// Pillow Block Housing for 608 Bearing
// Press-fit bearing housing with mounting base and set-screw

/* [Bearing Specifications] */
// Nominal bearing outer diameter (608 = 22 mm)
bearing_od = 22.0;            // [15:0.5:35]
// Interference fit reduction on diameter
interference_fit = 0.1;       // [0.0:0.02:0.3]
// Bearing width (608 = 7 mm)
bearing_width = 7.0;          // [5:0.5:15]
// Shaft pass-through diameter
shaft_clearance_dia = 12.0;   // [8:0.5:18]

/* [Housing Dimensions] */
// Radial wall thickness around bearing
wall_thickness = 6.0;         // [3:0.5:12]
// Height from base bottom to shaft center
center_height = 20.0;         // [15:1:35]
// Depth of the upper bearing ring (Y-axis)
housing_depth = 12.0;         // [7:1:25]
// Include rear retaining shoulder lip
include_shoulder = true;
// Thickness of retaining shoulder
shoulder_thickness = 1.5;     // [1:0.5:4]

/* [Base Dimensions] */
// Base length along X-axis
base_length = 50.0;           // [35:1:80]
// Base width along Y-axis
base_width = 20.0;            // [12:1:40]
// Base plate thickness
base_thickness = 6.0;         // [4:0.5:12]
// Base corner rounding radius
base_corner_radius = 4.0;     // [0:0.5:10]

/* [Mounting Slots] */
// Diameter of mounting bolts/slots
mount_hole_diameter = 5.5;    // [3:0.5:10]
// Center-to-center spacing of mounting slots
mount_hole_spacing = 37.0;    // [25:1:65]
// Extra slot travel length along X
slot_travel = 4.0;            // [0:0.5:10]

/* [Set Screw] */
// Set screw hole diameter (e.g. M3 tap drill ~2.5-3.0mm)
set_screw_dia = 3.0;          // [2.0:0.5:5.0]

/* [Appearance & Quality] */
part_color = "SteelBlue";
$fn = 64;

// Calculated dimensions
bore_diameter = bearing_od - interference_fit;
boss_outer_diameter = bearing_od + 2 * wall_thickness;
boss_radius = boss_outer_diameter / 2;

module pillow_block() {
    color(part_color)
    difference() {
        // --- Solid Body ---
        union() {
            // 1. Base Plate with rounded corners
            hull() {
                for (x = [-base_length/2 + base_corner_radius, base_length/2 - base_corner_radius]) {
                    for (y = [-base_width/2 + base_corner_radius, base_width/2 - base_corner_radius]) {
                        translate([x, y, 0])
                            cylinder(r=base_corner_radius, h=base_thickness);
                    }
                }
            }

            // 2. Main Bearing Ring / Boss (Y-oriented)
            translate([0, 0, center_height])
                rotate([-90, 0, 0])
                cylinder(d=boss_outer_diameter, h=housing_depth, center=true);

            // 3. Smooth transition / gusset web connecting boss to base
            hull() {
                // Lower slice merging into base
                translate([-boss_radius * 1.05, -base_width/2, 0])
                    cube([boss_outer_diameter * 1.05, base_width, base_thickness]);

                // Mid/upper tangency on the cylindrical boss
                translate([0, 0, center_height])
                    rotate([-90, 0, 0])
                    cylinder(d=boss_outer_diameter, h=housing_depth, center=true);
            }

            // 4. Lateral reinforcing wing gussets tapering to base edges
            hull() {
                translate([-base_length/2 + 6, -housing_depth/2, 0])
                    cube([base_length - 12, housing_depth, base_thickness]);

                translate([0, 0, center_height])
                    rotate([-90, 0, 0])
                    cylinder(d=boss_outer_diameter * 0.9, h=housing_depth, center=true);
            }
        }

        // --- Subtractions & Cutouts ---

        // 1. Bearing Bore & Shaft Pocket
        if (include_shoulder) {
            // Bearing pocket from front face
            translate([0, -housing_depth/2 - 0.1, center_height])
                rotate([-90, 0, 0])
                cylinder(d=bore_diameter, h=bearing_width + 0.1);

            // Shaft clearance through-hole
            translate([0, -housing_depth, center_height])
                rotate([-90, 0, 0])
                cylinder(d=shaft_clearance_dia, h=housing_depth * 2);

            // Subtle lead-in chamfer for easy bearing pressing
            translate([0, -housing_depth/2 - 0.01, center_height])
                rotate([-90, 0, 0])
                cylinder(r1=bore_diameter/2 + 0.6, r2=bore_diameter/2, h=0.8);
        } else {
            // Full through-bore
            translate([0, -housing_depth, center_height])
                rotate([-90, 0, 0])
                cylinder(d=bore_diameter, h=housing_depth * 2);
        }

        // 2. Set Screw Hole (from top down to bearing bore)
        // Positioned over the bearing seat
        translate([0, include_shoulder ? (-housing_depth/2 + bearing_width/2) : 0, center_height])
            cylinder(d=set_screw_dia, h=boss_radius + 5);

        // Set screw countersink / entrance bevel
        translate([0, include_shoulder ? (-housing_depth/2 + bearing_width/2) : 0, center_height + boss_radius - 0.5])
            cylinder(r1=set_screw_dia/2, r2=set_screw_dia/2 + 0.8, h=1);

        // 3. Slotted Mounting Holes (Left and Right)
        for (side = [-1, 1]) {
            hull() {
                translate([side * mount_hole_spacing/2 - slot_travel/2, 0, -1])
                    cylinder(d=mount_hole_diameter, h=base_thickness + 2);
                translate([side * mount_hole_spacing/2 + slot_travel/2, 0, -1])
                    cylinder(d=mount_hole_diameter, h=base_thickness + 2);
            }
        }
    }
}

pillow_block();