Files
OpenNest/OpenNest.Core/CNC/CuttingStrategy/ContourCuttingStrategy.cs
T
aj 7127884584 fix(cutting): start tabbed lead-outs at the trimmed cut end
A tab trims the perimeter short of its entry, but the lead-out was still
generated from the nominal entry point. An arc lead-out therefore started
off its own radius (ExecutionMotionReader rejected it as inconsistent), and
a line lead-out ran diagonally back toward the entry.

Every lead-out style on a tabbed perimeter now leaves from the trimmed
cut's actual end, on that entity's normal, so arcs are tangent and the tab
gap stays uncut. Untabbed contours and the corner run-out rules are
unchanged. Malformed legacy output is still refused, never refit.

Red before the fix: the three tabbed arc cases threw "Arc has zero or
inconsistent radius" and the line case ended at y=5 instead of 4.8. Keeping
the entry's normal at the actual end fails the curved-perimeter case.
2026-10-04 23:13:41 -04:00

1026 lines
40 KiB
C#

using System;
using System.Collections.Generic;
using OpenNest.Geometry;
using OpenNest.Math;
namespace OpenNest.CNC.CuttingStrategy
{
public class ContourCuttingStrategy
{
public CuttingParameters Parameters { get; set; }
private record ContourEntry(Shape Shape, Vector Point, Entity Entity);
public CuttingResult Apply(Program partProgram, Vector approachPoint)
{
return Apply(partProgram, approachPoint, Vector.Invalid);
}
public CuttingResult Apply(Program partProgram, Vector approachPoint, Vector nextPartStart)
{
var entities = partProgram.ToGeometry();
entities.RemoveAll(e => e.Layer == SpecialLayers.Rapid);
var scribeEntities = entities.FindAll(e => e.Layer == SpecialLayers.Scribe);
entities.RemoveAll(e => e.Layer == SpecialLayers.Scribe);
var profile = new ShapeProfile(entities);
// Start from the bounding box corner opposite the origin (max X, max Y)
var bbox = entities.GetBoundingBox();
var startCorner = new Vector(bbox.Right, bbox.Top);
// Initial pass: sequence cutouts from bbox corner
var seedPoint = startCorner;
var orderedCutouts = SequenceCutouts(profile.Cutouts, seedPoint);
orderedCutouts.Reverse();
var perimeterSeed = profile.Perimeter.ClosestPointTo(seedPoint, out _);
var cutoutEntries = ResolveLeadInPoints(orderedCutouts, perimeterSeed);
Vector perimeterPt;
Entity perimeterEntity;
if (!double.IsNaN(nextPartStart.X) && cutoutEntries.Count > 0)
{
// Iterate: each pass refines the perimeter lead-in which changes
// the internal sequence which changes the last cutout position
for (var iter = 0; iter < 3; iter++)
{
var lastCutoutPt = cutoutEntries[cutoutEntries.Count - 1].Point;
perimeterSeed = FindPerimeterIntersection(
profile.Perimeter,
lastCutoutPt,
nextPartStart,
out _
);
orderedCutouts = SequenceCutouts(profile.Cutouts, perimeterSeed);
orderedCutouts.Reverse();
cutoutEntries = ResolveLeadInPoints(orderedCutouts, perimeterSeed);
}
var finalLastCutout = cutoutEntries[cutoutEntries.Count - 1].Point;
perimeterPt = FindPerimeterIntersection(
profile.Perimeter,
finalLastCutout,
nextPartStart,
out perimeterEntity
);
}
else
{
var perimeterRef = cutoutEntries.Count > 0 ? cutoutEntries[0].Point : approachPoint;
perimeterPt = profile.Perimeter.ClosestPointTo(perimeterRef, out perimeterEntity);
}
var result = new Program(Mode.Absolute);
EmitScribeContours(result, scribeEntities);
foreach (var entry in cutoutEntries)
{
if (!entry.Shape.IsClosed())
EmitRawContour(result, entry.Shape);
else
EmitContour(result, entry.Shape, entry.Point, entry.Entity);
