poly_cylinder() now has a twist parameter.

Fixed rounding error in hangin_hole assert.

readme.md

@@ -2904,6 +2904,8 @@ These items are sysmtrical, so by default the origin is in the centre but it can
 ## Screws
 Machine screws and wood screws with various head styles.
 
+For an explanation of ```screw_polysink()``` see <https://hydraraptor.blogspot.com/2020/12/sinkholes.html>.
+
 
 [vitamins/screws.scad](vitamins/screws.scad) Object definitions.
 
@@ -2933,6 +2935,7 @@ Machine screws and wood screws with various head styles.
 | ```screw_head_depth(type, d = 0)``` | How far a counter sink head will go into a straight hole diameter d |
 | ```screw_longer_than(x)``` | Returns shortest screw length longer or equal to x |
 | ```screw_nut_radius(type)``` | Radius of matching nut |
+| ```screw_polysink_r(type, z)``` | Countersink hole profile corrected for rounded staircase extrusions. |
 | ```screw_shorter_than(x)``` | Returns longest screw length shorter than or equal to x |
 
 ### Modules
@@ -2941,6 +2944,7 @@ Machine screws and wood screws with various head styles.
 | ```screw(type, length, hob_point = 0, nylon = false)``` | Draw specified screw, optionally hobbed or nylon |
 | ```screw_and_washer(type, length, star = false, penny = false)``` | Screw with a washer which can be standard or penny and an optional star washer on top |
 | ```screw_countersink(type, drilled = true)``` | Countersink shape |
+| ```screw_polysink(type, h = 100, alt = false)``` | A countersink hole made from stacked polyholes for printed parts |
 
 ![screws](tests/png/screws.png)
 
@@ -2979,6 +2983,11 @@ Machine screws and wood screws with various head styles.
 |   1 | ```screw(No6_cs_screw, 30)``` |  Screw No6 cs wood x 30mm |
 |   1 | ```screw(No6_screw, 30)``` |  Screw No6 pan wood x 30mm |
 
+### Printed
+| Qty | Filename |
+| ---:|:--- |
+|   1 | polysink.stl |
+
 
 <a href="#top">Top</a>
 
@@ -6107,6 +6116,16 @@ it gets the linear dimensions right. See <https://hydraraptor.blogspot.com/2011/
 
 The module provides `poly_circle()`, `poly_cylinder()` and `poly_ring()` that is useful for making printed washers and pillars.
 
+`poly_cylinder()` has a `twist` parameter which can be set to make the polygon rotate each layer.
+This can be used to mitigate the number of sides being small and make small holes stronger and more round, but is quite slow due to the
+large increase in the number of facets.
+When set to 1 the polygons alternate each layer, when set higher the rotation takes `twist + 1` layers to repeat.
+A small additional rotation is added to make the polygon rotate one more side over the length of the hole to make it appear round when
+veiwed end on.
+
+When `twist` is set the resulting cylinder is extended by `eps` at each end so that the exact length of the hole can be used without
+leaving a scar on either surface.
+
 
 [utils/core/polyholes.scad](utils/core/polyholes.scad) Implementation.
 
@@ -6124,7 +6143,7 @@ The module provides `poly_circle()`, `poly_cylinder()` and `poly_ring()` that is
 |:--- |:--- |
 | ```drill(r, h = 100, center = true)``` | Make a cylinder for drilling holes suitable for CNC routing, set h = 0 for circle |
 | ```poly_circle(r, sides = 0)``` | Make a circle adjusted to print the correct size |
-| ```poly_cylinder(r, h, center = false, sides = 0, chamfer = false)``` | Make a cylinder adjusted to print the correct size |
+| ```poly_cylinder(r, h, center = false, sides = 0, chamfer = false, twist = 0)``` | Make a cylinder adjusted to print the correct size |
 | ```poly_drill(r, h = 100, center = true)``` | Make a cylinder for drilling holes suitable for CNC routing if cnc_bit_r is non zero, otherwise a poly_cylinder. |
 | ```poly_ring(or, ir, sides = 0)``` | Make a 2D ring adjusted to have the correct internal radius |
 | ```poly_tube(or, ir, h, center = false)``` | Make a tube adjusted to have the correct internal radius |
@@ -6158,6 +6177,11 @@ The module provides `poly_circle()`, `poly_cylinder()` and `poly_ring()` that is
 |   1 | ```rod(9.5, 43)``` |  Smooth rod 9.5mm x 43mm |
 |   1 | ```rod(9, 41)``` |  Smooth rod 9mm x 41mm |
 
