
right_temple_contour = poly.translate(right_temple_contour, translation_step, 0)
right_holes = poly.translate(right_holes, translation_step, 0)
right_hinge_contour = poly.translate(right_hinge_contour, translation_step, 0)
intersection = poly.intersection(left_temple_contour, right_temple_contour)
#
# Sarah commented the code below out as it seems to be speading the temples out farther than necessary
# And I don't think we need it?
# We're just overlapping, so now back off
# translation_step = 0.5
# left_temple_contour = poly.translate(left_temple_contour, translation_step, 0)
# left_holes = poly.translate(left_holes, translation_step, 0)
# left_hinge_contour = poly.translate(left_hinge_contour, translation_step, 0)
# right_temple_contour = poly.translate(right_temple_contour, -translation_step, 0)
# right_holes = poly.translate(right_holes, -translation_step, 0)
# right_hinge_contour = poly.translate(right_hinge_contour, -translation_step, 0)
# # sanity check that we fit on stock
total_width = poly.right(left_temple_contour) - poly.left(right_temple_contour)
print "before spreading, total width is:", total_width
if total_width > 55:
print 'Error! temples did not pack tight enough.', total_width
raise 'Sizing error'
#
## Spread them out
while total_width < 55:
print "spreading out temples"
left_temple_contour = poly.translate(left_temple_contour, translation_step, 0)
left_holes = poly.translate(left_holes, translation_step, 0)
left_hinge_contour = poly.translate(left_hinge_contour, translation_step, 0)
right_temple_contour = poly.translate(right_temple_contour, -translation_step, 0)
right_holes = poly.translate(right_holes, -translation_step, 0)
right_hinge_contour = poly.translate(right_hinge_contour, -translation_step, 0)
total_width = poly.right(left_temple_contour) - poly.left(right_temple_contour)
intersection = poly.intersection(left_temple_contour, right_temple_contour)
if len(intersection) > 0:
print 'Error! Temples are too big to fit on stock.', total_width
raise 'Sizing Error'
print 'Total width of temples', total_width
# Now they're packed togegther OK but not centred on the stock
#Midpoint of curves should be 0, so that's how much we'll shift it
y_centering_shift = poly.bottom(right_temple_contour) + (poly.top(left_temple_contour) - poly.bottom(right_temple_contour))/2.0
x_centering_shift = (poly.right(left_temple_contour) + poly.left(right_temple_contour))/2;
left_temple_contour = poly.translate(left_temple_contour, -x_centering_shift, -y_centering_shift)
right_temple_contour = poly.translate(right_temple_contour, -x_centering_shift, -y_centering_shift)
left_hinge_contour = poly.translate(left_hinge_contour, -x_centering_shift, -y_centering_shift)
right_hinge_contour = poly.translate(right_hinge_contour, -x_centering_shift, -y_centering_shift)
left_holes = poly.translate(left_holes, -x_centering_shift, -y_centering_shift)
right_holes = poly.translate(right_holes, -x_centering_shift, -y_centering_shift)
# The temple contours aren't closed, close them here
# NOTE: Taken out because we close the curves with a little arc to account for front curvature
#left_temple_contour.append(left_temple_contour[0])
#right_temple_contour.append(right_temple_contour[0])
return {
"pocket_depth": 1,
"left_hinge_contour": left_hinge_contour,
"right_hinge_contour": right_hinge_contour,
"left_hinge_holes": left_holes,
"right_hinge_holes": right_holes,
"left_temple_contour": left_temple_contour,
"right_temple_contour": right_temple_contour
}
def arrange_temple_curves(left_temple_contour, right_temple_contour, hinge,
lhinge_y, rhinge_y):
left_hinge = hinges.get_hinge(hinge)
right_hinge = hinges.get_hinge(hinge, False)
print 'first and last point of left_temple_contour'
print left_temple_contour[0], left_temple_contour[-1]
left_holes = poly.rotate_90(left_hinge['temple_holes'])
right_holes = poly.rotate(right_hinge['temple_holes'],
90) # opposite direction. FIX someday
left_hinge_contour = poly.rotate_90(left_hinge['temple_contour'])
right_hinge_contour = poly.rotate(right_hinge['temple_contour'], 90)
#right_hinge_contour = right_hinge['temple_contour']
#left_holes = left_hinge['temple_holes']
#right_holes = right_hinge['temple_holes']
# Get the thing as horizontal as possible
# When top-bottom distance is minimized, it's horizontal
height = poly.top(left_temple_contour) - poly.bottom(left_temple_contour)
opt_angle = 0
for angle in range(2, 41):
candidate_contour = poly.rotate(left_temple_contour, -angle)
candidate_height = poly.top(candidate_contour) - poly.bottom(
candidate_contour)
if candidate_height < height:
height = candidate_height
opt_angle = angle
else:
break
# The temple is raised or lowered as compared to the Y axis. We need
# to bring it to the Y origin for rotation to avoid offsetting it, then
# send it back to its original spot.
original_y_offset = left_temple_contour[0][1] - (
left_temple_contour[0][1] - left_temple_contour[-1][1]) / 2
left_temple_contour = poly.translate(left_temple_contour, 0,
-original_y_offset)
left_temple_contour = poly.rotate(left_temple_contour, -opt_angle)
left_temple_contour = poly.translate(left_temple_contour, 0,
original_y_offset)
right_temple_contour = poly.translate(right_temple_contour, 0,
-original_y_offset)
right_temple_contour = poly.rotate(right_temple_contour, opt_angle)
right_temple_contour = poly.translate(right_temple_contour, 0,
original_y_offset)
#left_holes = poly.rotate(left_hinge['temple_holes'], -opt_angle)
#right_holes = poly.rotate(right_hinge['temple_holes'], opt_angle)
#left_hinge_contour = poly.rotate(left_hinge['temple_contour'], -opt_angle)
#right_hinge_contour = poly.rotate(right_hinge['temple_contour'], opt_angle)
left_holes = poly.rotate(left_holes, -opt_angle)
right_holes = poly.rotate(right_holes, opt_angle)
left_hinge_contour = poly.rotate(left_hinge_contour, -opt_angle)
right_hinge_contour = poly.rotate(right_hinge_contour, opt_angle)
left_hinge_contour = poly.translate(left_hinge_contour, lhinge_y,
-left_hinge['pocket_depth'])
right_hinge_contour = poly.translate(right_hinge_contour, rhinge_y,
right_hinge['pocket_depth'])
# Left and right translate are reversed because we've rotated everything
left_holes = poly.translate(left_holes, lhinge_y,
-left_hinge['pocket_depth'])
right_holes = poly.translate(right_holes, rhinge_y,
right_hinge['pocket_depth'])
temple_width = poly.right(left_temple_contour) - poly.left(
left_temple_contour)
print "temple width", temple_width
lt_trans = [temple_width / 2, 0]
rt_trans = [-lt_trans[0], 0]
#lt_trans = [180-poly.right(left_temple_contour), -poly.top(left_temple_contour) - 30]
#lt_trans = [-poly.right(left_temple_contour)-30, 180 -poly.top(left_temple_contour)]
#rt_trans = [-poly.left(right_temple_contour)+25, lt_trans[1]-height]
# Translate them
left_temple_contour = poly.translate(left_temple_contour, lt_trans[0],
lt_trans[1])
right_temple_contour = poly.translate(right_temple_contour, rt_trans[0],
rt_trans[1])
left_hinge_contour = poly.translate(left_hinge_contour, lt_trans[1],
-lt_trans[0])
right_hinge_contour = poly.translate(right_hinge_contour, rt_trans[1],
-rt_trans[0])
left_holes = poly.translate(left_holes, lt_trans[1], -lt_trans[0])
right_holes = poly.translate(right_holes, rt_trans[1], -rt_trans[0])
# Translate bottom one upward as much as we can
trans_amount = poly.bottom(left_temple_contour) - poly.top(
right_temple_contour) - 8
for i in range(1, 100):
candidate = poly.translate(right_temple_contour, 0, trans_amount + i)
intersection = poly.intersection(candidate, left_temple_contour)
if len(intersection) > 0:
trans_amount = trans_amount + i - 8
right_temple_contour = poly.translate(right_temple_contour, 0,
trans_amount)
break
print 'trans amount:', trans_amount
right_hinge_contour = poly.translate(right_hinge_contour, trans_amount, 0)
right_holes = poly.translate(right_holes, trans_amount, 0)
return {
"pocket_depth": left_hinge['pocket_depth'],
"left_hinge_contour": left_hinge_contour,
"right_hinge_contour": right_hinge_contour,
"left_hinge_holes": left_holes,
"right_hinge_holes": right_holes,
"left_temple_contour": left_temple_contour,
"right_temple_contour": right_temple_contour
}
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 arrange_temple_curves(left_temple_contour, right_temple_contour, hinge, lhinge_y, rhinge_y):
left_hinge = hinges.get_hinge(hinge)
right_hinge = hinges.get_hinge(hinge, False)
print 'first and last point of left_temple_contour'
print left_temple_contour[0], left_temple_contour[-1]
left_holes = poly.rotate_90(left_hinge['temple_holes'])
right_holes = poly.rotate(right_hinge['temple_holes'], 90) # opposite direction. FIX someday
left_hinge_contour = poly.rotate_90(left_hinge['temple_contour'])
right_hinge_contour = poly.rotate(right_hinge['temple_contour'], 90)
#right_hinge_contour = right_hinge['temple_contour']
#left_holes = left_hinge['temple_holes']
#right_holes = right_hinge['temple_holes']
# Get the thing as horizontal as possible
# When top-bottom distance is minimized, it's horizontal
height = poly.top(left_temple_contour) - poly.bottom(left_temple_contour)
opt_angle = 0
for angle in range(2, 41):
candidate_contour = poly.rotate(left_temple_contour, -angle)
candidate_height = poly.top(candidate_contour)-poly.bottom(candidate_contour)
if candidate_height < height:
height = candidate_height
opt_angle = angle
else:
break
# The temple is raised or lowered as compared to the Y axis. We need
# to bring it to the Y origin for rotation to avoid offsetting it, then
# send it back to its original spot.
original_y_offset = left_temple_contour[0][1] - (left_temple_contour[0][1] - left_temple_contour[-1][1])/2
left_temple_contour = poly.translate(left_temple_contour, 0, -original_y_offset)
left_temple_contour = poly.rotate(left_temple_contour, -opt_angle);
left_temple_contour = poly.translate(left_temple_contour, 0, original_y_offset)
right_temple_contour = poly.translate(right_temple_contour, 0, -original_y_offset)
right_temple_contour = poly.rotate(right_temple_contour, opt_angle);
right_temple_contour = poly.translate(right_temple_contour, 0, original_y_offset)
#left_holes = poly.rotate(left_hinge['temple_holes'], -opt_angle)
#right_holes = poly.rotate(right_hinge['temple_holes'], opt_angle)
#left_hinge_contour = poly.rotate(left_hinge['temple_contour'], -opt_angle)
#right_hinge_contour = poly.rotate(right_hinge['temple_contour'], opt_angle)
left_holes = poly.rotate(left_holes, -opt_angle)
right_holes = poly.rotate(right_holes, opt_angle)
left_hinge_contour = poly.rotate(left_hinge_contour, -opt_angle)
right_hinge_contour = poly.rotate(right_hinge_contour, opt_angle)
left_hinge_contour = poly.translate(left_hinge_contour, lhinge_y, -left_hinge['pocket_depth'])
right_hinge_contour = poly.translate(right_hinge_contour, rhinge_y, right_hinge['pocket_depth'])
# Left and right translate are reversed because we've rotated everything
left_holes = poly.translate(left_holes, lhinge_y, -left_hinge['pocket_depth'])
right_holes = poly.translate(right_holes, rhinge_y, right_hinge['pocket_depth'])
temple_width = poly.right(left_temple_contour) - poly.left(left_temple_contour)
print "temple width", temple_width
lt_trans = [temple_width/2, 0]
rt_trans = [-lt_trans[0], 0]
#lt_trans = [180-poly.right(left_temple_contour), -poly.top(left_temple_contour) - 30]
#lt_trans = [-poly.right(left_temple_contour)-30, 180 -poly.top(left_temple_contour)]
#rt_trans = [-poly.left(right_temple_contour)+25, lt_trans[1]-height]
# Translate them
left_temple_contour = poly.translate(left_temple_contour, lt_trans[0], lt_trans[1])
right_temple_contour = poly.translate(right_temple_contour, rt_trans[0], rt_trans[1])
left_hinge_contour = poly.translate(left_hinge_contour, lt_trans[1], -lt_trans[0])
right_hinge_contour = poly.translate(right_hinge_contour, rt_trans[1], -rt_trans[0])
left_holes = poly.translate(left_holes, lt_trans[1], -lt_trans[0])
right_holes = poly.translate(right_holes, rt_trans[1], -rt_trans[0])
# Translate bottom one upward as much as we can
trans_amount = poly.bottom(left_temple_contour) - poly.top(right_temple_contour) - 8
for i in range(1, 100):
candidate = poly.translate(right_temple_contour, 0, trans_amount + i)
intersection = poly.intersection(candidate, left_temple_contour)
if len(intersection) > 0:
trans_amount = trans_amount + i -8
right_temple_contour = poly.translate(right_temple_contour, 0, trans_amount)
break
print 'trans amount:', trans_amount
right_hinge_contour = poly.translate(right_hinge_contour, trans_amount, 0)
right_holes = poly.translate(right_holes, trans_amount, 0)
return {
"pocket_depth": left_hinge['pocket_depth'],
"left_hinge_contour": left_hinge_contour,
"right_hinge_contour": right_hinge_contour,
"left_hinge_holes": left_holes,
"right_hinge_holes": right_holes,
"left_temple_contour": left_temple_contour,
"right_temple_contour": right_temple_contour
}
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