}
if (!profile.Perimeter.IsClosed())
EmitRawContour(result, profile.Perimeter);
else
EmitContour(
result,
profile.Perimeter,
perimeterPt,
perimeterEntity,
ContourType.External
);
result.Mode = Mode.Incremental;
return new CuttingResult { Program = result, LastCutPoint = perimeterPt };
}
public CuttingResult ApplySingle(
Program partProgram,
Vector point,
Entity entity,
ContourType contourType
)
{
var entities = partProgram.ToGeometry();
entities.RemoveAll(e => e.Layer == SpecialLayers.Rapid);
var scribeEntities = entities.FindAll(e => e.Layer == SpecialLayers.Scribe);
entities.RemoveAll(e => e.Layer == SpecialLayers.Scribe);
var profile = new ShapeProfile(entities);
var result = new Program(Mode.Absolute);
EmitScribeContours(result, scribeEntities);
// Find the target shape that contains the clicked entity
var (targetShape, matchedEntity) = FindTargetShape(profile, point, entity);
// Emit cutouts — only the target gets lead-in/out (skip open contours)
foreach (var cutout in profile.Cutouts)
{
if (!cutout.IsClosed())
{
EmitRawContour(result, cutout);
}
else if (cutout == targetShape)
{
var ct = DetectContourType(cutout);
EmitContour(result, cutout, point, matchedEntity, ct);
}
else
{
EmitRawContour(result, cutout);
}
}
// Emit perimeter
if (!profile.Perimeter.IsClosed())
{
EmitRawContour(result, profile.Perimeter);
}
else if (profile.Perimeter == targetShape)
{
EmitContour(result, profile.Perimeter, point, matchedEntity, ContourType.External);
}
else
{
EmitRawContour(result, profile.Perimeter);
}
result.Mode = Mode.Incremental;
return new CuttingResult { Program = result, LastCutPoint = point };
}
private static (Shape Shape, Entity Entity) FindTargetShape(
ShapeProfile profile,
Vector point,
Entity clickedEntity
)
{
var matched = FindMatchingEntity(profile.Perimeter, clickedEntity);
if (matched != null)
return (profile.Perimeter, matched);
foreach (var cutout in profile.Cutouts)
{
matched = FindMatchingEntity(cutout, clickedEntity);
if (matched != null)
return (cutout, matched);
}
// Fallback: closest shape, use closest point to find entity
var best = profile.Perimeter;
var bestPt = profile.Perimeter.ClosestPointTo(point, out var bestEntity);
var bestDist = bestPt.DistanceTo(point);
foreach (var cutout in profile.Cutouts)
{
var pt = cutout.ClosestPointTo(point, out var cutoutEntity);
var dist = pt.DistanceTo(point);
if (dist < bestDist)
{
best = cutout;
bestEntity = cutoutEntity;
bestDist = dist;
}
}
return (best, bestEntity);
}
private static Entity FindMatchingEntity(Shape shape, Entity clickedEntity)
{
foreach (var shapeEntity in shape.Entities)
{
if (shapeEntity.GetType() != clickedEntity.GetType())
continue;
if (shapeEntity is Line sLine && clickedEntity is Line cLine)
{
if (
sLine.StartPoint.DistanceTo(cLine.StartPoint) < Math.Tolerance.Epsilon
&& sLine.EndPoint.DistanceTo(cLine.EndPoint) < Math.Tolerance.Epsilon
)
return shapeEntity;
}
else if (shapeEntity is Arc sArc && clickedEntity is Arc cArc)
{
if (
System.Math.Abs(sArc.Radius - cArc.Radius) < Math.Tolerance.Epsilon
&& sArc.Center.DistanceTo(cArc.Center) < Math.Tolerance.Epsilon
)
return shapeEntity;
}
else if (shapeEntity is Circle sCircle && clickedEntity is Circle cCircle)
{
if (
System.Math.Abs(sCircle.Radius - cCircle.Radius) < Math.Tolerance.Epsilon
&& sCircle.Center.DistanceTo(cCircle.Center) < Math.Tolerance.Epsilon
)
return shapeEntity;
}
}
return null;
}
