ViewDesignEngine/tests/brep/test_brep_modeling.cpp

#include <gtest/gtest.h>
#include "vde/brep/brep.h"
#include "vde/brep/modeling.h"
#include <cmath>

using namespace vde::brep;
using namespace vde::core;

// ═══════════════════════════════════════════════════════════
//  Fillet Tests
// ═══════════════════════════════════════════════════════════

TEST(FilletTest, FilletOnBoxEdge) {
    auto box = make_box(4.0, 4.0, 4.0);
    ASSERT_TRUE(box.is_valid());
    ASSERT_GE(box.num_edges(), 12u);  // 4 edges × 6 faces / shared? Actually 4*6=24 in current impl

    // Fillet edge 0 (first edge of first face)
    auto result = fillet(box, 0, 0.5);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    // Should have more faces than original (fillet adds new faces, removes sharper ones)
    // The fillet replaces 2 faces with their trimmed versions + N fillet faces
    EXPECT_GT(result.num_faces(), 4u);
    EXPECT_GT(result.num_vertices(), 8u);
}

TEST(FilletTest, FilletOnBoxEdge_ValidBody) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = fillet(box, 0, 0.3);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    EXPECT_GE(result.num_faces(), 3u);
    EXPECT_GE(result.num_vertices(), 8u);
}

TEST(FilletTest, FilletOnBoxEdge_ToMesh) {
    auto box = make_box(3.0, 3.0, 3.0);
    auto result = fillet(box, 0, 0.3);

    auto mesh = result.to_mesh();
    EXPECT_GT(mesh.num_faces(), 0u);
    EXPECT_GT(mesh.num_vertices(), 0u);
}

TEST(FilletTest, Fillet_ZeroRadius_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = fillet(box, 0, 0.0);

    // Zero radius should return original unchanged
    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(FilletTest, Fillet_InvalidEdge_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = fillet(box, -1, 0.5);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(FilletTest, Fillet_NonexistentEdge_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    int fake_edge = static_cast<int>(box.num_edges() + 10);
    auto result = fillet(box, fake_edge, 0.5);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(FilletTest, Fillet_NonManifoldEdge_ReturnsOriginal) {
    // With shared topology (v4.2+), each edge is shared by exactly 2 faces
    auto box = make_box(2.0, 2.0, 2.0);
    auto faces = box.edge_faces(0);
    EXPECT_EQ(faces.size(), 2u);
}

TEST(FilletTest, Fillet_MultipleEdges) {
    auto box = make_box(4.0, 4.0, 4.0);

    // First verify our model has enough edges
    ASSERT_GE(box.num_edges(), 4u);

    // Fillet first edge
    auto result1 = fillet(box, 0, 0.3);
    EXPECT_TRUE(result1.is_valid());
    EXPECT_GT(result1.num_faces(), 4u);

    // Fillet a different edge
    if (box.num_edges() >= 5) {
        auto result2 = fillet(box, 4, 0.3);
        EXPECT_TRUE(result2.is_valid());
    }
}

// ═══════════════════════════════════════════════════════════
//  Variable-Radius Fillet Tests
// ═══════════════════════════════════════════════════════════

TEST(FilletVariableTest, FilletVariableBoxEdge) {
    auto box = make_box(2.0, 2.0, 2.0);
    ASSERT_TRUE(box.is_valid());

    auto result = fillet_variable(box, 0, 0.2, 0.5, 8);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    // Should add fillet faces (at least the original 6 + fillet strip faces)
    EXPECT_GE(result.num_faces(), 6u);
    EXPECT_GE(result.num_vertices(), 8u);
}

TEST(FilletVariableTest, FilletVariableBoxEdge_ToMesh) {
    auto box = make_box(3.0, 3.0, 3.0);
    auto result = fillet_variable(box, 0, 0.2, 0.6, 10);

    EXPECT_TRUE(result.is_valid());
    auto mesh = result.to_mesh();
    EXPECT_GT(mesh.num_faces(), 0u);
    EXPECT_GT(mesh.num_vertices(), 0u);
}

