Counterbore/countersink samples

public/kcl-samples/car-wheel-assembly/car-wheel.kcl

@@ -13,13 +13,13 @@ lugBase = startSketchOn(XZ)
   |> subtract2d(tool = circle(center = [0, 0], radius = (lugSpacing - 1.5) / 2))
   |> extrude(length = wheelWidth / 20)
 
-// Extend the wheel center and bore holes to accomidate the lug heads
+// Extend the wheel center and bore holes to accommodate the lug heads
 lugExtrusion = startSketchOn(lugBase, face = END)
   |> circle(center = [0, 0], radius = (lugSpacing + 1.5) / 2)
   |> subtract2d(tool = circle(center = [0, 0], radius = (lugSpacing - 1.5) / 2))
   |> extrude(length = wheelWidth / 10)
 
-// Create the circular pattern for the lugs
+// Counterbore a hole for each lug, then circular pattern the counterbore to each lug position
 lugClearance = startSketchOn(lugExtrusion, face = END)
   |> circle(center = [lugSpacing / 2, 0], radius = 1.2 / 2)
   |> patternCircular2d(
@@ -30,7 +30,7 @@ lugClearance = startSketchOn(lugExtrusion, face = END)
      )
   |> extrude(length = -wheelWidth / 10)
 
-// Create the circular pattern for the lug holes
+// Add a through hole in the counterbore for each lug
 lugHoles = startSketchOn(lugBase, face = END)
   |> circle(center = [lugSpacing / 2, 0], radius = 16mm / 2)
   |> patternCircular2d(
@@ -65,12 +65,11 @@ wheelCenterOuter = startSketchOn(XY)
 
 // Write a function that defines the spoke geometry, patterns and extrudes it
 fn spoke(spokeGap, spokeAngle, spokeThickness) {
-  // Seperating the spoke base planes
+  // Separating the spoke base planes
   plane001 = {
     origin = [0.0, 0.0, spokeGap / 2],
     xAxis = [1.0, 0.0, spokeAngle],
-    yAxis = [0.0, 1.0, 0.0],
-    zAxis = [0.0, 0.0, 1.0]
+    yAxis = [0.0, 1.0, 0.0]
   }
 
