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increase tolerance on helical shapes to avoid crash / broken geometry (#17356)

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* increase tolerance on helical shapes to avoid crash

fix #17113
fix #9377
fix #11083

* added test cases for additive and subtractive helix

* fixed whitespace issue, reduced turncount for speed

* relaxed large scale testcases for OCCT 7.3 and below, work around windows CI error #17394

* Further reduce max size in test for buggy Ubuntu OCCT
This commit is contained in:
Eric Price
2024-11-11 17:44:27 +01:00
committed by GitHub
parent 0e25675aeb
commit 7680872e41
4 changed files with 162 additions and 1 deletions
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2
src/Mod/Part/App/TopoShape.cpp
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@@ -2333,7 +2333,7 @@ TopoDS_Shape TopoShape::makeSpiralHelix(Standard_Real radiusbottom, Standard_Rea
}
TopoDS_Wire wire = mkWire.Wire();
BRepLib::BuildCurves3d(wire, Precision::Confusion(), GeomAbs_Shape::GeomAbs_C1, 14, 10000);
BRepLib::BuildCurves3d(wire, Precision::Confusion() * 1e-6 * (radiusbottom+radiustop), GeomAbs_Shape::GeomAbs_C1, 14, 10000); // precision must be reduced for very large parts to avoid #17113
return TopoDS_Shape(std::move(wire));
}

18
src/Mod/PartDesign/App/FeatureHelix.cpp
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@@ -34,6 +34,7 @@
# include <BRepOffsetAPI_MakePipe.hxx>
# include <BRepOffsetAPI_MakePipeShell.hxx>
# include <BRepPrimAPI_MakeRevol.hxx>
# include <ShapeFix_ShapeTolerance.hxx>
# include <Precision.hxx>
# include <TopoDS.hxx>
# include <TopoDS_Face.hxx>
@@ -61,6 +62,7 @@ PROPERTY_SOURCE(PartDesign::Helix, PartDesign::ProfileBased)
// we purposely use not FLT_MAX because this would not be computable
const App::PropertyFloatConstraint::Constraints Helix::floatTurns = { Precision::Confusion(), INT_MAX, 1.0 };
const App::PropertyFloatConstraint::Constraints Helix::floatTolerance = { 0.1, INT_MAX, 1.0 };
const App::PropertyAngle::Constraints Helix::floatAngle = { -89.0, 89.0, 1.0 };
Helix::Helix()
@@ -104,6 +106,9 @@ Helix::Helix()
ADD_PROPERTY_TYPE(HasBeenEdited, (false), group, App::Prop_Hidden,
QT_TRANSLATE_NOOP("App::Property", "If false, the tool will propose an initial value for the pitch based on the profile bounding box,\n"
"so that self intersection is avoided."));
ADD_PROPERTY_TYPE(Tolerance, (0.1), group, App::Prop_None,
QT_TRANSLATE_NOOP("App::Property", "Fusion Tolerance for the Helix, increase if helical shape does not merge nicely with part."));
Tolerance.setConstraints(&floatTolerance);
setReadWriteStatusForMode(initialMode);
}
@@ -229,6 +234,17 @@ App::DocumentObjectExecReturn* Helix::execute()
TopoDS_Shape face = sketchshape;
face.Move(invObjLoc);
Bnd_Box bounds;
BRepBndLib::Add(path, bounds);
double size=sqrt(bounds.SquareExtent());
ShapeFix_ShapeTolerance fix;
fix.LimitTolerance(path, Precision::Confusion() * 1e-6 * size ); // needed to produce valid Pipe for very big parts
// We introduce final part tolerance with the second call to LimitTolerance below, however
// OCCT has a bug where the side-walls of the Pipe disappear with very large (km range) pieces
// increasing a tiny bit of extra tolerance to the path fixes this. This will in any case
// be less than the tolerance lower limit below, but sufficient to avoid the bug
BRepOffsetAPI_MakePipe mkPS(TopoDS::Wire(path), face, GeomFill_Trihedron::GeomFill_IsFrenet, Standard_False);
result = mkPS.Shape();
@@ -237,6 +253,8 @@ App::DocumentObjectExecReturn* Helix::execute()
if (SC.State() == TopAbs_IN) {
result.Reverse();
}
fix.LimitTolerance(result, Precision::Confusion() * size * Tolerance.getValue() ); // significant precision reduction due to helical approximation - needed to allow fusion to succeed
AddSubShape.setValue(result);