TEST(FilletVariableTest, FilletVariableZeroStartRadius) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = fillet_variable(box, 0, 0.0, 0.3, 8);

    // Zero start radius should still produce a valid body
    // (fillet fades from 0 at start to 0.3 at end)
    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    EXPECT_GE(result.num_faces(), 6u);
}

TEST(FilletVariableTest, FilletVariableBothZero_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = fillet_variable(box, 0, 0.0, 0.0, 8);

    // Both radii zero: should return original unchanged
    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(FilletVariableTest, FilletVariableInvalidEdge_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = fillet_variable(box, -1, 0.2, 0.5, 8);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(FilletVariableTest, FilletVariableNonexistentEdge_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    int fake_edge = static_cast<int>(box.num_edges() + 10);
    auto result = fillet_variable(box, fake_edge, 0.2, 0.5, 8);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(FilletVariableTest, FilletVariableHighSamples) {
    auto box = make_box(4.0, 4.0, 4.0);
    auto result = fillet_variable(box, 0, 0.3, 0.8, 20);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    // More samples → more fillet strip faces (20 samples = 20 quad faces)
    EXPECT_GE(result.num_faces(), 25u);  // at least 20 fillet + a few rebuild faces
}

TEST(FilletVariableTest, FilletVariableSymmetric) {
    // r_start == r_end should behave like constant fillet
    auto box = make_box(3.0, 3.0, 3.0);
    auto result = fillet_variable(box, 0, 0.4, 0.4, 8);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    EXPECT_GE(result.num_faces(), 6u);
}

// ═══════════════════════════════════════════════════════════
//  Chamfer Tests
// ═══════════════════════════════════════════════════════════

TEST(ChamferTest, ChamferOnBoxEdge) {
    auto box = make_box(4.0, 4.0, 4.0);
    ASSERT_TRUE(box.is_valid());

    auto result = chamfer(box, 0, 0.5);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    // Chamfer adds faces (bevel face replaces sharp corner)
    EXPECT_GT(result.num_faces(), 4u);
    EXPECT_GT(result.num_vertices(), 8u);
}

TEST(ChamferTest, Chamfer_ToMesh) {
    auto box = make_box(3.0, 3.0, 3.0);
    auto result = chamfer(box, 0, 0.3);

    auto mesh = result.to_mesh();
    EXPECT_GT(mesh.num_faces(), 0u);
    EXPECT_GT(mesh.num_vertices(), 0u);
}

TEST(ChamferTest, Chamfer_ZeroDistance_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = chamfer(box, 0, 0.0);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(ChamferTest, Chamfer_InvalidEdge_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = chamfer(box, -1, 0.5);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

TEST(ChamferTest, Chamfer_NonexistentEdge_ReturnsOriginal) {
    auto box = make_box(2.0, 2.0, 2.0);
    int fake_edge = static_cast<int>(box.num_edges() + 5);
    auto result = chamfer(box, fake_edge, 0.5);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_faces(), box.num_faces());
}

// ═══════════════════════════════════════════════════════════
//  Shell Tests
// ═══════════════════════════════════════════════════════════

TEST(ShellTest, Shell_OpenBox_CreatesThinWall) {
    auto box = make_box(2.0, 2.0, 2.0);

    // Shell with open face (remove first face, thickness = 0.2)
    auto result = shell(box, 0, 0.2);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);

    // Shell creates both outer and inner faces + side walls for each edge of open face
    // Open face has 4 edges → 4 side wall quads
    // Remaining 5 faces → 5 outer + 5 inner = 10 faces
    // Total: 4 side walls + 10 offset faces = 14 faces
    EXPECT_GE(result.num_faces(), 10u);
    EXPECT_GE(result.num_vertices(), 16u);

    // Bounds should expand outward slightly (both inner and outer vertices exist)
    auto b = result.bounds();
    EXPECT_NEAR(b.extent().x(), 2.0, 0.3);
    EXPECT_NEAR(b.extent().y(), 2.0, 0.3);
    EXPECT_NEAR(b.extent().z(), 2.0, 0.3);
}