   // Spoke cross sections

public/kcl-samples/counterdrilled-weldment/main.kcl

@@ -0,0 +1,120 @@
+// Counterdrilled Weldment
+// A metal weldment consisting of a counterdrilled plate, a centrally mounted housing tube, and four structural support fins.
+
+// Set units
+@settings(defaultLengthUnit = in)
+
+// Define parameters
+boltSpacingX = 5
+boltSpacingY = 3
+boltDiameter = 1 / 4
+counterdrillDiameter = 7 / 16
+counterdrillDepth = 3 / 16
+tubeInnerDiameter = 1 + 1 / 4
+tubeThickness = 0.115
+tubeHeight = 2
+stockThickness = .5
+
+// Calculate the dimensions of the block using the specified bolt spacing. The size of the block can be defined by adding a multiple of the counterdrill diameter to the bolt spacing
+blockLength = boltSpacingX + boltDiameter * 6
+blockWidth = boltSpacingY + boltDiameter * 6
+
+// Draw the base plate
+plateSketch = startSketchOn(XY)
+  |> startProfile(at = [-blockLength / 2, -blockWidth / 2])
+  |> angledLine(angle = 0, length = blockLength, tag = $rectangleSegmentA001)
+  |> angledLine(angle = segAng(rectangleSegmentA001) + 90, length = blockWidth, tag = $rectangleSegmentB001)
+  |> angledLine(angle = segAng(rectangleSegmentA001), length = -segLen(rectangleSegmentA001), tag = $rectangleSegmentC001)
+  |> line(endAbsolute = [profileStartX(%), profileStartY(%)], tag = $rectangleSegmentD001)
+  |> close()
+  |> subtract2d(tool = circle(center = [0, 0], radius = tubeInnerDiameter / 2))
+plateBody = extrude(plateSketch, length = stockThickness)
+  |> chamfer(
+       length = boltDiameter * 2,
+       tags = [
+         getNextAdjacentEdge(rectangleSegmentB001),
+         getNextAdjacentEdge(rectangleSegmentA001),
+         getNextAdjacentEdge(rectangleSegmentC001),
+         getNextAdjacentEdge(rectangleSegmentD001)
+       ],
+     )
+
+// Define hole positions
+holePositions = [
+  [-boltSpacingX / 2, -boltSpacingY / 2],
+  [-boltSpacingX / 2, boltSpacingY / 2],
+  [boltSpacingX / 2, -boltSpacingY / 2],
+  [boltSpacingX / 2, boltSpacingY / 2]
+]
+
+// Function to create a counterdrilled hole
+fn counterdrill(holePosition) {
+  cbdrill = startSketchOn(plateBody, face = END)
+    |> circle(center = holePosition, radius = counterdrillDiameter / 2)
+    |> extrude(length = -counterdrillDepth)
+  cbBolt = startSketchOn(cbdrill, face = START)
+    |> circle(center = holePosition, radius = boltDiameter / 2, tag = $hole01)
+    |> extrude(length = -stockThickness + counterdrillDepth)
+    // Use a chamfer to create a 90-degree counterdrill edge
+    |> chamfer(length = (counterdrillDiameter - boltDiameter) / 2 * sqrt(2), tags = [hole01])
+  return {  }
+}
+
+// Place a counterdrilled hole at each bolt hole position
+map(holePositions, f = counterdrill)
+
+// Drill a small pin hole in the side of the tube
+pinhole = startSketchOn(YZ)
+  |> circle(center = [0, 2.2], radius = 0.125)
+  |> extrude(length = -10)
+
+// Model the central tube and subtract the pin hole
+centralTube = startSketchOn(offsetPlane(XY, offset = stockThickness))
+  |> circle(center = [0, 0], radius = tubeInnerDiameter / 2 + tubeThickness)
+  |> subtract2d(tool = circle(center = [0, 0], radius = tubeInnerDiameter / 2))
+  |> extrude(length = tubeHeight)
+  |> subtract(tools = [pinhole])
+
+// Create a function to create a fin which spans from the central tube to the bolt hole
+fn fin(i) {
+  diagPlane = {
+    origin = [0.0, 0.0, 0.0],
+    xAxis = [
+      boltSpacingX / 2 * i,
+      boltSpacingY / 2,
+      0.0
+    ],
+    yAxis = [0.0, 0.0, 1.0]
+  }
+
+  finSketch = startSketchOn(diagPlane)
+    |> startProfile(at = [
+         tubeInnerDiameter / 2 + tubeThickness,
+         stockThickness
+       ])
+    |> xLine(endAbsolute = sqrt((boltSpacingX / 2) ^ 2 + (boltSpacingY / 2) ^ 2) - counterdrillDiameter)
+    |> yLine(length = 0.15)
+    |> line(endAbsolute = [
+         profileStartX(%) + 0.15,
+         stockThickness + tubeHeight * .8
+       ])
+    |> xLine(length = -0.15)
+    |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
+    |> close()
+    |> extrude(length = tubeThickness, symmetric = true)
+
+  // Use a circular pattern to create an identical fin on the opposite side
+  otherFin = patternCircular3d(
+    finSketch,
+    instances = 2,
+    axis = [0, 0, 1],
+    center = [0, 0, 0],
+    arcDegrees = 360,
+    rotateDuplicates = true,
+  )
+  return {  }
+}
+
+// Place a pair of support fins along each diagonal axis of the bolt pattern
+fin(1)
+fin(-1)

public/kcl-samples/countersunk-plate/main.kcl

@@ -0,0 +1,50 @@
+// Plate with countersunk holes
+// A small mounting plate with a countersunk hole at each end
+
+// Set units
+@settings(defaultLengthUnit = in)
+
+// Define parameters
+boltSpacing = 5
+boltDiameter = 1 / 4
+centerHoleDiameter = 1 + 3 / 4
+plateThickness = 0.375
+
+// Check that the plate is thick enough to countersink a hole
+//assertGreaterThan(plateThickness, boltDiameter, "This plate is not thick enough for the necessary countersink dimensions")
+
+// A bit of math to calculate the tangent line between the two diameters
+r1 = centerHoleDiameter / 2 * 1.5 + .35
+r2 = boltDiameter * 2 + .25
+d = boltSpacing / 2
+tangentAngle = (asin((r1 - r2) / d))
+tangentLength = (r1 - r2) / tan((tangentAngle))
+
+plateBody = startSketchOn(XY)
+  // Use polar coordinates to start the sketch at the tangent point of the larger radius
+  |> startProfile(at = polar(angle = 90 - tangentAngle, length = r1))
+  |> angledLine(angle = -tangentAngle, length = tangentLength)
+  |> tangentialArc(radius = r2, angle = (tangentAngle - 90) * 2)
+  |> angledLine(angle = tangentAngle, length = -tangentLength)
+  |> tangentialArc(radius = r1, angle = -tangentAngle * 2)
+  |> angledLine(angle = -tangentAngle, length = -tangentLength)
+  |> tangentialArc(radius = r2, angle = (tangentAngle - 90) * 2)
+  |> angledLine(angle = tangentAngle, length = tangentLength)
+  |> tangentialArc(endAbsolute = [profileStartX(%), profileStartY(%)])
+  |> close()
+  |> subtract2d(tool = circle(center = [0, 0], radius = centerHoleDiameter / 2 * 1.5))
+  |> extrude(%, length = plateThickness)
+
+// Function to create a countersunk hole
+fn countersink(holePosition) {
+  startSketchOn(plateBody, face = END)
+    |> circle(center = [holePosition, 0], radius = boltDiameter / 2, tag = $hole01)
+    |> extrude(length = -plateThickness)
+    // Use a chamfer to create a 90-degree countersink
+    |> chamfer(length = boltDiameter, tags = [hole01])
+  return {  }
+}
+
+// Place a countersunk hole at each bolt hole position
+countersink(-boltSpacing / 2)
+countersink(boltSpacing / 2)

public/kcl-samples/axial-fan/fan-housing.kcl → public/kcl-samples/cpu-cooler/fan-housing.kcl

