Merge pull request #223 from alexneufeld/din603

add Din603 mushroom-head square-neck bolts

FastenersCmd.py

@@ -127,6 +127,8 @@
     "GOST1144-3": (translate("FastenerCmd", "GOST 1144 (Type 3) Half — round head wood screw"), HCrossGroup, ScrewParametersLC),
     "GOST1144-4": (translate("FastenerCmd", "GOST 1144 (Type 4) Half — round head wood screw"), HCrossGroup, ScrewParametersLC),
 
+    "DIN603": (translate("FastenerCmd", "DIN 603 Mushroom head square neck bolts"), OtherHeadGroup, ScrewParametersLC),
+
     "ISO4032": (translate("FastenerCmd", "ISO 4032 Hexagon nuts, Style 1"), NutGroup, NutParameters),
     "ISO4033": (translate("FastenerCmd", "ISO 4033 Hexagon nuts, Style 2"), NutGroup, NutParameters),
     "ISO4035": (translate("FastenerCmd", "ISO 4035 Hexagon thin nuts, chamfered"), NutGroup, NutParameters),

FsData/din603def.csv

@@ -0,0 +1,9 @@
+"DIN603def"
+"Dia","P","b1","b2","b3","dk_max","dk_min","ds_max","ds_min","f_max","f_min","k_max","k_min","r1_approx","r2_max","r2_max","v_max","v_min"
+"M5",0.8,16,22,22,13.55,12.45,5,4.52,4.1,2.9,3.3,2.7,10.7,0.5,0.75,5.48,4.52
+"M6",1,18,24,24,16.55,15.45,6,5.52,4.6,3.4,3.88,3.12,12.6,0.5,0.9,6.48,5.52
+"M8",1.25,22,28,41,20.65,19.35,8,7.42,5.6,4.4,4.88,4.12,16,0.5,1.2,8.58,7.42
+"M10",1.5,26,32,45,24.65,23.35,10,9.42,6.6,5.4,5.38,4.62,19.2,0.5,1.5,10.58,9.42
+"M12",1.75,30,36,49,30.65,29.35,12,11.3,8.75,7.25,6.95,6.05,24.1,1,1.8,12.7,11.3
+"M16",2,38,44,57,38.8,37.2,16,15.3,12.9,11.1,8.95,8.05,29.3,1,2.4,16.7,15.3
+"M20",2.5,46,52,65,46.8,45.2,20,19.16,15.9,14.1,11.05,9.95,33.9,1,3,20.84,19.16

FsData/din603length.csv

@@ -0,0 +1,25 @@
+"DIN603length"
+"Nominal","Min","Max"
+"16",15.1,16.9
+"20",18.95,21.05
+"25",23.95,26.05
+"30",28.95,31.05
+"35",33.75,36.25
+"40",38.75,41.25
+"45",43.75,46.25
+"50",48.75,51.25
+"55",53.5,56.5
+"60",58.5,61.5
+"65",63.5,66.5
+"70",68.5,71.5
+"80",78.5,81.5
+"90",88.25,91.75
+"100",98.25,101.75
+"110",108.25,111.75
+"120",118.25,121.75
+"130",128,132
+"140",138,142
+"150",148,152
+"160",156,164
+"180",176,184
+"200",195.4,204.6

FsData/din603range.csv

@@ -0,0 +1,9 @@
+"DIN603range"
+"Dia","Min_L","Max_L"
+"M5","16","80"
+"M6","16","150"
+"M8","20","150"
+"M10","20","200"
+"M12","30","200"
+"M16","55","200"
+"M20","70","200"

FsFunctions/FSmakeCarriageBolt.py

@@ -29,31 +29,56 @@
 import FastenerBase
 
 # ASMEB18.5.2 UNC Round head square neck bolts
+# DIN603 Mushroom head square neck bolts
 cos22_5 = math.cos(math.radians(22.5))
 sin22_5 = math.sin(math.radians(22.5))
 sqrt2 = math.sqrt(2)
 
-def makeCarriageBolt(self, fa): # dynamically loaded method of class Screw
+
+def makeCarriageBolt(self, fa):  # dynamically loaded method of class Screw
     SType = fa.type
-    l = fa.calc_len
+    length = fa.calc_len
     d = self.getDia(fa.calc_diam, False)
     if SType == 'ASMEB18.5.2':
         tpi, _, A, H, O, P, _, _ = fa.dimTable
         A, H, O, P = (25.4 * x for x in (A, H, O, P))
         pitch = 25.4 / tpi
-        if l <= 152.4:
+        if length <= 152.4:
             L_t = d * 2 + 6.35
         else:
             L_t = d * 2 + 12.7
-
+    elif SType == 'DIN603':
+        pitch, b1, b2, b3, dk_max, dk_min, ds_max, ds_min, f_max, f_min, \
+            k_max, k_min, r1_approx, r2_max, r2_max, v_max, v_min = fa.dimTable
+        A = (dk_max+dk_min)/2
+        H = k_max
+        O = v_max
+        P = f_max
+        if length <= 125:
+            L_t = b1
+        elif (125 < length) and (length <= 200):
+            L_t = b2
+        else:  # len > 200
+            L_t = b3
     head_r = A / sqrt2
-    flat_len = l - P
+    flat_len = length - P
 
