// Two-Piece Split Ring Tube Clamp for 25 mm OD Tube
// With M4 clamping flanges and slotted mounting foot

/* [General Settings] */
// Display mode
part_display = "both"; // [both:Both Halves (Side-by-Side), assembled:Assembled, lower:Lower Half Only, upper:Upper Half Only]
// Explode distance when assembled
explode_distance = 0; // [0:1:50]
// Spacing between halves when displayed side-by-side
part_spacing = 68; // [40:1:120]

/* [Tube Clamp Dimensions] */
// Outer diameter of the tube to be clamped
tube_diameter = 25.0; // [10:0.5:60]
// Wall thickness around the tube
wall_thickness = 4.0; // [2:0.5:10]
// Width (depth) of the clamp along tube axis
clamp_width = 12.0; // [6:1:40]
// Clamping gap between halves for tight compression
clamping_gap = 1.0; // [0:0.1:3]

/* [Flange & Clamping Bolts] */
// Clamping bolt hole diameter (4.5mm for M4)
flange_hole_diameter = 4.5; // [3:0.1:8]
// Distance from tube outer surface to bolt hole center
flange_hole_offset = 8.0; // [4:0.5:20]
// Flange thickness (height of clamping ears)
flange_thickness = 5.0; // [3:0.5:10]
// Outer margin beyond the bolt hole center
flange_edge_margin = 4.5; // [2:0.5:10]
// Smooth fillet radius on flange corners
flange_corner_radius = 2.0; // [0:0.5:5]

/* [Mounting Foot (Lower Half)] */
// Total width of the mounting foot
foot_width = 64.0; // [35:1:100]
// Thickness of the mounting foot plate
foot_thickness = 4.0; // [2:0.5:10]
// Foot depth along tube axis
foot_depth = 12.0; // [6:1:40]
// Width of the mounting slots (4.5mm for M4)
slot_width = 4.5; // [3:0.1:8]
// Total length of the mounting slots
slot_length = 9.0; // [4.5:0.5:20]
// Center-to-center distance between mounting slots
slot_spacing = 46.0; // [20:1:80]

/* [Colors] */
lower_color = "SteelBlue";
upper_color = "SkyBlue";
fastener_color = "LightGray";

/* [Quality] */
$fn = 90;

// Derived parameters
r_inner = tube_diameter / 2;
r_outer = r_inner + wall_thickness;
hole_x = r_inner + flange_hole_offset;
flange_max_x = hole_x + flange_edge_margin;
half_gap = clamping_gap / 2;

// --- Main Assembly Logic ---

if (part_display == "both") {
    // Show lower half flat on bed and upper half side-by-side
    translate([-part_spacing / 2, 0, 0])
    color(lower_color)
    lower_clamp_half();

    translate([part_spacing / 2, 0, 0])
    color(upper_color)
    upper_clamp_half();
} else if (part_display == "assembled") {
    translate([0, 0, explode_distance])
    color(upper_color)
    upper_clamp_half();

    translate([0, 0, -explode_distance])
    color(lower_color)
    lower_clamp_half();
} else if (part_display == "lower") {
    color(lower_color)
    lower_clamp_half();
} else if (part_display == "upper") {
    color(upper_color)
    upper_clamp_half();
}

// --- Component Modules ---

// Upper Clamp Half (with flanges on both sides)
module upper_clamp_half() {
    difference() {
        // Outer body
        linear_extrude(height = clamp_width, center = true) {
            difference() {
                union() {
                    // Semicircular top arch
                    intersection() {
                        circle(r = r_outer);
                        translate([-r_outer - 5, half_gap])
                        square([2 * r_outer + 10, r_outer + 5]);
                    }

                    // Left flange
                    flange_2d_profile(side = -1, upper = true);

                    // Right flange
                    flange_2d_profile(side = 1, upper = true);
                }

                // Inner tube clearance
                circle(r = r_inner);
            }
        }

        // Flange bolt holes (left and right)
        translate([-hole_x, 0, 0])
        cylinder(d = flange_hole_diameter, h = 3 * clamp_width, center = true);

        translate([hole_x, 0, 0])
        cylinder(d = flange_hole_diameter, h = 3 * clamp_width, center = true);

