Added check to Revolution and Groove for sketch axis intersecting the sketch face

src/Mod/PartDesign/App/FeatureGroove.cpp

@@ -33,6 +33,7 @@
 # include <TopExp_Explorer.hxx>
 # include <BRepAlgoAPI_Cut.hxx>
 # include <Precision.hxx>
+# include <gp_Lin.hxx>
 #endif
 
 #include <Base/Axis.h>
@@ -152,6 +153,10 @@ App::DocumentObjectExecReturn *Groove::execute(void)
         support.Move(invObjLoc);
         sketchshape.Move(invObjLoc);
 
+        // Check distance between sketchshape and axis - to avoid failures and crashes
+        if (checkLineCrossesFace(gp_Lin(pnt, dir), TopoDS::Face(sketchshape)))
+            return new App::DocumentObjectExecReturn("Revolve axis intersects the sketch");
+
         // revolve the face to a solid
         BRepPrimAPI_MakeRevol RevolMaker(sketchshape, gp_Ax1(pnt, dir), angle);
 

src/Mod/PartDesign/App/FeatureRevolution.cpp

@@ -33,6 +33,7 @@
 # include <TopExp_Explorer.hxx>
 # include <BRepAlgoAPI_Fuse.hxx>
 # include <Precision.hxx>
+# include <gp_Lin.hxx>
 #endif
 
 #include <Base/Axis.h>
@@ -40,6 +41,7 @@
 #include <Base/Tools.h>
 
 #include "FeatureRevolution.h"
+#include <Base/Console.h>
 
 
 using namespace PartDesign;
@@ -158,6 +160,10 @@ App::DocumentObjectExecReturn *Revolution::execute(void)
         support.Move(invObjLoc);
         sketchshape.Move(invObjLoc);
 
+        // Check distance between sketchshape and axis - to avoid failures and crashes
+        if (checkLineCrossesFace(gp_Lin(pnt, dir), TopoDS::Face(sketchshape)))
+            return new App::DocumentObjectExecReturn("Revolve axis intersects the sketch");
+
         // revolve the face to a solid
         BRepPrimAPI_MakeRevol RevolMaker(sketchshape, gp_Ax1(pnt, dir), angle);
 

src/Mod/PartDesign/App/FeatureSketchBased.cpp

@@ -52,6 +52,11 @@
 # include <ShapeAnalysis_Surface.hxx>
 # include <ShapeFix_Shape.hxx>
 # include <Standard_Version.hxx>
+# include <BRepBuilderAPI_MakeEdge.hxx>
+# include <Extrema_ExtCC.hxx>
+# include <Extrema_POnCurv.hxx>
+# include <BRepAdaptor_CompCurve.hxx>
+# include <BRepAdaptor_Curve.hxx>
 #endif
 
 
@@ -532,6 +537,61 @@ const bool SketchBased::checkWireInsideFace(const TopoDS_Wire& wire, const TopoD
     return (proj.More() && proj.Current().Closed());
 }
 
+const bool SketchBased::checkLineCrossesFace(const gp_Lin &line, const TopoDS_Face &face) {
+    // This is not as easy as it looks, because a distance of zero might be OK if
+    // the axis touches the sketchshape in in a linear edge or a vertex
+    // Note: This algorithm does not catch cases where the sketchshape touches the
+    // axis in two or more points
+    // Note: And it only works on closed outer wires
+    TopoDS_Wire outerWire = ShapeAnalysis::OuterWire(face);
+    BRepBuilderAPI_MakeEdge mkEdge(line);
+    if (!mkEdge.IsDone())
+        throw Base::Exception("Revolve: Unexpected OCE failure");
+    BRepAdaptor_Curve axis(TopoDS::Edge(mkEdge.Shape()));
+
+    TopExp_Explorer ex;
+    int intersections = 0;
+    std::vector<gp_Pnt> intersectionpoints;
+
+    // Note: We need to look at evey edge separately to catch coincident lines
+    for (ex.Init(outerWire, TopAbs_EDGE); ex.More(); ex.Next()) {
+        BRepAdaptor_Curve edge(TopoDS::Edge(ex.Current()));
+        Extrema_ExtCC intersector(axis, edge);
+
+        if (intersector.IsDone()) {
+            for (int i = 1; i <= intersector.NbExt(); i++) {
+
+
+                if (intersector.SquareDistance(i) < Precision::Confusion()) {
+                    if (intersector.IsParallel()) {
+                        // A line that is coincident with the axis produces three intersections
+                        // 1 with the line itself and 2 with the adjacent edges
+                        intersections -= 2;
+                    } else {
+                        Extrema_POnCurv p1, p2;
+                        intersector.Points(i, p1, p2);
+                        intersectionpoints.push_back(p1.Value());
+                        intersections++;
+                    }
+                }
+            }
+        }
+    }
+
+    // Note: We might check this inside the loop but then we have to rely on TopExp_Explorer
+    // returning the wire's edges in adjacent order (because of the coincident line checking)
+    if (intersections > 1) {
+        // Check that we don't touch the sketchface just in two identical vertices
+        if ((intersectionpoints.size() == 2) &&
+            (intersectionpoints[0].IsEqual(intersectionpoints[1], Precision::Confusion())))
+            return false;
+        else
+            return true;
+    }
+
+    return false;
+}
+
 void SketchBased::remapSupportShape(const TopoDS_Shape& newShape)
 {
     TopTools_IndexedMapOfShape faceMap;

src/Mod/PartDesign/App/FeatureSketchBased.h

@@ -32,6 +32,7 @@ class TopoDS_Shape;
 class TopoDS_Face;
 class TopoDS_Wire;
 class gp_Dir;
+class gp_Lin;
 
 namespace PartDesign
 {
@@ -110,6 +111,10 @@ protected:
     static const bool checkWireInsideFace(const TopoDS_Wire& wire,
                                           const TopoDS_Face& face,
                                           const gp_Dir& dir);
+
+    /// Check whether the line crosses the face (line and face must be on the same plane)
+    static const bool checkLineCrossesFace(const gp_Lin& line, const TopoDS_Face& face);
+
 };
 
 } //namespace PartDesign