internal Program EmitPrepared(Shape[] shapes, List<Entity> scribes,
IReadOnlyList<CuttingPlanning.ContourChoice> choices)
{
var result = new Program(Mode.Absolute);
EmitScribeContours(result, scribes);
foreach (var choice in choices)
{
var shape = shapes[choice.ContourOrdinal];
EmitContour(result, shape, choice.Point, shape.Entities[choice.EntityOrdinal],
choice.ContourOrdinal == shapes.Length - 1 ? ContourType.External : null,
exactCirclePrograms: true);
}
result.Mode = Mode.Incremental;
return result;
}
private void EmitRawContour(Program program, Shape shape)
{
var startPoint = GetShapeStartPoint(shape);
program.Codes.Add(new RapidMove(startPoint));
program.Codes.AddRange(ConvertShapeToMoves(shape, startPoint));
}
private static List<ContourEntry> ResolveLeadInPoints(
List<Shape> cutouts,
Vector startPoint
)
{
var entries = new ContourEntry[cutouts.Count];
var currentPoint = startPoint;
// Walk backward through cutting order (from perimeter outward)
// so each cutout's lead-in point faces the next cutout to be cut
for (var i = cutouts.Count - 1; i >= 0; i--)
{
var closestPt = cutouts[i].ClosestPointTo(currentPoint, out var entity);
entries[i] = new ContourEntry(cutouts[i], closestPt, entity);
currentPoint = closestPt;
}
return new List<ContourEntry>(entries);
}
private static Vector FindPerimeterIntersection(
Shape perimeter,
Vector lastCutout,
Vector nextPartStart,
out Entity entity
)
{
var ray = new Line(lastCutout, nextPartStart);
if (perimeter.Intersects(ray, out var pts) && pts.Count > 0)
{
// Pick the intersection closest to the last cutout
var best = pts[0];
var bestDist = best.DistanceTo(lastCutout);
for (var i = 1; i < pts.Count; i++)
{
var dist = pts[i].DistanceTo(lastCutout);
if (dist < bestDist)
{
best = pts[i];
bestDist = dist;
}
}
return perimeter.ClosestPointTo(best, out entity);
}
// Fallback: closest point on perimeter to the last cutout
return perimeter.ClosestPointTo(lastCutout, out entity);
}
private static int ComputeSubProgramKey(double radius, double normalAngle)
{
var r = System.Math.Round(radius, 6);
var a = System.Math.Round(normalAngle, 6);
return HashCode.Combine(r, a);
}
// Prepared emission compares the actual resolved, generated motions, not a
// rounded geometry hash. Labels are deterministic encounter-order identifiers;
// legacy Apply/ApplySingle retain their existing cache and labels unchanged.
private static int RegisterPreparedCircleProgram(Program owner, Program generated)
{
CuttingPlanning.ExecutionMotionReader.ReadSupported(generated, Vector.Zero, null);
if (generated.Variables.Count != 0 || generated.SubPrograms.Count != 0)
throw new NotSupportedException("Unsupported generated circle program metadata.");
foreach (var code in generated.Codes)
if (code is not (RapidMove or LinearMove or ArcMove) || ((Motion)code).VariableRefs != null)
throw new NotSupportedException("Unsupported generated circle instruction.");
foreach (var pair in owner.SubPrograms)
if (SameGeneratedCircleProgram(pair.Value, generated))
return pair.Key;
var key = checked(owner.SubPrograms.Count + 1);
owner.SubPrograms.Add(key, generated);
return key;
}
private static bool SameGeneratedCircleProgram(Program a, Program b)
{
if (a.Mode != b.Mode || !SameBits(a.Rotation, b.Rotation) || a.Codes.Count != b.Codes.Count)
return false;
for (var i = 0; i < a.Codes.Count; i++)
{
var left = (Motion)a.Codes[i];
var right = (Motion)b.Codes[i];
if (left.GetType() != right.GetType() || left.Suppressed != right.Suppressed
