CascadeStudio_3D_Manual

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// test
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function lever(r1, r2, d, h, t)
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{
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//  This function creates a lever between two bearings, 
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//  the axles of the bearings are aligned
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//  r1 = radius larger bearing
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//  r2 = radois smaller bearing
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//  d  = distance between two bearings
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//  h  = height or width of the lever
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//  t  = wallthickness around bearing and cutout
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    let sinus_a = (r1 - r2) / d ;
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    let a = Math.asin(sinus_a);
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    // points of outer contour of the lever
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    let p1 = [r1 * Math.sin(a), r1 * Math.cos(a)];
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    let p2 = [d + r2 * Math.sin(a), r2 * Math.cos(a)];
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    let p3 = [d + r2, 0];
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    let p4 = [d + r2 * Math.sin(a), - r2 * Math.cos(a)];
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    let p5 = [r1 * Math.sin(a), - r1 * Math.cos(a)];
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    let p6 = [- r1, 0 ];
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    // points of cutout of the lever (not used as cutout became too small)
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    let c1 = [(r1-t) * Math.sin(a), (r1-t) * Math.cos(a)];
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    let c2 = [d + (r2-t) * Math.sin(a), (r2-t) * Math.cos(a)]; ;
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    let c3 = [d - r2 + t , 0];
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    let c4 = [d + (r2-t) * Math.sin(a), - (r2-t) * Math.cos(a)]; 
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    let c5 = [(r1-t) * Math.sin(a), - (r1-t) * Math.cos(a)];
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    let c6 = [r1-t,0]; 
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    let sketchLever = new Sketch(p1).
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                    LineTo(p2).
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                    ArcTo(p3,p4).
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                    LineTo(p5).
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                    ArcTo(p6,p1).
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                    End(false).Face(true);
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    let leverbody = Extrude(sketchLever,[0,0,h]);
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    let big_hole = Cylinder((r1-t), 2* (h + 10), true);
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    let small_hole =  Translate([d, 0,0 ], Cylinder((r2-t), 2* (h + 10), true));
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    let rough_lever = Difference(leverbody,[big_hole, small_hole]);
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    let cutout  = new Sketch(p1).
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                    LineTo(p2).
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                    ArcTo(c3,p4).
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                    LineTo(p5).
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                    ArcTo(c6,p1).
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                    End(false).Face(true);
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    let cutoutbody = Extrude(cutout,[0,0,h+10]);
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    let cutoutsmaller = Offset(cutoutbody, (-1.5 * t));
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    // ALTERNATIVE APPROACH FOR FILLETING
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    // make shrunk version of cutout a bit smaller and then offset it again with
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    // the filletradius
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    let cutoutbigger = Offset(cutoutsmaller, (0.5 * t));
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    let cutoutround = cutoutbigger;
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    let cutout_top = Translate([0,0,(h + t)/2],cutoutround);
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    let cutout_bot = Translate([0,0,(-h - t)/2 -10],cutoutround);
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    let rough_lever2 = Difference(rough_lever, [cutout_top, cutout_bot]);
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    return rough_lever2;
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}
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function sideviewblock(r1, r2, d, h, t)
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{
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//  r1 = radius larger bearing
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//  r2 = radois smaller bearing
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//  d  = distance between two bearings
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//  h  = height or width of the lever
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//  t  = wallthickness around bearing and cutout
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    let sideview = new Sketch( [-r1-1,0]  )
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    .LineTo([-r1-1,0.5*h])
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    .LineTo([r1,0.5*h])
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    .LineTo([d-r2,(0.1*h)+(1.2*t)])
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    .LineTo([d+r2,(0.1*h)+(1.2*t)])
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    .LineTo([d+r2,(-0.1*h)-(1.2*t)])
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    .LineTo([d-r2,(-0.1*h)-(1.2*t)])
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    .LineTo([r1,-0.5*h])
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    .LineTo([-r1-1,-0.5*h])
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    .LineTo([-r1-1,0])
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    .End(false,false).Face();
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    let block = Extrude(sideview, [0,0,(2*r1)+(2*t)]);
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    let side1 = Rotate([1,0,0],90,block);
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    let side2 = Translate([0, r1+1,0.5*h],side1);
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    return side2;
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}
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let sidecut = sideviewblock(30,10,100,40,2);
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let levershape = lever(30,10,100,40,2);
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Intersection([levershape,sidecut]); 
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