Add gcode generation script

For generating gcode to cut rings and bulkheads with a cnc router

Signed-off-by: Mike Beattie <mike@ethernal.org>

3 files changed, 395 insertions, 0 deletions

diff --git a/gcode/.gitignore b/gcode/.gitignore
new file mode 100644
index 0000000..d6f32f8
--- /dev/null
+++ b/gcode/.gitignore
@@ -0,0 +1,2 @@
+*.pyc
+mjbl3*
diff --git a/gcode/rings.py b/gcode/rings.py
new file mode 100755
index 0000000..2a9abe0
--- /dev/null
+++ b/gcode/rings.py
@@ -0,0 +1,200 @@
+#! /usr/bin/python
+# Copyright 2008 by Bdale Garbee <bdale@gag.com>.  GPLv2
+# Copyright 2011 by Anthony Towns <aj@erisian.com.au>. GPLv2
+
+import math
+from rocket_gcode import *
+
+Zfree = 0.2500          # height in Z to clear all obstructions
+Speed = 10              # cutting speed
+
+MMT_OD      = mm2inch(79.3)
+Coupler_ID  = 3.74
+Airframe_ID = 3.90
+Nose_ID     = 3.75
+
+FinCount = 3
+FinWidth = mm2inch(6.25) # Actually 6.85, but allowance for wandering bit.
+
+
+### AFT CR - Aeropack holes and fin slots - 1/8" bit
+CutterOD = 0.125           # 1/8"
+gcode = Gcode(output=open("mjbl3_cr_aft-aeropack.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+RingThickness = 0.75
+RingID = MMT_OD
+RingOD = Airframe_ID
+AeropackRotation = 15  # Get the holes out of alignment with fin slots.
+AeropackDepth    = 0.8 # Go right through the bulkhead
+AeropackStep     = 0.2 # cut in 0.2 inch increments
+FinDepth     = RingThickness/2
+FinIncrement = 0.1
+
+gcode.comment("Aeropack retainer holes, depth %s" % (AeropackDepth,))
+gcode.aeropack_75mm(AeropackRotation, AeropackDepth, AeropackStep)
+
+gcode.comment("Fin slots, depth %1.3f in %1.1f increments" % (FinDepth, FinIncrement))
+gcode.fin_slots(FinCount, RingID, RingOD, FinWidth, FinDepth, FinIncrement)
+
+gcode.close()
+
+### AFT CR - MMT/Airframe cuts - 1/4" bit.
+CutterOD = 0.25           # 1/4" 
+gcode = Gcode(output=open("mjbl3_cr_aft-rings.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+RingID = MMT_OD
+RingOD = Airframe_ID
+
+for Zthrough in (0.25, 0.5, 0.8):
+    gcode.Zdepth = Zthrough
+    gcode.comment("MMT hole depth %s" % (Zthrough,))
+    gcode.circle(RingID - CutterOD)
+
+for Zthrough in (0.25, 0.5, 0.8):
+    gcode.Zdepth = Zthrough
+    gcode.comment("ring outer diameter")
+    gcode.circle(RingOD + CutterOD)
+
+gcode.close()
+
+### FORWARD FIN CR - fin slots
+CutterOD = 0.125           # 1/8"
+gcode = Gcode(output=open("mjbl3_cr_finfwd-slots.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+RingThickness = 0.75
+RingID = MMT_OD
+RingOD = Airframe_ID
+FinDepth     = RingThickness/2
+FinIncrement = 0.1
+
+gcode.fin_slots(FinCount, RingID, RingOD, FinWidth, FinDepth, FinIncrement)
+
+gcode.close()
+
+### AFT CR - MMT/Airframe cuts - 1/4" bit.