|| left.UseExactStop != right.UseExactStop || left.Feedrate != right.Feedrate
|| !SameVector(left.EndPoint, right.EndPoint))
return false;
if (left is LinearMove line && line.Layer != ((LinearMove)right).Layer)
return false;
if (left is ArcMove arc && (arc.Layer != ((ArcMove)right).Layer
|| arc.Rotation != ((ArcMove)right).Rotation
|| !SameVector(arc.CenterPoint, ((ArcMove)right).CenterPoint)))
return false;
}
return true;
}
private static bool SameVector(Vector a, Vector b) => SameBits(a.X, b.X) && SameBits(a.Y, b.Y);
private static bool SameBits(double a, double b) => BitConverter.DoubleToInt64Bits(a) == BitConverter.DoubleToInt64Bits(b);
private void EmitContour(
Program program,
Shape shape,
Vector point,
Entity entity,
ContourType? forceType = null,
bool exactCirclePrograms = false
)
{
var contourType = forceType ?? DetectContourType(shape);
var winding = DetermineWinding(shape);
var normal = ComputeNormal(point, entity, contourType, winding);
var leadIn = SelectLeadIn(contourType);
var leadOut = SelectLeadOut(contourType);
if (contourType == ContourType.ArcCircle && entity is Circle circle)
{
if (Parameters.RoundLeadInAngles && Parameters.LeadInAngleIncrement > 0)
{
var increment = Angle.ToRadians(Parameters.LeadInAngleIncrement);
normal = System.Math.Round(normal / increment) * increment;
normal = Angle.NormalizeRad(normal);
var outwardAngle = normal - System.Math.PI;
point = new Vector(
circle.Center.X + circle.Radius * System.Math.Cos(outwardAngle),
circle.Center.Y + circle.Radius * System.Math.Sin(outwardAngle)
);
}
leadIn = ClampLeadInForCircle(leadIn, circle, point, normal);
// Build hole sub-program relative to (0,0)
var holeCenter = circle.Center;
var relativePoint = new Vector(point.X - holeCenter.X, point.Y - holeCenter.Y);
var relativeCircle = new Circle(new Vector(0, 0), circle.Radius)
{
Rotation = circle.Rotation,
};
var relativeShape = new Shape();
relativeShape.Entities.Add(relativeCircle);
var subPgm = new Program(Mode.Absolute);
subPgm.Codes.AddRange(leadIn.Generate(relativePoint, normal, winding));
var reindexed = relativeShape.ReindexAt(relativePoint, relativeCircle);
subPgm.Codes.AddRange(ConvertShapeToMoves(reindexed, relativePoint));
subPgm.Codes.AddRange(leadOut.Generate(relativePoint, normal, winding));
subPgm.Mode = Mode.Incremental;
// Deduplicate: check if an identical sub-program already exists
var key = exactCirclePrograms
? RegisterPreparedCircleProgram(program, subPgm)
: ComputeSubProgramKey(circle.Radius, normal);
if (!program.SubPrograms.ContainsKey(key))
program.SubPrograms[key] = subPgm;
program.Codes.Add(
new SubProgramCall
{
Id = key,
Program = program.SubPrograms[key],
Offset = holeCenter,
}
);
return;
}
leadIn = ResolveLeadIn(shape, point, entity, contourType, leadIn, winding,
Parameters.PierceClearance, out var leadInNormal);
program.Codes.AddRange(leadIn.Generate(point, leadInNormal, winding));
var reindexedShape = shape.ReindexAt(point, entity);
var tabbed = Parameters.TabsEnabled
&& Parameters.TabConfig != null
&& contourType == ContourType.External;
// A tab leaves the contour short of the corner; a run-out through it would cut the tab.
var leadOutPoint = point;
var leadOutNormal = normal;
if (tabbed)
{
reindexedShape = TrimShapeForTab(reindexedShape, point, Parameters.TabConfig.Size);
// Leave from where the trimmed cut actually ends, on that entity's normal:
// an arc generated at the nominal entry would not start on its own radius.