        // Clamping gap split plane cut
        translate([-flange_max_x - 5, -r_outer - 10, -clamp_width])
        cube([2 * flange_max_x + 10, r_outer + 10 + half_gap, 2 * clamp_width + 5]);
    }
}

// Lower Clamp Half (with flanges and flat mounting foot)
module lower_clamp_half() {
    foot_y_top = -r_outer;
    foot_y_bottom = foot_y_top - foot_thickness;

    difference() {
        union() {
            // Main clamp ring body and flanges
            linear_extrude(height = clamp_width, center = true) {
                difference() {
                    union() {
                        // Semicircular bottom arch
                        intersection() {
                            circle(r = r_outer);
                            translate([-r_outer - 5, -r_outer - 5])
                            square([2 * r_outer + 10, r_outer + 5 - half_gap]);
                        }

                        // Left flange
                        flange_2d_profile(side = -1, upper = false);

                        // Right flange
                        flange_2d_profile(side = 1, upper = false);

                        // Gusset/support transition from clamp ring down to flat foot
                        polygon(points = [
                            [-r_outer * 0.95, -r_outer * 0.3],
                            [-foot_width / 2 + 3, foot_y_top],
                            [foot_width / 2 - 3, foot_y_top],
                            [r_outer * 0.95, -r_outer * 0.3]
                        ]);
                    }

                    // Inner tube bore
                    circle(r = r_inner);
                }
            }

            // Flat mounting foot plate
            translate([-foot_width / 2, foot_y_bottom, -foot_depth / 2])
            rounded_cube_xy([foot_width, foot_thickness, foot_depth], r = 2.0);
        }

        // Flange bolt holes (left and right)
        translate([-hole_x, 0, 0])
        cylinder(d = flange_hole_diameter, h = 3 * clamp_width, center = true);

        translate([hole_x, 0, 0])
        cylinder(d = flange_hole_diameter, h = 3 * clamp_width, center = true);

        // Clamping gap split cut
        translate([-flange_max_x - 5, -half_gap, -clamp_width])
        cube([2 * flange_max_x + 10, r_outer + 10, 2 * clamp_width + 5]);

        // Tube inner bore clean clearance
        cylinder(r = r_inner, h = 3 * clamp_width, center = true);

        // Mounting Foot Slots (two Ø4.5 mm slots)
        translate([-slot_spacing / 2, foot_y_top + 5, 0])
        rotate([90, 0, 0])
        linear_extrude(height = foot_thickness + 10)
        hull() {
            translate([- (slot_length - slot_width) / 2, 0])
            circle(d = slot_width);
            translate([ (slot_length - slot_width) / 2, 0])
            circle(d = slot_width);
        }

        translate([slot_spacing / 2, foot_y_top + 5, 0])
        rotate([90, 0, 0])
        linear_extrude(height = foot_thickness + 10)
        hull() {
            translate([- (slot_length - slot_width) / 2, 0])
            circle(d = slot_width);
            translate([ (slot_length - slot_width) / 2, 0])
            circle(d = slot_width);
        }
    }
}

// 2D Flange Ear Profile
module flange_2d_profile(side = 1, upper = true) {
    x_dir = side; // 1 for right, -1 for left
    y_dir = upper ? 1 : -1;

    hull() {
        // Base connection to clamp cylinder
        translate([x_dir * (r_inner + 1), y_dir * half_gap])
        square([1, flange_thickness]);

        // Outer rounded tip of flange
        translate([x_dir * (flange_max_x - flange_corner_radius), y_dir * (half_gap + flange_thickness - flange_corner_radius)])
        circle(r = flange_corner_radius);

        translate([x_dir * (flange_max_x - flange_corner_radius), y_dir * (half_gap + flange_corner_radius)])
        circle(r = flange_corner_radius);
    }
}

// Helper: 3D box with rounded corners in X-Z plane
module rounded_cube_xy(size, r = 2) {
    x = size[0];
    y = size[1];
    z = size[2];
    hull() {
        translate([r, 0, r])
        rotate([-90, 0, 0])
        cylinder(r = r, h = y);

        translate([x - r, 0, r])
        rotate([-90, 0, 0])
        cylinder(r = r, h = y);

        translate([r, 0, z - r])
        rotate([-90, 0, 0])
        cylinder(r = r, h = y);

        translate([x - r, 0, z - r])
        rotate([-90, 0, 0])
        cylinder(r = r, h = y);
    }
}