+CutterOD = 0.25           # 1/4" 
+gcode = Gcode(output=open("mjbl3_cr_finfwd-rings.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+RingID = MMT_OD
+RingOD = Airframe_ID
+
+for Zthrough in (0.25, 0.5, 0.8):
+    gcode.Zdepth = Zthrough
+    gcode.comment("MMT hole depth %s" % (Zthrough,))
+    gcode.circle(RingID - CutterOD)
+
+for Zthrough in (0.25, 0.5, 0.8):
+    gcode.Zdepth = Zthrough
+    gcode.comment("ring outer diameter")
+    gcode.circle(RingOD + CutterOD)
+
+gcode.close()
+
+### ZIPPERLESS FORWARD CR
+CutterOD = 0.25           # 1/4" 
+gcode = Gcode(output=open("mjbl3_cr_zipperless.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+RingID = MMT_OD
+RingOD = Coupler_ID
+
+for Zthrough in (0.25, 0.6):
+    gcode.Zdepth = Zthrough
+    gcode.comment("Zipperless CR, MMT diam")
+    gcode.circle(RingID - CutterOD)
+
+for Zthrough in (0.25, 0.6):
+    gcode.Zdepth = Zthrough
+    gcode.comment("Zipperless CR, coupler diam")
+    gcode.circle(RingOD + CutterOD)
+
+gcode.close()
+
+### EBAY BULKHEAD HOLES
+CutterOD = 0.125          # 1/8" 
+gcode = Gcode(output=open("mjbl3_bh_ebay-holes1.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+Allthread_width = 2.50
+
+gcode.hole(x=0, y= (Allthread_width/2), depth=0.6, increment=0.3, speed=25)
+gcode.hole(x=0, y=-(Allthread_width/2), depth=0.6, increment=0.3, speed=25)
+
+gcode.close()
+
+CutterOD = 0.25           # 1/4" 
+gcode = Gcode(output=open("mjbl3_bh_ebay-holes2.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+UBolt_width     = 0.945
+
+gcode.hole(x= (UBolt_width/2), y=0, depth=0.6, increment=0.3, speed=25)
+gcode.hole(x=-(UBolt_width/2), y=0, depth=0.6, increment=0.3, speed=25)
+
+gcode.close()
+
+### EBAY BULKHEADS
+CutterOD = 0.25           # 1/4" 
+gcode = Gcode(output=open("mjbl3_bh_ebay.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+BulkheadOD      = Airframe_ID
+StepOD          = Coupler_ID
+
+gcode.Zdepth = 0.25
+gcode.comment("ebay bulkhead - step, coupler diameter")
+gcode.circle(StepOD + CutterOD)
+
+for Zthrough in (0.25, 0.6):
+    gcode.Zdepth = Zthrough
+    gcode.comment("ebay bulkhead - outer diameter")
+    gcode.circle(BulkheadOD + CutterOD)
+
+gcode.close()
+
+### Nosecone bulkhead
+CutterOD = 0.25           # 1/4" 
+gcode = Gcode(output=open("mjbl3_bh_nose.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+BulkheadOD    = Nose_ID
+HatchOD       = 2.0
+HatchFlangeOD = 2.5
+
+for Zthrough in (0.25, 0.6):
+    gcode.Zdepth = Zthrough
+    gcode.comment("Nose bulkhead, hatch.")
+    gcode.circle(HatchOD - CutterOD)
+
+gcode.Zdepth = 0.25
+gcode.comment("Nose bulkhead, hatch flange")
+gcode.circle(HatchFlangeOD - CutterOD)
+
+for Zthrough in (0.25, 0.6):
+    gcode.Zdepth = Zthrough
+    gcode.comment("Nose bulkhead - outer diameter")
+    gcode.circle(BulkheadOD + CutterOD)
+
+gcode.close()
+
+### Nosecone bulkhead - hatch slot
+CutterOD = 0.125           # 1/8" 
+gcode = Gcode(output=open("mjbl3_bh_nose-hatch-slot.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+gcode.slot(startX=0, startY=0.75, stopX=0, stopY=-0.75, width=0.180, depth=0.6, increment=0.1)
+
+gcode.close()
+
+### Nosecone bulkhead - hatch
+CutterOD = 0.25           # 1/4" 
+gcode = Gcode(output=open("mjbl3_bh_nose-hatch.ngc","w"), speed=Speed, free=Zfree, cutter=CutterOD)
+
+HatchOD       = 2.0
+HatchFlangeOD = 2.5
+
+gcode.Zdepth = 0.25
+gcode.comment("Nose bulkhead, hatch")
+gcode.circle(HatchOD + CutterOD)
+
+for Zthrough in (0.25, 0.6):
+    gcode.Zdepth = Zthrough
+    gcode.comment("Nose bulkhead, hatch flange.")
