A wheel hub is the part that connects the wheel to the suspension

// Hub
// A wheel hub is the part that connects the wheel to the suspension
// Categories: Automotive

// Set units
@settings(defaultLengthUnit = in)

// Define Parameters
hubSpacing = 3in
hubBore = 2.5in
rotorBore = 3
lugCount = 5
lugSpacing = 114.3mm
lugDiameter = 24mm
lugThreadDiameter = lugDiameter / 1.75
lugLength = 5 / 8

baseArcRadius = lugSpacing / 7
rearHubOuterRadius = lugSpacing / 1.6
lugCircleRadius = lugSpacing / 2
upperSlopeLength = rearHubOuterRadius * 1.35
arcEndRise = baseArcRadius * sin(60deg)
rightArcEndX = rearHubOuterRadius - (baseArcRadius / 2)
upperSlopeEndX = rightArcEndX - (upperSlopeLength * cos(30deg))
upperSlopeEndY = arcEndRise + upperSlopeLength * sin(30deg)
leftArcCenterX = upperSlopeEndX - (baseArcRadius / 2)
leftWallX = upperSlopeEndX - (1.5 * baseArcRadius)
leftWallHalfHeight = upperSlopeEndY - arcEndRise

// Solver reconstruction of the rear hub extrusion
rearHubProfile = sketch(on = XZ) {
  rightArc = arc(start = [var 2.49in, var -0.56in], end = [var 2.49in, var 0.56in], center = [var 2.17in, var 0in])
  upperSlope = line(start = [var 2.49in, var 0.56in], end = [var -0.8in, var 2.46in])
  upperLeftArc = arc(start = [var -0.8in, var 2.46in], end = [var -1.76in, var 1.9in], center = [var -1.12in, var 1.9in])
  leftWall = line(start = [var -1.76in, var 1.9in], end = [var -1.76in, var -1.9in])
  lowerLeftArc = arc(start = [var -1.76in, var -1.9in], end = [var -0.8in, var -2.46in], center = [var -1.12in, var -1.9in])
  lowerSlope = line(start = [var -0.8in, var -2.46in], end = [var 2.49in, var -0.56in])
  coincident([rightArc.end, upperSlope.start])

  coincident([upperSlope.end, upperLeftArc.start])
  coincident([upperLeftArc.end, leftWall.start])
  coincident([leftWall.end, lowerLeftArc.start])
  coincident([lowerLeftArc.end, lowerSlope.start])
  coincident([lowerSlope.end, rightArc.start])

  vertical(leftWall)

  radius(rightArc) == baseArcRadius
  radius(upperLeftArc) == baseArcRadius
  radius(lowerLeftArc) == baseArcRadius

  horizontalDistance([ORIGIN, rightArc.center]) == rearHubOuterRadius - baseArcRadius
  verticalDistance([ORIGIN, rightArc.center]) == 0in
  horizontalDistance([ORIGIN, rightArc.end]) == rightArcEndX
  verticalDistance([ORIGIN, rightArc.end]) == arcEndRise
  horizontalDistance([ORIGIN, rightArc.start]) == rightArcEndX
  verticalDistance([ORIGIN, rightArc.start]) == -arcEndRise

  horizontalDistance([ORIGIN, upperSlope.end]) == upperSlopeEndX
  verticalDistance([ORIGIN, upperSlope.end]) == upperSlopeEndY

  horizontalDistance([ORIGIN, upperLeftArc.center]) == leftArcCenterX
  verticalDistance([ORIGIN, upperLeftArc.center]) == leftWallHalfHeight

  horizontalDistance([ORIGIN, leftWall.start]) == leftWallX
  verticalDistance([ORIGIN, leftWall.start]) == leftWallHalfHeight
  horizontalDistance([ORIGIN, leftWall.end]) == leftWallX
  verticalDistance([ORIGIN, leftWall.end]) == -leftWallHalfHeight

  horizontalDistance([ORIGIN, lowerLeftArc.center]) == leftArcCenterX
  verticalDistance([ORIGIN, lowerLeftArc.center]) == -leftWallHalfHeight
  horizontalDistance([ORIGIN, lowerSlope.start]) == upperSlopeEndX
  verticalDistance([ORIGIN, lowerSlope.start]) == -upperSlopeEndY
}