+### Printed
+| Qty | Filename |
+| ---:|:--- |
+|   1 | polyhole.stl |
+
 
 <a href="#top">Top</a>
 

tests/polyholes.scad

@@ -21,30 +21,60 @@ include <../utils/core/core.scad>
 use <../vitamins/rod.scad>
 include <../vitamins/sheets.scad>
 
-module polyholes() {
+module positions()
-    module positions()
+    for(i = [1 : 10]) {
-        for(i = [1 : 10]) {
+        translate([(i * i + i) / 2 + 3 * i , 8])
-            translate([(i * i + i) / 2 + 3 * i , 8])
+            let($r = i / 2)
-                let($r = i / 2)
+                children();
+
+        let(d = i + 0.5)
+            translate([(d * d + d) / 2 + 3 * d, 19])
+                let($r = d / 2)
                     children();
+    }
 
-            let(d = i + 0.5)
+module polyhole_stl() {
-                translate([(d * d + d) / 2 + 3 * d, 19])
+    stl("polyhole");
-                    let($r = d / 2)
-                        children();
-        }
 
-    stl_colour(pp1_colour) linear_extrude(3, center = true)
+    linear_extrude(3, center = true)
         difference() {
             square([100, 27]);
 
             positions()
                 poly_circle(r = $r);
         }
+}
 
-     positions()
+module alt_polyhole_stl() {
+    holes = [2.5, 2, 1.5];
+    n = len(holes);
+    size = [n * 10, 10, 10];
+    difference() {
+        translate([-size.x / n / 2, $preview ? 0 : -size.y / 2])
+            cube($preview ? [size.x, size.y / 2, size.z] : size);
+
+        for(i = [0 : n - 1])
+            translate([i * 10, 0])
+                if(i % 2)
+                    translate_z(size.z)
+                        poly_cylinder(r = holes[i] / 2, h = 2 * size.z, center = true, twist = i + 1);
+                else
+                    poly_cylinder(r = holes[i] / 2, h = size.z, center = false, twist = i + 1);
+    }
+}
+
+module polyholes() {
+    stl_colour(pp1_colour)
+        polyhole_stl();
+
+    positions()
         rod(d = 2 * $r, l = 8 * $r + 5);
     //
+    // Alternating polyholes
+    //
+    translate([30, -40])
+        alt_polyhole_stl();
+    //
     // Poly rings
     //
     ir = 3 / 2;
@@ -74,4 +104,11 @@ module polyholes() {
             }
 }
 
-polyholes();
+if($preview)
+    polyholes();
+else {
+    polyhole_stl();
+
+    translate([50, -20])
+        alt_polyhole_stl();
+}