+    gcode.circle(HatchFlangeOD + CutterOD)
+
+gcode.close()
+
diff --git a/gcode/rocket_gcode.py b/gcode/rocket_gcode.py
new file mode 100644
index 0000000..21da27e
--- /dev/null
+++ b/gcode/rocket_gcode.py
@@ -0,0 +1,193 @@
+#! /usr/bin/python
+# Copyright 2008 by Bdale Garbee <bdale@gag.com>.  GPLv2
+# Copyright 2011 by Anthony Towns <aj@erisian.com.au>. GPLv2
+
+# This is a Python library to emit g-code to cut motor mount centering
+# rings or bulkheads for a model rocket.
+#
+# Z reference plane is top surface of stock, X/Y origin is center of ring
+
+import math
+import sys
+
+def mm2inch(mm):
+    return mm/25.4
+
+def polar2xy(radius, degrees = None, radians = None):
+    if degrees is not None:
+        radians = degrees / 180.0 * math.pi
+    x = radius * math.cos(radians)
+    y = radius * math.sin(radians)
+    return x,y
+
+class Gcode(object):
+    def __init__(self,
+                 free, cutter, speed = 8,
+                 output = sys.stdout):
+        self.Zfree = free
+        self.Zdepth = 0.0
+        self.Speed = speed
+        self.CutterOD = cutter
+        self.output = output
+
+        self.write("%")
+        self.write("G17 G20 G90")
+        self.write("M3 S5000")
+
+        self.origin()
+
+    def comment(self, comment):
+        self.output.write("\n(%s)\n" % (comment))
+
+    def close(self):
+        self.write("M5 M2")
+        self.write("%")
+        self.output.close()
+
+    def write(self, gcode):
+        self.output.write(gcode + "\n")
+
+    def plunge(self):
+        self.write("(plunge)")
+        self.write("G01 Z %.4f F%d" % (-self.Zdepth, int(self.Speed/2)))
+
+    def retract(self):
+        self.write("(retract)")
+        self.write("G00 Z %.4f" % (self.Zfree))
+
+    def origin(self):
+        self.retract()
+        self.write("(origin)")
+        self.write("G00 X0 Y0")
+
+    def hole(self, x, y, depth, increment, speed):
+        self.write("G00 X %6.4f Y %6.4f" % (x, y))
+        self.write("G83 Z %6.4f R %.4f Q %6.4f F %d" % (-depth, self.Zfree, increment, speed))
+
+    def circle(self, diameter, x=0, y=0):
+        radius = diameter/2.0
+        self.write("G00 X %6.4f Y %6.4f" % (x, y + radius))
+        self.plunge()
+        self.write("G02 X %6.4f Y %6.4f I %6.4f J %6.4f F%d" % (
+            x, y - radius, 0, -radius, self.Speed))
+        self.write("G02 X %6.4f Y %6.4f I %6.4f J %6.4f F%d" % (
+            x, y + radius, 0, +radius, self.Speed))
+        self.retract()
+
+    def slot(self, startX, startY, stopX, stopY, width, depth, increment):
+        deltaX = stopX - startX
+        deltaY = stopY - startY
+        length = (deltaX**2 + deltaY**2)**0.5
+        offX = -deltaY / length  # unit vector, 90 degrees to slot
+        offY = deltaX / length 
+
+        width += 0.0
+        if increment > depth:
+            self.Zdepth = depth
+        else:
+	    self.Zdepth = increment
+
+        while self.Zdepth <= depth:
+            if width < self.CutterOD:
+                self.comment("***desired slot width smaller than cutter***")
+                runs = 1
+                step = 0
+            elif width == self.CutterOD:
+                runs = 1
+                step = 0
+            else:
+                runs = int(math.ceil((width)/self.CutterOD))
+                beginX = startX + offX * (width-self.CutterOD)/2
+                beginY = startY + offY * (width-self.CutterOD)/2
+                endX   = stopX  + offX * (width-self.CutterOD)/2
+                endY   = stopY  + offY * (width-self.CutterOD)/2
+                step = (width-self.CutterOD)/(runs-1)
+
+            self.write("G00 X%6.4f Y%6.4f" % (beginX, beginY))