@@ -9,7 +9,7 @@ import * from "parameters.kcl"
 
 // Model the housing which holds the motor, the fan, and the mounting provisions
 // Bottom mounting face
-bottomFaceSketch = startSketchOn(XY)
+bottomFaceSketch = startSketchOn(YZ)
   |> startProfile(at = [-fanSize / 2, -fanSize / 2])
   |> angledLine(angle = 0, length = fanSize, tag = $rectangleSegmentA001)
   |> angledLine(angle = segAng(rectangleSegmentA001) + 90, length = fanSize, tag = $rectangleSegmentB001)
@@ -150,4 +150,4 @@ startSketchOn(motorHousing, face = END)
          getNextAdjacentEdge(rectangleSegmentC002),
          getNextAdjacentEdge(rectangleSegmentD002)
        ],
-     )
+     )

public/kcl-samples/axial-fan/fan.kcl → public/kcl-samples/cpu-cooler/fan.kcl

@@ -8,33 +8,25 @@
 import * from "parameters.kcl"
 
 // Model the center of the fan
-fanCenter = startSketchOn(XZ)
-  |> startProfile(at = [-0.0001, fanHeight])
-  |> xLine(endAbsolute = -15 + 1.5)
-  |> tangentialArc(radius = 1.5, angle = 90)
-  |> yLine(endAbsolute = 4.5)
-  |> xLine(endAbsolute = -13)
-  |> yLine(endAbsolute = profileStartY(%) - 5)
-  |> tangentialArc(radius = 1, angle = -90)
-  |> xLine(endAbsolute = -1)
-  |> yLine(length = 2)
-  |> xLine(length = -0.15)
-  |> line(endAbsolute = [
-       profileStartX(%) - 1,
-       profileStartY(%) - 1.4
-     ])
-  |> xLine(endAbsolute = profileStartX(%))
-  |> yLine(endAbsolute = profileStartY(%))
+fanCenter = startSketchOn(XY)
+  |> startProfile(at = [fanHeight, -0.0001])
+  |> yLine(endAbsolute = -15 + 1.5)
+  |> tangentialArc(radius = 1.5, angle = -90)
+  |> xLine(endAbsolute = 4.5)
+  |> yLine(endAbsolute = -13)
+  |> xLine(endAbsolute = profileStartX(%) - 5)
+  |> tangentialArc(radius = 1, angle = 90)
+  |> yLine(endAbsolute = -1)
+  |> xLine(length = 2)
   |> close()
   |> revolve(axis = {
-       direction = [0.0, 1.0],
+       direction = [1.0, 0.0],
        origin = [0.0, 0.0]
      })
-  |> appearance(color = "#f3e2d8")
 
 // Create a function for a lofted fan blade cross section that rotates about the center hub of the fan
-fn fanBlade(offsetHeight, startAngle: number(deg)) {
-  fanBlade = startSketchOn(offsetPlane(XY, offset = offsetHeight))
+fn fanBlade(offsetHeight, startAngle) {
+  fanBlade = startSketchOn(offsetPlane(YZ, offset = offsetHeight))
     |> startProfile(at = [
          15 * cos(startAngle),
          15 * sin(startAngle)
@@ -72,17 +64,19 @@ fn fanBlade(offsetHeight, startAngle: number(deg)) {
 }
 
 // Loft the fan blade cross sections into a single blade, then pattern them about the fan center
-loft([
-       fanBlade(4.5, 50),
-       fanBlade((fanHeight - 2 - 4) / 2, 30),
-       fanBlade(fanHeight - 2, 0)
+fanBlades = loft([
+       fanBlade(4.5, 50deg),
+       fanBlade((fanHeight - 2 - 4) / 2, 30deg),
+       fanBlade(fanHeight - 2, 0deg)
      ])
   |> appearance(color = "#f3e2d8")
   |> patternCircular3d(
        %,
        instances = 9,
-       axis = [0, 0, 1],
+       axis = [1, 0, 0],
        center = [0, 0, 0],
        arcDegrees = 360,
        rotateDuplicates = true,
      )
+[fanCenter, fanBlades]
+  |> appearance(color = "#110803")