-    # create a profile for head generation. Basially when this profile revolves we get the head solid
-    # FSFaceMaker is a nice helper to build a profile from lines and arcs it make a profile on the x,z plane
+    # create a profile for head generation.
+    # Basially when this profile revolves we get the head solid
+    # FSFaceMaker is a nice helper to build a profile from lines and arcs.
+    # It make a profile on the x,z plane
     fm = FastenerBase.FSFaceMaker()
     fm.AddPoint(0, H)
-    fm.AddArc(head_r * sin22_5, H - head_r + head_r * cos22_5, A / 2, 0) # arcs are 3 point arcs where the first point is the last added
+    r_fillet = d * 0.05
+    # angle for determining an approximate fillet at the outer edge
+    theta = math.pi / 4
+    fm.AddArc(
+        head_r * math.sin(theta / 2),
+        head_r * math.cos(theta / 2) - head_r + H,
+        A / 2 - r_fillet + r_fillet * math.sin(theta),
+        r_fillet * (1 + math.cos(theta)),
+    )
+    fm.AddArc(A / 2, r_fillet, A / 2 - r_fillet, 0)
     fm.AddPoint(sqrt2 / 2 * O, 0)
     fm.AddPoint(sqrt2 / 2 * O, -1 * P + (sqrt2 / 2 * O - d / 2))
     fm.AddPoint(d / 2, -1 * P)
@@ -64,23 +89,41 @@ def makeCarriageBolt(self, fa): # dynamically loaded method of class Screw
         fm.Reset()
         fm.AddPoint(d / 2, -1 * P)
         if (flat_len > L_t):
-            fm.AddPoint(d / 2, -l + L_t)
-        fm.AddPoint(d / 2, -l + d / 10)
-        fm.AddPoint(d / 2 - d / 10, -l)
-        fm.AddPoint(0, -l)
+            fm.AddPoint(d / 2, -length + L_t)
+        fm.AddPoint(d / 2, -length + d / 10)
+        fm.AddPoint(d / 2 - d / 10, -length)
+        fm.AddPoint(0, -length)
         thread_profile_wire = fm.GetWire()
         shell_thread = self.RevolveZ(thread_profile_wire)
     else:
         # modeled threaded section
-        shell_thread = self.makeShellthread(d, pitch, flat_len, False, -P, L_t)
+        shell_thread = self.makeShellthread(d, pitch, flat_len, True, -P, L_t)
     p_shell = Part.Shell(head_shell.Faces + shell_thread.Faces)
     p_solid = Part.Solid(p_shell)
     # cut 4 flats under the head
     d_mod = d + 0.0002
-    outerBox = Part.makeBox(A * 4, A * 4, P + 0.0001, Base.Vector(-A * 2, -A * 2, -P + 0.0001))
-    innerBox = Part.makeBox(d_mod, d_mod, P * 3, Base.Vector(-d_mod / 2, -d_mod / 2, -P * 2))
+    outerBox = Part.makeBox(
+        A * 4,
+        A * 4,
+        P + 0.0001,
+        Base.Vector(-A * 2, -A * 2, -P + 0.0001)
+    )
+    innerBox = Part.makeBox(
+        d_mod,
+        d_mod,
+        P * 3,
+        Base.Vector(-d_mod / 2, -d_mod / 2, -P * 2)
+    )
+    # add fillets to the square cutting tool
+    edgelist = innerBox.Edges
+    edges_to_fillet = []
+    for edge in edgelist:
+        if (
+            abs(abs(edge.CenterOfMass.x) - d_mod / 2) < 0.0001 and
+            abs(abs(edge.CenterOfMass.y) - d_mod / 2) < 0.0001
+        ):
+            edges_to_fillet.append(edge)
+    innerBox = innerBox.makeFillet(d * 0.08, edges_to_fillet)
     tool = outerBox.cut(innerBox)
     p_solid = p_solid.cut(tool)
-    # removeSplitter is equivalent to the 'Refine' option for FreeCAD PartDesign objects
-    # return p_solid.removeSplitter()
-    return p_solid # not refining so thread location will be visible when not using real thread
+    return p_solid

FsFunctions/FSmakeNylocNut.py

@@ -27,7 +27,7 @@
 from screw_maker import *
 import FastenerBase
 
-# ASMEB18.5.2 UNC Round head square neck bolts
+# DIN985 Nyloc Nuts
 
 tan30 = math.tan(math.radians(30.0))
 

ScrewMaker.py

@@ -147,6 +147,7 @@
     'ISO14584': ("Screw", "makeCountersunkHeadScrew"),#
     'DIN7984':  ("Screw", "makeCylinderHeadScrew"),
     'DIN6912':  ("Screw", "makeCylinderHeadScrew"),
+    'DIN603': ("Screw",    "makeCarriageBolt"),
     'DIN571':   ("Screw", "makeWoodScrew"),
     'DIN96':    ("Screw", "makeWoodScrew"),
     'GOST1144-1':    ("Screw", "makeWoodScrew"),