tests/screws.scad

@@ -18,20 +18,46 @@
 //
 include <../core.scad>
 
-module screws()
+module polysink_stl() {
-for(y = [0 : len(screw_lists) -1])
+    stl("polysink");
-    for(x = [0 : len(screw_lists[y]) -1]) {
+
-        screw = screw_lists[y][x];
+    cs_screws = [for(list = screw_lists, screw = list) if(screw_head_type(screw) == hs_cs_cap) screw];
-        if(screw) {
+    n = len(cs_screws);
-             length = screw_head_type(screw) == hs_grub ? 6
+    size = [n * 20, 20, 10];
-                    : screw_radius(screw) <= 1.5 ? 10
+    difference() {
-                    : screw_max_thread(screw) ? screw_longer_than(screw_max_thread(screw) + 5)
+        translate([-size.x / n / 2, $preview ? 0 : -size.y / 2])
-                    : 30;
+            cube($preview ? [size.x, size.y / 2, size.z] : size);
-            translate([x * 20, y * 20])
+
-                screw(screw, length);
+        for(i = [0 : n - 1])
-        }
+            let(s = cs_screws[i])
+                translate([i * 20, 0]) {
+                    translate_z(size.z)
+                        screw_polysink(s, 2 * size.z + 1);
+
+                    screw_polysink(s, 2 * size.z + 1, alt = true);
+                }
     }
+}
+
+module screws() {
+    for(y = [0 : len(screw_lists) -1])
+        for(x = [0 : len(screw_lists[y]) -1]) {
+            screw = screw_lists[y][x];
+            if(screw) {
+                 length = screw_head_type(screw) == hs_grub ? 6
+                        : screw_radius(screw) <= 1.5 ? 10
+                        : screw_max_thread(screw) ? screw_longer_than(screw_max_thread(screw) + 5)
+                        : 30;
+                translate([x * 20, y * 20])
+                    screw(screw, length);
+            }
+        }
+        translate([80, 20])
+            polysink_stl();
+}
 
 if($preview)
     let($show_threads = true)
         screws();
+else
+    polysink_stl();

utils/core/polyholes.scad

@@ -22,6 +22,16 @@
 //! it gets the linear dimensions right. See <https://hydraraptor.blogspot.com/2011/02/polyholes.html>
 //!
 //! The module provides `poly_circle()`, `poly_cylinder()` and `poly_ring()` that is useful for making printed washers and pillars.
+//!
+//! `poly_cylinder()` has a `twist` parameter which can be set to make the polygon rotate each layer.
+//! This can be used to mitigate the number of sides being small and make small holes stronger and more round, but is quite slow due to the
+//! large increase in the number of facets.
+//! When set to 1 the polygons alternate each layer, when set higher the rotation takes `twist + 1` layers to repeat.
+//! A small additional rotation is added to make the polygon rotate one more side over the length of the hole to make it appear round when
+//! veiwed end on.
+//!
+//! When `twist` is set the resulting cylinder is extended by `eps` at each end so that the exact length of the hole can be used without
+//! leaving a scar on either surface.
 //
 function sides(r) = max(round(4 * r), 3);                                       //! Optimium number of sides for specified radius
 function corrected_radius(r, n = 0)   = r / cos(180 / (n ? n : sides(r)));      //! Adjusted radius to make flats lie on the circle
@@ -32,9 +42,26 @@ module poly_circle(r, sides = 0) { //! Make a circle adjusted to print the corre
     circle(r = corrected_radius(r,n), $fn = n);
 }
 
-module poly_cylinder(r, h, center = false, sides = 0, chamfer = false) {//! Make a cylinder adjusted to print the correct size
+module poly_cylinder(r, h, center = false, sides = 0, chamfer = false, twist = 0) {//! Make a cylinder adjusted to print the correct size
-    extrude_if(h, center)
+    if(twist) {
-        poly_circle(r, sides);
+        slices = ceil(h / layer_height);
+        twist = min(twist, slices - 1);
+        sides = sides ? sides : sides(r);
+        rot = 360 / sides / (twist + 1) * (1 + 1 / slices);
+        if(center)
+            for(side = [0, 1])
+                mirror([0, 0, side])
+                    poly_cylinder(r = r, h = h / 2, sides = sides, twist = twist);
+        else
+            render(convexity = 5)
+                for(i = [0 : slices - 1])
+                    translate_z(i * layer_height - eps)
+                        rotate(rot * i)
+                            poly_cylinder(r = r, h = layer_height + 2 * eps, sides = sides);
+    }
+    else
+        extrude_if(h, center)
+            poly_circle(r, sides);
 