2
src/Mod/PartDesign/App/FeatureHelix.h
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@@ -56,6 +56,7 @@ public:
App::PropertyEnumeration Mode;
App::PropertyBool Outside;
App::PropertyBool HasBeenEdited;
App::PropertyFloatConstraint Tolerance;
/** if this property is set to a valid link, both Axis and Base properties
* are calculated according to the linked line
@@ -95,6 +96,7 @@ protected:
static const App::PropertyFloatConstraint::Constraints floatTurns;
static const App::PropertyAngle::Constraints floatAngle;
static const App::PropertyFloatConstraint::Constraints floatTolerance;
private:
static const char* ModeEnums[];

141
src/Mod/PartDesign/PartDesignTests/TestHelix.py
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@@ -129,6 +129,147 @@ class TestHelix(unittest.TestCase):
expected = pi * 25 * 5 * 3
self.assertAlmostEqual(helix.Shape.Volume, expected, places=2)
def testGiantHelix(self):
""" Test giant helix """
_OCC_VERSION=[ int(v) for v in Part.OCC_VERSION.split('.') ]
if _OCC_VERSION[0]>7 or (_OCC_VERSION[0]==7 and _OCC_VERSION[1]>3):
mine=-1
maxe=10
else:
mine=-1
maxe=9
for iexponent in range(mine,maxe):
exponent = float(iexponent)
body = self.Doc.addObject('PartDesign::Body','GearBody')
gearSketch = self.Doc.addObject('Sketcher::SketchObject', 'GearSketch')
body.addObject(gearSketch)
TestSketcherApp.CreateRectangleSketch(gearSketch, (10*(10**exponent), 0), (1*(10**exponent), 1*(10**exponent)))
xz_plane = body.Origin.OriginFeatures[4]
gearSketch.AttachmentSupport = xz_plane
gearSketch.MapMode = 'FlatFace'
self.Doc.recompute()
helix = self.Doc.addObject("PartDesign::AdditiveHelix","AdditiveHelix")
body.addObject(helix)
helix.Profile = gearSketch
helix.ReferenceAxis = (gearSketch,"V_Axis")
helix.Placement = FreeCAD.Placement(FreeCAD.Vector(0,0,0), FreeCAD.Rotation(FreeCAD.Vector(0,0,1),0), FreeCAD.Vector(0,0,0))
helix.Pitch = 2*(10**exponent)
helix.Turns = 2
helix.Height = helix.Turns* helix.Pitch
helix.Angle = 0
helix.Mode = 0
self.Doc.recompute()
self.assertTrue(helix.Shape.isValid())
bbox = helix.Shape.BoundBox
self.assertAlmostEqual(bbox.ZMin/((10**exponent)**3),0,places=4)
# Computed exact value
# with r = radius, l = length of square, t = turns
# pi * r**2 * l * t
expected = pi * ( ((11*(10**exponent))**2) - ((10*(10**exponent))**2) ) * 1*(10**exponent) * helix.Turns
self.assertAlmostEqual(helix.Shape.Volume/ ((10**exponent)**3),expected/ ((10**exponent)**3),places=2)
def testGiantHelixAdditive(self):
""" Test giant helix added to Cylinder """
_OCC_VERSION=[ int(v) for v in Part.OCC_VERSION.split('.') ]
if _OCC_VERSION[0]>7 or (_OCC_VERSION[0]==7 and _OCC_VERSION[1]>3):
mine=-1
maxe=8
else:
mine=-1
maxe=6
for iexponent in range(mine,maxe):
exponent = float(iexponent)
body = self.Doc.addObject('PartDesign::Body','GearBody')
gearSketch = self.Doc.addObject('Sketcher::SketchObject', 'GearSketch')
body.addObject(gearSketch)
TestSketcherApp.CreateRectangleSketch(gearSketch, (10*(10**exponent), 0), (1*(10**exponent), 1*(10**exponent)))
xz_plane = body.Origin.OriginFeatures[4]
gearSketch.AttachmentSupport = xz_plane
gearSketch.MapMode = 'FlatFace'
self.Doc.recompute()
cylinder = self.Doc.addObject('PartDesign::AdditiveCylinder','Cylinder')
