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2026-07-22 13:48:46 +08:00
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+"""Modeled bolts, threaded fasteners, and joint bushings for Example 18."""
+
+from __future__ import annotations
+
+import simplecadapi as scad
+
+from leg_common import make_part_with_connectors_rpart
+from leg_dimensions import KNEE_AXIS
+
+
+def make_socket_head_screw_rpart(
+    *,
+    part_id: str,
+    shank_radius: float,
+    shank_length: float,
+    head_radius: float,
+    head_height: float,
+    material: scad.Material,
+) -> scad.Part:
+    """Create a socket-head screw with its seat plane at local Z=0."""
+
+    shank = scad.make_cylinder_rsolid(
+        radius=shank_radius,
+        height=shank_length,
+        bottom_face_center=(0.0, 0.0, -head_height - shank_length),
+        axis=(0.0, 0.0, 1.0),
+    )
+    head = scad.make_cylinder_rsolid(
+        radius=head_radius,
+        height=head_height,
+        bottom_face_center=(0.0, 0.0, -head_height),
+        axis=(0.0, 0.0, 1.0),
+    )
+    screw = scad.union_rsolid(shank, head, glue=False)
+    screw = scad.apply_tag(shape=screw, tag="role.socket_head_screw")
+    return make_part_with_connectors_rpart(
+        part_id=part_id,
+        body=screw,
+        name=f"Socket-head screw {shank_radius * 2.0:.1f} x {shank_length:.1f} mm",
+        material=material,
+        connectors=(("head_top_axis", (0.0, 0.0, 0.0), "z", "Flush screw head top plane"),),
+    )
+
+
+def make_clamp_bolt_stack_rpart(*, material: scad.Material) -> scad.Part:
+    """Create an M4 bolt plus flange-nut stack for a split collar."""
+
+    shank_length = 12.2
+    shank = scad.make_cylinder_rsolid(
+        radius=2.0,
+        height=shank_length,
+        bottom_face_center=(0.0, 0.0, -shank_length),
+        axis=(0.0, 0.0, 1.0),
+    )
+    head = scad.make_cylinder_rsolid(
+        radius=3.6,
+        height=3.2,
+        bottom_face_center=(0.0, 0.0, -0.05),
+        axis=(0.0, 0.0, 1.0),
+    )
+    nut = scad.make_cylinder_rsolid(
+        radius=3.8,
+        height=3.2,
+        bottom_face_center=(0.0, 0.0, -shank_length - 3.15),
+        axis=(0.0, 0.0, 1.0),
+    )
+    stack = scad.union_rsolid(shank, head, nut, glue=False)
+    stack = scad.apply_tag(shape=stack, tag="role.clamp_bolt_and_nut")
+    return make_part_with_connectors_rpart(
+        part_id="m4_split_clamp_bolt_stack",
+        body=stack,
+        name="M4 split-clamp socket bolt and flange nut",
+        material=material,
+        connectors=(("seat_axis", (0.0, 0.0, 0.0), "z", "Clamp bolt head seat"),),
+    )
+
+
+def make_knee_bushing_rpart(*, material: scad.Material) -> scad.Part:
+    """Create a continuous bronze knee sleeve and axial spacer."""
+
+    outer = scad.make_cylinder_rsolid(
+        radius=5.95,
+        height=13.0,
+        bottom_face_center=(KNEE_AXIS[0], KNEE_AXIS[1], 0.0),
+        axis=(0.0, 0.0, 1.0),
+    )
+    bore = scad.make_cylinder_rsolid(
+        radius=3.2,
+        height=15.0,
+        bottom_face_center=(KNEE_AXIS[0], KNEE_AXIS[1], -1.0),
+        axis=(0.0, 0.0, 1.0),
+    )
+    sleeve = scad.cut_rsolid(outer, bore, skip_non_intersecting=False)
+    sleeve = scad.apply_tag(shape=sleeve, tag="role.knee_bearing_bushing")
+    return make_part_with_connectors_rpart(
+        part_id="knee_bronze_bushing",
+        body=sleeve,
+        name="12 mm OD bronze knee bushing and spacer",
+        material=material,
+        connectors=(
+            ("knee_axis", (KNEE_AXIS[0], KNEE_AXIS[1], 6.5), "z", "Knee revolute axis"),
+            ("bolt_head_top_axis", (KNEE_AXIS[0], KNEE_AXIS[1], 16.0), "z", "Shoulder bolt head top plane"),
+        ),
+    )
+
+
+def make_knee_shoulder_bolt_stack_rpart(*, material: scad.Material) -> scad.Part:
+    """Create the knee shoulder axle, socket head, and retained nut."""
+
+    shaft = scad.make_cylinder_rsolid(
+        radius=3.0,
+        height=13.0,
+        bottom_face_center=(KNEE_AXIS[0], KNEE_AXIS[1], 0.0),
+        axis=(0.0, 0.0, 1.0),
+    )
+    head = scad.make_cylinder_rsolid(
+        radius=5.5,
+        height=3.0,
+        bottom_face_center=(KNEE_AXIS[0], KNEE_AXIS[1], 13.0),
+        axis=(0.0, 0.0, 1.0),
+    )
+    nut = scad.make_cylinder_rsolid(
+        radius=5.5,
+        height=4.0,
+        bottom_face_center=(KNEE_AXIS[0], KNEE_AXIS[1], -4.0),
+        axis=(0.0, 0.0, 1.0),
+    )
+    axle = scad.union_rsolid(shaft, head, nut, glue=False)
+    axle = scad.apply_tag(shape=axle, tag="role.knee_shoulder_axle")
+    return make_part_with_connectors_rpart(
+        part_id="knee_shoulder_bolt_stack",
+        body=axle,
+        name="M6 knee shoulder axle with socket head and retained nut",
+        material=material,
+        connectors=(("knee_axis", (KNEE_AXIS[0], KNEE_AXIS[1], 6.5), "z", "Knee axle axis"),),
+    )
+def make_linkage_pin_stack_rpart(*, material: scad.Material) -> scad.Part:
+    """Create a retained M4 shoulder pin spanning crank, gap, and pushrod."""
+
+    span = 9.3
+    shaft = scad.make_cylinder_rsolid(
+        radius=2.0,
+        height=span,
+        bottom_face_center=(0.0, 0.0, -span / 2.0),
+        axis=(0.0, 0.0, 1.0),
+    )
+    retainers = [
+        scad.make_cylinder_rsolid(
+            radius=3.5,
+            height=1.2,
+            bottom_face_center=(0.0, 0.0, sign * span / 2.0 - (1.2 if sign < 0.0 else 0.0)),
+            axis=(0.0, 0.0, 1.0),
+        )
+        for sign in (-1.0, 1.0)
+    ]
+    pin = scad.union_rsolid(shaft, retainers, glue=False)
+    pin = scad.apply_tag(shape=pin, tag="role.retained_linkage_pin")
+    return make_part_with_connectors_rpart(
+        part_id="m4_linkage_shoulder_pin_stack",
+        body=pin,
+        name="M4 retained linkage shoulder pin",
+        material=material,
+        connectors=(("pin_axis", (0.0, 0.0, 0.0), "z", "Linkage pin axis"),),
+    )