rearHubRegion = region(segments = [
  rearHubProfile.rightArc,
  rearHubProfile.upperSlope
])
rearHubBlank = extrude(rearHubRegion, length = hubSpacing * 5 / 4)
hide(rearHubProfile)

hubBoreProfile = sketch(on = XZ) {
  radiusGuide = line(start = [var 0in, var 0in], end = [var 1.25in, var 0in], construction = true)
  circle1 = circle(start = [var 1.25in, var 0in], center = [var 0in, var 0in])

  coincident([radiusGuide.start, ORIGIN])
  coincident([circle1.center, radiusGuide.start])
  coincident([radiusGuide.end, circle1.start])

  horizontal(radiusGuide)
  distance([radiusGuide.start, radiusGuide.end]) == hubBore / 2
  radius(circle1) == hubBore / 2
}

hubBoreRegion = region(segments = [hubBoreProfile.circle1])
hubBoreCutter = extrude(hubBoreRegion, length = hubSpacing * 5 / 4)
hide(hubBoreProfile)

lugHoleProfile = sketch(on = XZ) {
  centerGuide = line(start = [var 0in, var 0in], end = [var 2.25in, var 0in], construction = true)
  radiusGuide = line(start = [var 2.25in, var 0in], end = [var 2.52in, var 0in], construction = true)
  circle1 = circle(start = [var 2.52in, var 0in], center = [var 2.25in, var 0in])

  coincident([centerGuide.start, ORIGIN])
  coincident([centerGuide.end, circle1.center])
  coincident([radiusGuide.start, circle1.center])
  coincident([radiusGuide.end, circle1.start])

  horizontal(centerGuide)
  horizontal(radiusGuide)
  distance([centerGuide.start, centerGuide.end]) == lugCircleRadius
  distance([radiusGuide.start, radiusGuide.end]) == lugThreadDiameter / 2
  radius(circle1) == lugThreadDiameter / 2
}

lugHoleRegion = region(segments = [lugHoleProfile.circle1])
lugHoleCutter = extrude(lugHoleRegion, length = hubSpacing * 5 / 4)
lugHoleCutters = patternCircular3d(
  lugHoleCutter,
  instances = 3,
  axis = Y,
  center = [0, 0, 0],
)
hide(lugHoleProfile)

rearHubBase = subtract([rearHubBlank], tools = [hubBoreCutter, lugHoleCutters])

// Solver reconstruction of the revolved trim cut
trimProfile = sketch(on = XY) {
  startHeightGuide = line(start = [var 0in, var 0in], end = [var 0in, var -0.75in], construction = true)
  startOffsetGuide = line(start = [var 0in, var -0.75in], end = [var 1.5in, var -0.75in], construction = true)

  line1 = line(start = [var 1.5in, var -0.75in], end = [var 2.98in, var -0.49in])
  line2 = line(start = [var 2.98in, var -0.49in], end = [var 2.98in, var -4.99in])
  line3 = line(start = [var 2.98in, var -4.99in], end = [var 1.5in, var -4.99in])
  line4 = line(start = [var 1.5in, var -4.99in], end = [var 1.5in, var -0.75in])

  coincident([startHeightGuide.start, ORIGIN])
  coincident([
    startHeightGuide.end,
    startOffsetGuide.start
  ])
  coincident([startOffsetGuide.end, line1.start])

  coincident([line1.end, line2.start])
  coincident([line2.end, line3.start])
  coincident([line3.end, line4.start])
  coincident([line4.end, line1.start])

  vertical(startHeightGuide)
  horizontal(startOffsetGuide)
  vertical(line2)
  horizontal(line3)
  vertical(line4)

  verticalDistance([
  startHeightGuide.start,
  startHeightGuide.end
]) == -hubSpacing / 4
  horizontalDistance([
  startOffsetGuide.start,
  startOffsetGuide.end
]) == rotorBore / 2
  distance([line1.start, line1.end]) == lugSpacing / 3
  angle([startOffsetGuide, line1]) == 10deg
  distance([line2.start, line2.end]) == hubSpacing * 1.5
}

trimRegion = region(segments = [trimProfile.line1, trimProfile.line2])
revolveTrim = revolve(trimRegion, axis = Y)
rearHubBody = subtract([rearHubBase], tools = [revolveTrim])
hide(trimProfile)

flangePlane = offsetPlane(XZ, offset = hubSpacing * 3 / 4)
flangeOuterRadius = lugSpacing / 1.5
flangeBoreRadius = rotorBore / 2