if (reindexedShape.Entities.Count > 0 && reindexedShape.Entities[^1] is Line or Arc)
{
var last = reindexedShape.Entities[^1];
leadOutPoint = EntityEndPoint(last);
leadOutNormal = ComputeNormal(leadOutPoint, last, contourType, winding);
}
}
else
{
leadOut = ResolveLeadOut(shape, point, entity, contourType, leadOut, winding,
Parameters.PierceClearance, out leadOutNormal);
}
program.Codes.AddRange(ConvertShapeToMoves(reindexedShape, point));
program.Codes.AddRange(leadOut.Generate(leadOutPoint, leadOutNormal, winding));
}
private void EmitScribeContours(Program program, List<Entity> scribeEntities)
{
if (scribeEntities.Count == 0)
return;
var shapes = ShapeBuilder.GetShapes(scribeEntities);
foreach (var shape in shapes)
{
var startPt = GetShapeStartPoint(shape);
program.Codes.Add(new RapidMove(startPt));
program.Codes.AddRange(ConvertShapeToMoves(shape, startPt, LayerType.Scribe));
}
}
private List<Shape> SequenceCutouts(List<Shape> cutouts, Vector startPoint)
{
var remaining = new List<Shape>(cutouts);
var ordered = new List<Shape>();
var currentPoint = startPoint;
while (remaining.Count > 0)
{
var nearest = remaining[0];
var nearestPt = nearest.ClosestPointTo(currentPoint);
var nearestDist = nearestPt.DistanceTo(currentPoint);
for (var i = 1; i < remaining.Count; i++)
{
var pt = remaining[i].ClosestPointTo(currentPoint);
var dist = pt.DistanceTo(currentPoint);
if (dist < nearestDist)
{
nearest = remaining[i];
nearestPt = pt;
nearestDist = dist;
}
}
ordered.Add(nearest);
remaining.Remove(nearest);
currentPoint = nearestPt;
}
return ordered;
}
public static ContourType DetectContourType(Shape cutout)
{
if (cutout.Entities.Count == 1 && cutout.Entities[0] is Circle)
return ContourType.ArcCircle;
return ContourType.Internal;
}
/// <summary>
/// Uses the inward angle bisector for straight lead-ins at cutout corners.
/// Edge interiors and other lead-in styles keep the entity normal. Shared
/// by program generation and the manual placement preview.
/// </summary>
public static double ComputeLeadInNormal(
Shape shape,
Vector point,
Entity entity,
ContourType contourType,
LeadIn leadIn,
RotationType winding = RotationType.CW
)
{
var normal = ComputeNormal(point, entity, contourType, winding);
if (contourType != ContourType.Internal || leadIn is not LineLeadIn
|| !TryGetCorner(shape, point, entity, out var corner))
return normal;
return BisectCorner(point, corner, contourType, winding) ?? normal;
}
/// <summary>
/// Returns the lead-in to emit at <paramref name="point"/> and the normal to
/// generate it with. At a corner of an outside perimeter, a straight
/// (<see cref="LineLeadIn"/>) lead-in extends the edge cut first so the torch
/// enters on that edge's line, provided the pierce keeps
/// <paramref name="pierceClearance"/> from the contour; the approach angle is
/// ignored there. Otherwise it is perpendicular to the edge cut first, and at a
/// reflex corner it bisects the notch. The result does not depend on which of
/// the two edges meeting at the corner was picked. Other styles and contour
/// types keep <see cref="ComputeLeadInNormal"/>.
/// </summary>
public static LeadIn ResolveLeadIn(
Shape shape,
Vector point,
Entity entity,
ContourType contourType,
LeadIn leadIn,
RotationType winding,
double pierceClearance,
out double normal
)
{
normal = ComputeLeadInNormal(shape, point, entity, contourType, leadIn, winding);
if (contourType != ContourType.External || leadIn is not LineLeadIn line
|| !TryGetCorner(shape, point, entity, out var corner))
return leadIn;
switch (ClassifyCorner(corner, winding))
{
case CornerKind.Convex:
var pierce = point - corner.TangentOut * line.Length;
if (IsClearStraightLead(shape, point, pierce, pierceClearance))
{
normal = Angle.NormalizeRad((-corner.TangentOut).Angle());
return new LineLeadIn { Length = line.Length, ApproachAngle = 90 };
}
normal = ComputeNormal(point, corner.Outgoing, contourType, winding);
return leadIn;
case CornerKind.Smooth:
normal = ComputeNormal(point, corner.Outgoing, contourType, winding);
return leadIn;
case CornerKind.Reflex:
normal = BisectCorner(point, corner, contourType, winding) ?? normal;
return leadIn;
default:
return leadIn;
}
}
/// <summary>
/// Lead-out counterpart of <see cref="ResolveLeadIn"/>. At a convex outside
/// perimeter corner a <see cref="LineLeadOut"/> runs straight on past the corner
/// along the edge cut last, when its end keeps <paramref name="clearance"/> from
/// the contour; otherwise it is perpendicular to that edge. At a reflex corner it
/// bisects the notch. Other styles and contour types keep the entity normal.