     if(h && chamfer)
         poly_cylinder(r + layer_height, center ? layer_height * 2 : layer_height, center, sides = sides ? sides : sides(r));

utils/hanging_hole.scad

@@ -35,7 +35,7 @@ module hanging_hole(z, ir, h = 100, h2 = 100) { //! Hole radius ```ir``` hanging
                         poly_cylinder(r - eps, h - layer_height);
             }
     }
-    assert(z % layer_height == 0, str(z));
+    assert(z - layer_height * floor(z / layer_height) < eps, str(z));
     infill_angle = z % (2 * layer_height) ? -45 : 45;
     below = min(z + eps, h2);
     big = 1000;

vitamins/blowers.scad

@@ -21,7 +21,7 @@
 //                                                   n     d   p   r     r              b   i            r    r                               i    b    s    p    l    g
 //                                                   g     t   t   e     e                  s            e    e                               t         e         l
 //                                                   t     h   h         w              d                w    w                                              t
-//                                                   h                                                  h    s                                         t         t
+//                                                   h                                                   h    s                                         t         t
 RB5015 = ["RB5015", "Blower Runda RB5015",           51.3, 51, 15, 31.5, M4_cap_screw, 26, [27.3, 25.4], 4.5, [[4.3, 45.4], [47.3,7.4]],     20,   14,  1.5, 1.3, 1.2, 15];
 PE4020 = ["PE4020", "Blower Pengda Technology 4020", 40,   40, 20, 27.5, M3_cap_screw, 22, [21.5, 20  ], 3.2, [[37,3],[3,37],[37,37]],       29.3, 17,  1.7, 1.2, 1.3, 13];
 BL40x10 =["BL40x10","Square radial 4010",            40,   40,9.5, 27,   M2_cap_screw, 16, [24,   20  ], 2.4, [[2,2],[38,2],[2,38],[38,38]], 30  , 9.5, 1.5, 1.5, 1.1, 1.5];

vitamins/inserts.scad

@@ -29,7 +29,7 @@
 //                          d         d          h    d    d
 //                                         d
 //
-F1BM2   = [ "F1BM2",    4.0, 3.6, 3.2, 2,   3.0,  1.0, 3.4, 3.1 ];
+F1BM2   = [ "F1BM2",   4.0, 3.6, 3.2, 2,   3.0,  1.0, 3.4, 3.1 ];
 F1BM2p5 = [ "F1BM2p5", 5.8, 4.6, 4.0, 2.5, 3.65, 1.6, 4.4, 3.9 ];
 F1BM3   = [ "F1BM3",   5.8, 4.6, 4.0, 3,   3.65, 1.6, 4.4, 3.9 ];
 F1BM4   = [ "F1BM4",   8.2, 6.3, 5.6, 4,   5.15, 2.3, 6.0, 5.55 ];

vitamins/screw.scad

@@ -19,6 +19,8 @@
 
 //
 //! Machine screws and wood screws with various head styles.
+//!
+//! For an explanation of ```screw_polysink()``` see <https://hydraraptor.blogspot.com/2020/12/sinkholes.html>.
 //
 include <../utils/core/core.scad>
 
@@ -258,7 +260,7 @@ module screw_countersink(type, drilled = true) { //! Countersink shape
     if(head_type == hs_cs || head_type == hs_cs_cap)
         translate_z(-head_height)
             if(drilled)
-                cylinder(h = head_height, r1 = 0, r2 = head_rad + head_t);
+                cylinder(h = head_height + eps, r1 = 0, r2 = head_rad + head_t);
             else
                 intersection() {
                     cylinder(h = head_height + eps, r1 = 0, r2 = head_rad + head_t);
@@ -267,6 +269,37 @@ module screw_countersink(type, drilled = true) { //! Countersink shape
                 }
 }
 
