main.kcl

// Shelf Bracket
// This is a bracket that holds a shelf. It is made of aluminum and is designed to hold a force of 300 lbs. The bracket is 6 inches wide and the force is applied at the end of the shelf, 12 inches from the wall. The bracket has a factor of safety of 1.2. The legs of the bracket are 5 inches and 2 inches long. The thickness of the bracket is calculated from the constraints provided.

// Set units
@settings(defaultLengthUnit = in)

// Define constants
sigmaAllow = 35000 // psi (6061-T6 aluminum)
width = 6
p = 300 // Force on shelf - lbs
factorOfSafety = 1.2 // FOS of 1.2
shelfMountL = 5
wallMountL = 2
shelfDepth = 12 // Shelf is 12 inches in depth from the wall
moment = shelfDepth * p // assume the force is applied at the end of the shelf to be conservative (lb-in)


filletRadius = .375
extFilletRadius = .25
mountingHoleDiameter = 0.5

// Calculate required thickness of bracket
thickness = sqrt(moment * factorOfSafety * 6 / (sigmaAllow * width)) // this is the calculation of two brackets holding up the shelf (inches)


// Sketch the bracket body and fillet the inner and outer edges of the bend
bracketLeg1Sketch = startSketchOn('XY')
  |> startProfileAt([0, 0], %)
  |> line(end = [shelfMountL - filletRadius, 0], tag = $fillet1)
  |> line(end = [0, width], tag = $fillet2)
  |> line(end = [-shelfMountL + filletRadius, 0])
  |> close()
  |> hole(circle({
       center = [1, 1],
       radius = mountingHoleDiameter / 2
     }, %), %)
  |> hole(circle({
       center = [shelfMountL - 1.5, width - 1],
       radius = mountingHoleDiameter / 2
     }, %), %)
  |> hole(circle({
       center = [1, width - 1],
       radius = mountingHoleDiameter / 2
     }, %), %)
  |> hole(circle({
       center = [shelfMountL - 1.5, 1],
       radius = mountingHoleDiameter / 2
     }, %), %)

// Extrude the leg 2 bracket sketch
bracketLeg1Extrude = extrude(bracketLeg1Sketch, length = thickness)
  |> fillet({
       radius = extFilletRadius,
       tags = [
         getNextAdjacentEdge(fillet1),
         getNextAdjacentEdge(fillet2)
       ]
     }, %)

// Sketch the fillet arc
filletSketch = startSketchOn('XZ')
  |> startProfileAt([0, 0], %)
  |> line(end = [0, thickness])
  |> arc({
       angleEnd = 180,
       angleStart = 90,
       radius = filletRadius + thickness
     }, %)
  |> line(end = [thickness, 0])
  |> arc({
       angleEnd = 90,
       angleStart = 180,
       radius = filletRadius
     }, %)

// Sketch the bend
filletExtrude = extrude(filletSketch, length = -width)

// Create a custom plane for the leg that sits on the wall
customPlane = {
  plane = {
    origin = { x = -filletRadius, y = 0, z = 0 },
    xAxis = { x = 0, y = 1, z = 0 },
    yAxis = { x = 0, y = 0, z = 1 },
    zAxis = { x = 1, y = 0, z = 0 }
  }
}

// Create a sketch for the second leg
bracketLeg2Sketch = startSketchOn(customPlane)
  |> startProfileAt([0, -filletRadius], %)
  |> line(end = [width, 0])
  |> line(end = [0, -wallMountL], tag = $fillet3)
  |> line(end = [-width, 0], tag = $fillet4)
  |> close()
  |> hole(circle({
       center = [1, -1.5],
       radius = mountingHoleDiameter / 2
     }, %), %)
  |> hole(circle({
       center = [5, -1.5],
       radius = mountingHoleDiameter / 2
     }, %), %)

// Extrude the second leg
bracketLeg2Extrude = extrude(bracketLeg2Sketch, length = -thickness)
  |> fillet({
       radius = extFilletRadius,
       tags = [
         getNextAdjacentEdge(fillet3),
         getNextAdjacentEdge(fillet4)
       ]
     }, %)