/// </summary>
public static LeadOut ResolveLeadOut(
Shape shape,
Vector point,
Entity entity,
ContourType contourType,
LeadOut leadOut,
RotationType winding,
double clearance,
out double normal
)
{
normal = ComputeNormal(point, entity, contourType, winding);
if (contourType != ContourType.External || leadOut is not LineLeadOut line
|| !TryGetCorner(shape, point, entity, out var corner))
return leadOut;
switch (ClassifyCorner(corner, winding))
{
case CornerKind.Convex:
var end = point + corner.TangentIn * line.Length;
if (IsClearStraightLead(shape, point, end, clearance))
{
normal = Angle.NormalizeRad(corner.TangentIn.Angle());
return new LineLeadOut { Length = line.Length, ApproachAngle = 90 };
}
normal = ComputeNormal(point, corner.Incoming, contourType, winding);
return leadOut;
case CornerKind.Smooth:
normal = ComputeNormal(point, corner.Incoming, contourType, winding);
return leadOut;
case CornerKind.Reflex:
normal = BisectCorner(point, corner, contourType, winding) ?? normal;
return leadOut;
default:
return leadOut;
}
}
private enum CornerKind
{
Convex,
Reflex,
Smooth,
Cusp,
}
/// <summary>A contour vertex: the entity cut into it and the one cut away from it.</summary>
private readonly record struct ContourCorner(
Entity Incoming,
Entity Outgoing,
Vector TangentIn,
Vector TangentOut
);
private static bool TryGetCorner(Shape shape, Vector point, Entity entity, out ContourCorner corner)
{
corner = default;
if (entity is not (Line or Arc) || entity.Length <= Tolerance.Epsilon
|| shape.Entities.Count < 2 || !shape.IsClosed())
return false;
var index = shape.Entities.IndexOf(entity);
if (index < 0)
return false;
var atStart = point.DistanceTo(EntityStartPoint(entity)) <= Tolerance.Epsilon;
if (!atStart && point.DistanceTo(EntityEndPoint(entity)) > Tolerance.Epsilon)
return false;
var adjacentIndex = atStart
? (index + shape.Entities.Count - 1) % shape.Entities.Count
: (index + 1) % shape.Entities.Count;
var adjacent = shape.Entities[adjacentIndex];
var adjacentPoint = atStart ? EntityEndPoint(adjacent) : EntityStartPoint(adjacent);
if (adjacent is not (Line or Arc) || adjacent.Length <= Tolerance.Epsilon
|| point.DistanceTo(adjacentPoint) > Tolerance.Epsilon)
return false;
var incoming = atStart ? adjacent : entity;
var outgoing = atStart ? entity : adjacent;
var tangentIn = TravelTangent(incoming, point);
var tangentOut = TravelTangent(outgoing, point);
if (!IsFinite(tangentIn) || !IsFinite(tangentOut))
return false;
corner = new ContourCorner(incoming, outgoing, tangentIn, tangentOut);
return true;
}
/// <summary>Unit direction of travel along a line or arc at a point on it.</summary>
private static Vector TravelTangent(Entity entity, Vector point)
{
if (entity is Line line)
return (line.EndPoint - line.StartPoint).Normalize();
var arc = (Arc)entity;
var radial = (point - arc.Center).Normalize();
return arc.IsReversed ? new Vector(radial.Y, -radial.X) : new Vector(-radial.Y, radial.X);
}
private static bool IsFinite(Vector v) => double.IsFinite(v.X) && double.IsFinite(v.Y);
/// <summary>
/// Convex corners point away from the part (interior angle under 180 degrees).
/// A turn whose offset over the tangent is within chaining tolerance is smooth,
/// not a corner.
/// </summary>
private static CornerKind ClassifyCorner(ContourCorner corner, RotationType winding)
{
var cross = corner.TangentIn.X * corner.TangentOut.Y - corner.TangentIn.Y * corner.TangentOut.X;
var dot = corner.TangentIn.DotProduct(corner.TangentOut);
var turn = winding == RotationType.CCW ? cross : -cross;
if (System.Math.Abs(turn) <= Tolerance.Epsilon)
return dot > 0 ? CornerKind.Smooth : CornerKind.Cusp;
return turn > 0 ? CornerKind.Convex : CornerKind.Reflex;
}
private static double? BisectCorner(
Vector point,
ContourCorner corner,
ContourType contourType,
RotationType winding
)
{
var normal = ComputeNormal(point, corner.Outgoing, contourType, winding);
var adjacentNormal = ComputeNormal(point, corner.Incoming, contourType, winding);
// Sum unit normals rather than averaging angles (which fails at 0/2π).