// Solver reconstruction of the mounting flange
mountingFlangeProfile = sketch(on = flangePlane) {
  outerRadiusGuide = line(start = [var 0in, var 0in], end = [var 3in, var 0in], construction = true)
  centerBoreRadiusGuide = line(start = [var 0in, var 0in], end = [var 1.5in, var 0in], construction = true)
  outerCircle = circle(start = [var 3in, var 0in], center = [var 0in, var 0in])
  centerBoreCircle = circle(start = [var 1.5in, var 0in], center = [var 0in, var 0in])

  coincident([outerRadiusGuide.start, ORIGIN])
  coincident([
    outerCircle.center,
    outerRadiusGuide.start
  ])
  coincident([
    outerRadiusGuide.end,
    outerCircle.start
  ])

  coincident([centerBoreRadiusGuide.start, ORIGIN])
  coincident([
    centerBoreCircle.center,
    centerBoreRadiusGuide.start
  ])
  coincident([
    centerBoreRadiusGuide.end,
    centerBoreCircle.start
  ])

  horizontal(outerRadiusGuide)
  horizontal(centerBoreRadiusGuide)
  distance([
  outerRadiusGuide.start,
  outerRadiusGuide.end
]) == flangeOuterRadius
  distance([
  centerBoreRadiusGuide.start,
  centerBoreRadiusGuide.end
]) == flangeBoreRadius
  radius(outerCircle) == flangeOuterRadius
  radius(centerBoreCircle) == flangeBoreRadius
}

mountingFlangeRegion = region(point = [2.1in, 0in], sketch = mountingFlangeProfile)
mountingFlangeBlank = extrude(
  mountingFlangeRegion,
  length = hubSpacing / 4,
  tagStart = $capStart001,
  tagEnd = $capEnd001,
)
hide(mountingFlangeProfile)

flangeHoleProfile = sketch(on = flangePlane) {
  centerGuide = line(start = [var 0in, var 0in], end = [var 2.25in, var 0in], construction = true)
  radiusGuide = line(start = [var 2.25in, var 0in], end = [var 2.52in, var 0in], construction = true)
  circle1 = circle(start = [var 2.52in, var 0in], center = [var 2.25in, var 0in])

  coincident([centerGuide.start, ORIGIN])
  coincident([centerGuide.end, circle1.center])
  coincident([radiusGuide.start, circle1.center])
  coincident([radiusGuide.end, circle1.start])

  horizontal(centerGuide)
  horizontal(radiusGuide)
  distance([centerGuide.start, centerGuide.end]) == lugCircleRadius
  distance([radiusGuide.start, radiusGuide.end]) == lugThreadDiameter / 2
  radius(circle1) == lugThreadDiameter / 2
}

flangeHoleRegion = region(segments = [flangeHoleProfile.circle1])
flangeHoleCutter = extrude(flangeHoleRegion, length = hubSpacing / 4)
flangeHoleCutters = patternCircular3d(
  flangeHoleCutter,
  instances = lugCount * 2,
  axis = Y,
  center = [0, 0, 0],
)
hide(flangeHoleProfile)

// Solver reconstruction of the flange chamfers
chamfer001 = chamfer(
  mountingFlangeBlank,
  tags = getCommonEdge(faces = [
    mountingFlangeRegion.tags.outerCircle,
    capStart001
  ]),
  length = lugSpacing / 30,
)
chamfer002 = chamfer(
  chamfer001,
  tags = getCommonEdge(faces = [
    mountingFlangeRegion.tags.outerCircle,
    capEnd001
  ]),
  length = lugSpacing / 20,
)
mountingFlange = subtract([chamfer002], tools = [flangeHoleCutters])