+
+            self.plunge()
+            for n in range(runs-1):
+                self.write("G01 X%6.4f Y%6.4f F%d" % (endX, endY, self.Speed))
+                beginX, endX = endX - offX * step, beginX - offX * step
+                beginY, endY = endY - offY * step, beginY - offY * step
+                self.write("G01 X%6.4f Y%6.4f F%d" % (beginX, beginY, self.Speed))
+
+            self.write("G01 X%6.4f Y%6.4f F%d" % (endX, endY, self.Speed))
+
+            self.retract()
+
+            if self.Zdepth == depth:
+                break
+            self.Zdepth += increment
+            if self.Zdepth > depth:
+                self.Zdepth = depth
+
+
+    def fin_slots(self, FinCount, innerD, outerD, width, depth, increment = 0.1, rotate = 0):
+        for fin in range(FinCount):
+            self.comment("fin slot %d" % (fin))
+
+            FinDegrees = 90 + rotate + 360.0 / FinCount * fin
+            while FinDegrees > 360: FinDegrees -= 360
+            # angle from origin (on y-axis)
+
+            FinSlotInX, FinSlotInY = polar2xy((innerD/2.0)-self.CutterOD, 
+                                              degrees=FinDegrees)
+            FinSlotOutX, FinSlotOutY = polar2xy((outerD/2.0)+self.CutterOD, 
+                                              degrees=FinDegrees)
+    
+            self.slot(FinSlotInX, FinSlotInY, FinSlotOutX, FinSlotOutY, width, depth, increment)
+
+    def ring_cluster(self, count, diam, sep = 1.0, rotation = 0, dist = None):
+        base_dist = diam/2.0 / math.sin(math.pi/count)
+        if (dist is not None):
+            sep = dist / base_dist
+
+        for cluster in range(count):
+            self.comment("cluster MMT hole %d" % (cluster))
+
+            degrees = rotation + cluster*360.0/count
+            while degrees > 360: degrees -= 360
+
+            ClusX, ClusY = polar2xy(base_dist * sep, degrees=degrees)
+            self.circle(diam - self.CutterOD, x=ClusX, y=ClusY)
+
+    def aeropack(self, count, hole_radius, rotation, depth, increment, speed):
+        for h in range(count):
+            self.comment("Aeropack screw hole %d" % (h))
+
+            degrees = rotation + h*360.0/count
+            while degrees > 360: degrees -= 360
+
+            HoleX, HoleY = polar2xy(hole_radius, degrees=degrees)
+            self.hole(x=HoleX, y=HoleY, depth=depth, increment=increment, speed=speed)
+
+    def aeropack_54mm(self, rotation = 15, depth = 0.125, increment = 0.125, speed = 25):
+	self.aeropack(12, mm2inch(46), rotation, depth, increment, speed)
+
+    def aeropack_75mm(self, rotation = 15, depth = 0.125, increment = 0.125, speed = 25):
+	self.aeropack(12, mm2inch(46), rotation, depth, increment, speed)
+
+    def aeropack_98mm(self, rotation = 15, depth = 0.125, increment = 0.125, speed = 25):
+	self.aeropack(12, mm2inch(46), rotation, depth, increment, speed)
+
+
+    def dsub(self, x, y, rotation = 0):
+        # 9pin dsub female
+        # 1mm deep frame, 30mm long by 12mm wide
+
+        old_depth = self.Zdepth
+        self.Zdepth = mm2inch(1)
+        dX, dY = polar2xy(mm2inch(15), degrees = rotation)
+        self.slot(x-dX, y-dY, x+dX, y+dY, mm2inch(12))
+
+        #    need approx 1cm of depth for connector + room for wires
+        #    so that's basically all the way through...
+        #    connector is barely 1mm (maybe 0.5mm?) on sides
+        #    connector is 6mm from either edge on longer side
+        #    connector is 8mm from either edge on shorter side
+
+        self.Zdepth = old_depth
+        dX, dY = polar2xy(mm2inch(9), degrees = rotation)
+        self.slot(x-dX, y-dY, x+dX, y+dY, mm2inch(10))
+