// Winding makes this point into the scrap even at reflex corners.
var x = System.Math.Cos(normal) + System.Math.Cos(adjacentNormal);
var y = System.Math.Sin(normal) + System.Math.Sin(adjacentNormal);
if (!double.IsFinite(x) || !double.IsFinite(y)
|| x * x + y * y <= Tolerance.Epsilon * Tolerance.Epsilon)
return null; // Opposing normals at a cusp have no unique bisector.
return Angle.NormalizeRad(System.Math.Atan2(y, x));
}
/// <summary>
/// A straight lead from <paramref name="end"/> to the corner stays in the scrap:
/// its free end keeps <paramref name="clearance"/> from the contour and the lead
/// crosses the contour nowhere but at the corner.
/// </summary>
private static bool IsClearStraightLead(Shape shape, Vector corner, Vector end, double clearance)
{
if (!IsFinite(end) || end.DistanceTo(corner) <= Tolerance.Epsilon)
return false;
var nearest = shape.ClosestPointTo(end, out _);
if (nearest.DistanceTo(end) < System.Math.Max(clearance, 0) - Tolerance.Epsilon)
return false;
if (shape.Intersects(new Line(end, corner), out var crossings))
{
foreach (var crossing in crossings)
{
if (crossing.DistanceTo(corner) > Tolerance.ChainTolerance)
return false;
}
}
return true;
}
private static Vector EntityEndPoint(Entity entity)
{
if (entity is Line line)
return line.EndPoint;
if (entity is Arc arc)
return arc.EndPoint();
return Vector.Invalid;
}
public static double ComputeNormal(
Vector point,
Entity entity,
ContourType contourType,
RotationType winding = RotationType.CW
)
{
double normal;
if (entity is Line line)
{
// Perpendicular to line direction: tangent + π/2 = left side.
// Left side = outward for CW winding; for CCW winding, outward
// is on the right side, so flip.
var tangent = line.EndPoint.AngleFrom(line.StartPoint);
normal = tangent + Math.Angle.HalfPI;
if (winding == RotationType.CCW)
normal += System.Math.PI;
}
else if (entity is Arc arc)
{
// Radial direction from center to point.
// Flip when the arc direction differs from the contour winding —
// that indicates a concave feature where radial points inward.
normal = point.AngleFrom(arc.Center);
if (arc.Rotation != winding)
normal += System.Math.PI;
}
else if (entity is Circle circle)
{
// Radial outward — always correct regardless of winding
normal = point.AngleFrom(circle.Center);
}
else
{
normal = 0;
}
// For internal contours, flip the normal (point into scrap)
if (contourType == ContourType.Internal || contourType == ContourType.ArcCircle)
normal += System.Math.PI;
return Math.Angle.NormalizeRad(normal);
}
public static RotationType DetermineWinding(Shape shape)
{
if (shape.Entities.Count == 1 && shape.Entities[0] is Circle circle)
return circle.Rotation;
var polygon = shape.ToPolygon();
if (polygon.Vertices.Count < 3)
return RotationType.CCW;
return polygon.RotationDirection();
}
private LeadIn ClampLeadInForCircle(
LeadIn leadIn,
Circle circle,
Vector contourPoint,
double normalAngle
)
{
if (leadIn is NoLeadIn || Parameters.PierceClearance <= 0)
return leadIn;
var piercePoint = leadIn.GetPiercePoint(contourPoint, normalAngle);
var maxRadius = circle.Radius - Parameters.PierceClearance;
if (maxRadius <= 0)
return leadIn;
var distFromCenter = piercePoint.DistanceTo(circle.Center);
if (distFromCenter <= maxRadius)
return leadIn;
// Compute max distance from contourPoint toward piercePoint that stays
// inside a circle of radius maxRadius centered at circle.Center.