+function screw_polysink_r(type, z) = //! Countersink hole profile corrected for rounded staircase extrusions.
+    let(rad = screw_radius(type),
+        head_t = rad / 5,
+        head_rad = screw_head_radius(type)
+    )
+    limit(head_rad + head_t - z + (sqrt(2) - 1) * layer_height / 2, screw_clearance_radius(type), head_rad);
+
+module screw_polysink(type, h = 100, alt = false) { //! A countersink hole made from stacked polyholes for printed parts
+    head_depth = screw_head_depth(type);
+    assert(head_depth, "Not a countersunk screw");
+    layers = ceil(head_depth / layer_height);
+    rmin = screw_clearance_radius(type);
+    sides = sides(rmin);
+    lh = layer_height + eps;
+    render(convexity = 5)
+        for(side = [0, 1]) mirror([0, 0, side]) {
+            for(i = [0 : layers - 1])
+                translate_z(i * layer_height) {
+                    r = screw_polysink_r(type, i * layer_height + layer_height / 2);
+                    if(alt)
+                        rotate(i % 2 == layers % 2 ? 180 / sides : 0)
+                            poly_cylinder(r = r, h = lh, center = false, sides = sides);
+                    else
+                        poly_cylinder(r = r, h = lh, center = false);
+                }
+
+            translate_z(layers * layer_height)
+                poly_cylinder(r = rmin, h = h / 2 - layers * layer_height, center = false);
+        }
+}
+
 module screw_and_washer(type, length, star = false, penny = false) { //! Screw with a washer which can be standard or penny and an optional star washer on top
     washer = screw_washer(type);
     head_type = screw_head_type(type);

vitamins/screws.scad

@@ -107,14 +107,14 @@ No6_screw        = ["No6", "No6 pan wood",      hs_pan, 3.5, 6.7, 2.2,    0,   0
 No6_cs_screw     = ["No6_cs", "No6 cs wood",    hs_cs,  3.5, 7.0, 0,      0,   0, 0,   M4_washer, false,    No6_pilot_radius, No6_clearance_radius];
 
 screw_lists = [
-[ M2_cap_screw, M2p5_cap_screw, M3_cap_screw,    M4_cap_screw, M5_cap_screw, M6_cap_screw, M8_cap_screw],
+[ M2_cap_screw,    M2p5_cap_screw, M3_cap_screw,    M4_cap_screw, M5_cap_screw, M6_cap_screw, M8_cap_screw],
-[ 0,            0,              M3_low_cap_screw],
+[ 0,               0,              M3_low_cap_screw],
-[ 0,            0,              M3_hex_screw,    M4_hex_screw, M5_hex_screw, M6_hex_screw, M8_hex_screw],
+[ M2_cs_cap_screw, 0,              M3_cs_cap_screw, M4_cs_cap_screw],
-[ 0,            M2p5_pan_screw, M3_pan_screw,    M4_pan_screw, M5_pan_screw, M6_pan_screw, No632_pan_screw],
+[ M2_dome_screw,   0,              M3_dome_screw,   M4_dome_screw],
-[ 0,            No2_screw,      No4_screw,       No6_screw,    No6_cs_screw],
+[ 0,               0,              M3_hex_screw,    M4_hex_screw, M5_hex_screw, M6_hex_screw, M8_hex_screw],
-[ 0,            M2_cs_cap_screw,M3_cs_cap_screw, M4_cs_cap_screw],
+[ 0,               M2p5_pan_screw, M3_pan_screw,    M4_pan_screw, M5_pan_screw, M6_pan_screw, No632_pan_screw],
-[ 0,            M2_dome_screw,  M3_dome_screw,   M4_dome_screw],
+[ No2_screw,       0,              No4_screw,       No6_screw,    No6_cs_screw],
-[ 0,            0,              M3_grub_screw,   M4_grub_screw]
+[ 0,               0,              M3_grub_screw,   M4_grub_screw]
 ];
 
 use <screw.scad>