/*
 *    polyScrewThread.scad    by aubenc @ Thingiverse
 *
 * This script contains the library modules that can be used to generate
 * threaded rods, screws and nuts.
 *
 * http://www.thingiverse.com/thing:8796
 *
 * CC Public Domain
 */

module screw_thread(od,st,lf0,lt,rs,cs)
{
    or=od/2;
    ir=or-st/2*cos(lf0)/sin(lf0);
    pf=2*PI*or;
    sn=floor(pf/rs);
    lfxy=360/sn;
    ttn=round(lt/st)+1;
    zt=st/sn;

    intersection()
    {
        if (cs >= -1)
        {
           # thread_shape(cs,lt,or,ir,sn,st);
        }

        full_thread(ttn,st,sn,zt,lfxy,or,ir);
    }
}

module hex_nut(df,hg,sth,clf,cod,crs)
{

    difference()
    {
        hex_head(hg,df);

        hex_countersink_ends(sth/2,cod,clf,crs,hg);

        screw_thread(cod,sth,clf,hg,crs,-2);
    }
}

module hex_screw(od,st,lf0,lt,rs,cs,df,hg,ntl,ntd)
{
    ntr=od/2-(st/2+0.1)*cos(lf0)/sin(lf0);

    union()
    {
        hex_head(hg,df);

        translate([0,0,hg])
        if ( ntl == 0 )
        {
            cylinder(h=0.01, r=ntr, center=true);
        }
        else
        {
            if ( ntd == -1 )
            {
                cylinder(h=ntl+0.01, r=ntr, $fn=floor(od*PI/rs), center=false);
            }
            else if ( ntd == 0 )
            {
                union()
                {
                    cylinder(h=ntl-st/2,
                             r=od/2, $fn=floor(od*PI/rs), center=false);

                    translate([0,0,ntl-st/2])
                    cylinder(h=st/2,
                             r1=od/2, r2=ntr, 
                             $fn=floor(od*PI/rs), center=false);
                }
            }
            else
            {
                cylinder(h=ntl, r=ntd/2, $fn=ntd*PI/rs, center=false);
            }
        }

        translate([0,0,ntl+hg]) screw_thread(od,st,lf0,lt,rs,cs);
    }
}

module thread_shape(cs,lt,or,ir,sn,st)
{
    if ( cs == 0 )
    {
        cylinder(h=lt, r=or, $fn=sn, center=false);
    }
    else
    {
        union()
        {
            translate([0,0,st/2])
              cylinder(h=lt-st+0.005, r=or, $fn=sn, center=false);

            if ( cs == -1 || cs == 2 )
            {
                cylinder(h=st/2, r1=ir, r2=or, $fn=sn, center=false);
            }
            else
            {
                cylinder(h=st/2, r=or, $fn=sn, center=false);
            }

            translate([0,0,lt-st/2])
            if ( cs == 1 || cs == 2 )
            {
                  cylinder(h=st/2, r1=or, r2=ir, $fn=sn, center=false);
            }
            else
            {
                cylinder(h=st/2, r=or, $fn=sn, center=false);
            }
        }
    }
}

module full_thread(ttn,st,sn,zt,lfxy,or,ir)
{
    for(i=[0:ttn-1])
    {
        for(j=[0:sn-1])
        {
            polyhedron(
                  points=[
                          [0,                  0,                  i*st-st            ],
                          [ir*cos((j+1)*lfxy), ir*sin((j+1)*lfxy), i*st+(j+1)*zt-st   ],
                          [ir*cos(j*lfxy),     ir*sin(j*lfxy),     i*st+j*zt-st       ],
                          [or*cos((j+1)*lfxy), or*sin((j+1)*lfxy), i*st+(j+1)*zt-st/2 ],
                          [or*cos(j*lfxy),     or*sin(j*lfxy),     i*st+j*zt-st/2     ],
                          [0,                  0,                  i*st+st            ],
                          [ir*cos((j+1)*lfxy), ir*sin((j+1)*lfxy), i*st+(j+1)*zt      ],
                          [ir*cos(j*lfxy),     ir*sin(j*lfxy),     i*st+j*zt          ]
                         ],
               triangles=[
                          [0,1,2],
                          [5,6,3],[5,3,0],[0,3,1],
                          [3,4,1],[1,4,2],
                          [3,6,4],[4,6,7],
                          [0,2,4],[0,4,5],[5,4,7],
                          [5,7,6]
                         ],
               convexity=5);
        }
    }
}

module hex_head(hg,df)
{
    cylinder(h=hg, r=df/2/sin(60), $fn=6, center=false);
}

module hex_countersink_ends(chg,cod,clf,crs,hg)
{
    translate([0,0,-0.1])
    cylinder(h=chg+0.01, 
             r1=cod/2, 
             r2=cod/2-(chg+0.1)*cos(clf)/sin(clf),
             $fn=floor(cod*PI/crs), center=false);

    translate([0,0,hg-chg+0.1])
    cylinder(h=chg+0.01, 
             r1=cod/2-(chg+0.1)*cos(clf)/sin(clf),
             r2=cod/2, 
             $fn=floor(cod*PI/crs), center=false);
}