// Solve: |contourPoint + t*d - center|^2 = maxRadius^2
var currentDist = contourPoint.DistanceTo(piercePoint);
if (currentDist < Math.Tolerance.Epsilon)
return leadIn;
var dx = (piercePoint.X - contourPoint.X) / currentDist;
var dy = (piercePoint.Y - contourPoint.Y) / currentDist;
var vx = contourPoint.X - circle.Center.X;
var vy = contourPoint.Y - circle.Center.Y;
var b = 2.0 * (vx * dx + vy * dy);
var c = vx * vx + vy * vy - maxRadius * maxRadius;
var discriminant = b * b - 4.0 * c;
if (discriminant < 0)
return leadIn;
var t = (-b + System.Math.Sqrt(discriminant)) / 2.0;
if (t <= 0)
return leadIn;
var scale = t / currentDist;
if (scale >= 1.0)
return leadIn;
return leadIn.Scale(scale);
}
private LeadIn SelectLeadIn(ContourType contourType)
{
return contourType switch
{
ContourType.ArcCircle => Parameters.ArcCircleLeadIn ?? Parameters.InternalLeadIn,
ContourType.Internal => Parameters.InternalLeadIn,
_ => Parameters.ExternalLeadIn,
};
}
private LeadOut SelectLeadOut(ContourType contourType)
{
return contourType switch
{
ContourType.ArcCircle => Parameters.ArcCircleLeadOut ?? Parameters.InternalLeadOut,
ContourType.Internal => Parameters.InternalLeadOut,
_ => Parameters.ExternalLeadOut,
};
}
private static Shape TrimShapeForTab(Shape shape, Vector center, double tabSize)
{
var tabCircle = new Circle(center, tabSize);
var entities = new List<Entity>(shape.Entities);
// Trim end: walk backward removing entities inside the tab circle
while (entities.Count > 0)
{
var entity = entities[entities.Count - 1];
if (entity.Intersects(tabCircle, out var pts) && pts.Count > 0)
{
// Find intersection furthest from center (furthest along path from end)
var best = pts[0];
var bestDist = best.DistanceTo(center);
for (var j = 1; j < pts.Count; j++)
{
var dist = pts[j].DistanceTo(center);
if (dist > bestDist)
{
best = pts[j];
bestDist = dist;
}
}
if (entity is Line line)
{
var (first, _) = line.SplitAt(best);
entities.RemoveAt(entities.Count - 1);
if (first != null)
entities.Add(first);
}
else if (entity is Arc arc)
{
var (first, _) = arc.SplitAt(best);
entities.RemoveAt(entities.Count - 1);
if (first != null)
entities.Add(first);
}
break;
}
// No intersection — entity is entirely inside circle, remove it
if (EntityStartPoint(entity).DistanceTo(center) <= tabSize + Tolerance.Epsilon)
{
entities.RemoveAt(entities.Count - 1);
continue;
}
break;
}
var result = new Shape();
result.Entities.AddRange(entities);
return result;
}
private static Vector EntityStartPoint(Entity entity)
{
if (entity is Line line)
return line.StartPoint;
if (entity is Arc arc)
return arc.StartPoint();
return Vector.Zero;
}
private List<ICode> ConvertShapeToMoves(
Shape shape,
Vector startPoint,
LayerType layer = LayerType.Display
)
{
var moves = new List<ICode>();
foreach (var entity in shape.Entities)
{
if (entity is Line line)
{
moves.Add(new LinearMove(line.EndPoint) { Layer = layer });
}
else if (entity is Arc arc)
{
moves.Add(
new ArcMove(
arc.EndPoint(),
arc.Center,
arc.IsReversed ? RotationType.CW : RotationType.CCW
)
{
Layer = layer,
}
);
}
else if (entity is Circle circle)
{
moves.Add(
new ArcMove(startPoint, circle.Center, circle.Rotation) { Layer = layer }
);
}
else
{
throw new System.InvalidOperationException(
$"Unsupported entity type: {entity.Type}"
);
}
}
return moves;
}
private static Vector GetShapeStartPoint(Shape shape)
{
var first = shape.Entities[0];
if (first is Line line)
return line.StartPoint;
if (first is Arc arc)
return arc.StartPoint();
if (first is Circle circle)
return new Vector(circle.Center.X + circle.Radius, circle.Center.Y);
return Vector.Zero;
}
}
}