Detects pairs of consecutive 135° vertices (characteristic of filleted
90° corners) and reconstructs circular arcs from tangent-perpendicular
intersection. Verified on sandbox 2: 2 arcs detected at R=7.5mm with
correct centers. Chain continuity validated.
When arcs are detected, v1 boundaries get promoted to v2 typed segments
and the polyline is re-densified with proper arc interpolation.
- Add explicit corner vertices of the inset boundary (w_frame offset) to Delaunay point set
- This guarantees no triangle can cross a boundary corner
- Updated test_data geometry files to v2.0 format with typed segments
- Sandbox 2 now has proper arc curves (4 arc segments) from extract_sandbox
- Preserved holes from v1.0 geometry
- Boundary vertices also enforced on keepout boundaries
profile_assembly.py now checks each pocket's polyline against the plate
boundary using Shapely contains(). Pockets extending outside are dropped.
Sandbox 1: 1 pocket removed (was crossing corner near x=150, y=-20).
Brain: profile_assembly.py now exports 'rib_web' — the actual material
geometry from Shapely boolean (exterior + interior rings). This is the
rib shape, not the pocket cutouts.
import_profile.py: prefers rib_web when available, drawing exterior +
interior polyline rings directly. Falls back to pocket-based drawing
for older rib JSONs without rib_web.
Complete rewrite of triangulation engine:
- Regular hexagonal-packed vertex grid (equilateral triangles)
- Density-adaptive refinement: denser near holes, coarser in open areas
- Boundary-conforming vertices along frame edge and hole keepouts
- Delaunay on point set + clip to valid region (inside frame, outside keepouts)
- Result: proper isogrid layout, 87 pockets from 234 triangles
- 553 NX entities, min fillet 4.89mm, mass 2770g
- No more dependency on Shewchuk Triangle library (scipy.spatial.Delaunay)
- Switched to uniform triangulation (no density-adaptive refinement for
initial pass — saves that for stress-informed iterations)
- s_min=45mm, s_max=55mm (was 12/35) — larger triangles fit 6mm fillets
- Boss keepout circles: 12 segments (was 32) — less boundary clutter
- Fillet must be >= 80% of r_f at every corner or pocket is skipped
- Result: 75 pockets, 481 NX entities, min fillet 4.85mm, mass 4066g
- adaptive_density=True param enables density refinement for future stress iterations
- Default r_f raised from 1.5mm to 6mm (machining constraint)
- Default min_pocket_radius raised to 6mm
- Pockets that can't fit r_f at any corner (within 80% tolerance) are
skipped entirely — left solid for more stiffness in tight areas
- Result: 26 pockets (was 432), 187 NX entities (was 13,061)
- Min fillet radius: 4.88mm, all >= 4.8mm (80% of 6mm)
- Mass: 4,601g (was 3,480g — more solid = heavier but manufacturable)