cylinder.Radius = 10*(10**exponent)
cylinder.Height = 8*(10**exponent)
cylinder.Angle = 360
body.addObject(cylinder)
self.Doc.recompute()
helix = self.Doc.addObject("PartDesign::AdditiveHelix","AdditiveHelix")
body.addObject(helix)
helix.Profile = gearSketch
helix.ReferenceAxis = (gearSketch,"V_Axis")
helix.Placement = FreeCAD.Placement(FreeCAD.Vector(0,0,0), FreeCAD.Rotation(FreeCAD.Vector(0,0,1),0), FreeCAD.Vector(0,0,0))
helix.Pitch = 2*(10**exponent)
helix.Turns = 2.5 # workaround for OCCT bug with very large helices - full turns truncate the cylinder due to seam alignment
helix.Height = helix.Turns* helix.Pitch
helix.Angle = 0
helix.Mode = 0
self.Doc.recompute()
self.assertTrue(helix.Shape.isValid())
bbox = helix.Shape.BoundBox
self.assertAlmostEqual(bbox.ZMin/((10**exponent)**3),0,places=4)
# Computed exact value
# with r = radius, l = length of square, t = turns
# pi * r**2 * l * t
cyl = pi * ((10*(10**exponent))**2) * 8*(10**exponent)
expected = cyl + (pi * ( ((11*(10**exponent))**2) - ((10*(10**exponent))**2) ) * 1*(10**exponent) * helix.Turns )
self.assertAlmostEqual(helix.Shape.Volume/ ((10**exponent)**3),expected/ ((10**exponent)**3),places=2)
def testGiantHelixSubtractive(self):
""" Test giant helix subtracted from Cylinder """
_OCC_VERSION=[ int(v) for v in Part.OCC_VERSION.split('.') ]
if _OCC_VERSION[0]>7 or (_OCC_VERSION[0]==7 and _OCC_VERSION[1]>3):
mine=-1
maxe=8
else:
mine=-1
maxe=6
for iexponent in range(mine,maxe):
exponent = float(iexponent)
body = self.Doc.addObject('PartDesign::Body','GearBody')
gearSketch = self.Doc.addObject('Sketcher::SketchObject', 'GearSketch')
body.addObject(gearSketch)
TestSketcherApp.CreateRectangleSketch(gearSketch, (10*(10**exponent), 0), (1*(10**exponent), 1*(10**exponent)))
xz_plane = body.Origin.OriginFeatures[4]
gearSketch.AttachmentSupport = xz_plane
gearSketch.MapMode = 'FlatFace'
self.Doc.recompute()
cylinder = self.Doc.addObject('PartDesign::AdditiveCylinder','Cylinder')
cylinder.Radius = 11*(10**exponent)
cylinder.Height = 8*(10**exponent)
cylinder.Angle = 360
body.addObject(cylinder)
self.Doc.recompute()
helix = self.Doc.addObject("PartDesign::SubtractiveHelix","SubtractiveHelix")
body.addObject(helix)
helix.Profile = gearSketch
helix.ReferenceAxis = (gearSketch,"V_Axis")
helix.Placement = FreeCAD.Placement(FreeCAD.Vector(0,0,0), FreeCAD.Rotation(FreeCAD.Vector(0,0,1),0), FreeCAD.Vector(0,0,0))
helix.Pitch = 2*(10**exponent)
helix.Turns = 2.5 # workaround for OCCT bug with very large helices - full turns truncate the cylinder due to seam alignment
helix.Height = helix.Turns* helix.Pitch
helix.Angle = 0
helix.Mode = 0
self.Doc.recompute()
self.assertTrue(helix.Shape.isValid())
bbox = helix.Shape.BoundBox
self.assertAlmostEqual(bbox.ZMin/((10**exponent)**3),0,places=4)
# Computed exact value
# with r = radius, l = length of square, t = turns
# pi * r**2 * l * t
cyl = pi * ((11*(10**exponent))**2) * 8*(10**exponent)
expected = cyl - (pi * ( ((11*(10**exponent))**2) - ((10*(10**exponent))**2) ) * 1*(10**exponent) * helix.Turns )
self.assertAlmostEqual(helix.Shape.Volume/ ((10**exponent)**3),expected/ ((10**exponent)**3),places=2)
def testCone(self):
""" Test helix following a cone """