// Solver reconstruction of the welded lug bolts
boltHeadProfile = sketch(on = startSketchOn(mountingFlange, face = START)) {
  centerGuide = line(start = [var 0in, var 0in], end = [var -2.25in, var 0in], construction = true)
  boltHeadCircle = circle(start = [var -1.82in, var 0in], center = [var -2.25in, var 0in], construction = true)

  line1 = line(start = [var -2.68in, var 0in], end = [var -2.47in, var 0.37in])
  line2 = line(start = [var -2.47in, var 0.37in], end = [var -2.03in, var 0.37in])
  coincident([line1.end, line2.start])

  line3 = line(start = [var -2.03in, var 0.37in], end = [var -1.82in, var 0in])
  coincident([line2.end, line3.start])

  line4 = line(start = [var -1.82in, var 0in], end = [var -2.03in, var -0.37in])
  coincident([line3.end, line4.start])

  line5 = line(start = [var -2.03in, var -0.37in], end = [var -2.47in, var -0.37in])
  coincident([line4.end, line5.start])

  line6 = line(start = [var -2.47in, var -0.37in], end = [var -2.68in, var 0in])
  coincident([line5.end, line6.start])
  coincident([line6.end, line1.start])

  coincident([centerGuide.start, ORIGIN])
  coincident([centerGuide.end, boltHeadCircle.center])

  coincident([line1.start, boltHeadCircle])
  coincident([line2.start, boltHeadCircle])
  coincident([line3.start, boltHeadCircle])
  coincident([line4.start, boltHeadCircle])
  coincident([line5.start, boltHeadCircle])
  coincident([line6.start, boltHeadCircle])

  horizontal(centerGuide)
  horizontal(line2)
  horizontal(line5)

  equalLength([
    line1,
    line2,
    line3,
    line4,
    line5,
    line6
  ])

  boltHeadRadiusGuide = line(start = [var -2.25in, var 0in], end = [var -1.82in, var 0in], construction = true)
  coincident([
    boltHeadRadiusGuide.start,
    boltHeadCircle.center
  ])
  coincident([boltHeadRadiusGuide.end, line4.start])
  coincident([
    boltHeadCircle.start,
    boltHeadRadiusGuide.end
  ])

  horizontal(boltHeadRadiusGuide)
  horizontalDistance([centerGuide.start, centerGuide.end]) == -lugSpacing / 2
  horizontalDistance([
  boltHeadRadiusGuide.start,
  boltHeadRadiusGuide.end
]) == lugThreadDiameter / 1.25
}

boltHeadRegion = region(point = [-lugSpacing / 2, 0], sketch = boltHeadProfile)
boltHead = extrude(boltHeadRegion, length = hubSpacing / 8, method = NEW)
  |> appearance(color = "#121212")
hide(boltHeadProfile)

boltStemProfile = sketch(on = startSketchOn(boltHead, face = START)) {
  centerGuide = line(start = [var 0in, var 0in], end = [var 2.25in, var 0in], construction = true)
  radiusGuide = line(start = [var 2.25in, var 0in], end = [var 2.52in, var 0in], construction = true)
  circle1 = circle(start = [var 2.52in, var 0in], center = [var 2.25in, var 0in])

  coincident([centerGuide.start, ORIGIN])
  coincident([centerGuide.end, circle1.center])
  coincident([radiusGuide.start, circle1.center])
  coincident([radiusGuide.end, circle1.start])

  horizontal(centerGuide)
  horizontal(radiusGuide)
  horizontalDistance([centerGuide.start, centerGuide.end]) == lugSpacing / 2
  distance([radiusGuide.start, radiusGuide.end]) == lugThreadDiameter / 2
  radius(circle1) == lugThreadDiameter / 2
}

boltStemRegion = region(segments = [boltStemProfile.circle1])
boltStem = extrude(boltStemRegion, length = hubSpacing / 4 + lugLength)
  |> patternCircular3d(instances = lugCount, axis = Y, center = [0, 0, 0])
hide(boltStemProfile)


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