TEST(ShellTest, Shell_OpenBox_ToMesh) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = shell(box, 0, 0.2);

    auto mesh = result.to_mesh();
    EXPECT_GT(mesh.num_faces(), 0u);
    EXPECT_GT(mesh.num_vertices(), 0u);
}

TEST(ShellTest, Shell_ClosedBody_HollowSphere) {
    auto sphere = make_sphere(1.5, 16, 8);

    // Closed shell: no opening, just hollow
    auto result = shell(sphere, -1, 0.1);

    EXPECT_TRUE(result.is_valid());
    EXPECT_EQ(result.num_bodies(), 1u);
    // With closed shell, we get inner + outer faces for each original face
    EXPECT_GE(result.num_faces(), sphere.num_faces() * 2);

    auto mesh = result.to_mesh();
    EXPECT_GT(mesh.num_faces(), 0u);
}

TEST(ShellTest, Shell_ClosedBody_ToMesh) {
    auto sphere = make_sphere(1.0, 12, 6);
    auto result = shell(sphere, -1, 0.15);

    auto mesh = result.to_mesh();
    EXPECT_GT(mesh.num_faces(), 0u);
    EXPECT_GT(mesh.num_vertices(), 0u);
}

TEST(ShellTest, Shell_PositiveThickness_OutwardOffset) {
    auto box = make_box(2.0, 2.0, 2.0);

    // Positive thickness → outward offset
    auto result = shell(box, 0, 0.3);

    EXPECT_TRUE(result.is_valid());
    auto b = result.bounds();
    // Outer bounds should expand
    EXPECT_GT(b.extent().x(), 2.0 - 1e-6);
}

TEST(ShellTest, Shell_NegativeThickness_InwardOffset) {
    auto box = make_box(2.0, 2.0, 2.0);

    // Negative thickness → inward offset
    // Note: current implementation always uses -abs(thickness) for inward
    auto result = shell(box, 0, -0.2);

    EXPECT_TRUE(result.is_valid());
    // Should still produce valid geometry
    EXPECT_GT(result.num_faces(), 4u);
}

TEST(ShellTest, Shell_InvalidOpenFace) {
    auto box = make_box(2.0, 2.0, 2.0);
    int fake_face = static_cast<int>(box.num_faces() + 10);
    auto result = shell(box, fake_face, 0.2);

    // Should still work (just no side walls)
    EXPECT_TRUE(result.is_valid());
    EXPECT_GE(result.num_faces(), 4u);
}

TEST(ShellTest, Shell_SideWallsExist) {
    auto box = make_box(2.0, 2.0, 2.0);
    auto result = shell(box, 0, 0.2);

    // With an open face, the face count should be:
    // 5 outer faces + 5 inner faces + (4 edges * 1 side wall each) = 14
    // But our box has 6 faces, each with 4 edges, 24 total edges
    // Face 0 has 4 edges → 4 side walls
    auto open_edges = box.face_edges(0);
    size_t expected_walls = open_edges.size();
    // Total faces = (num_faces-1)*2 + expected_walls
    size_t expected_total = (box.num_faces() - 1) * 2 + expected_walls;
    EXPECT_GE(result.num_faces(), expected_total);
}

TEST(ShellTest, Shell_ThinWall_VeryThin) {
    auto box = make_box(2.0, 2.0, 2.0);

    // Very thin wall should still work
    auto result = shell(box, 0, 0.01);

    EXPECT_TRUE(result.is_valid());
    EXPECT_GT(result.num_faces(), 4u);
}

TEST(ShellTest, Shell_ClosedBox) {
    auto box = make_box(2.0, 2.0, 2.0);

    // Closed shell (open_face = -1) — no opening, fully hollow box
    auto result = shell(box, -1, 0.1);

    EXPECT_TRUE(result.is_valid());
    // All 6 faces → 6 outer + 6 inner = 12 faces (no side walls)
    EXPECT_GE(result.num_faces(), 12u);
}

TEST(ShellTest, Shell_ZeroSized) {
    auto box = make_box(1.0, 1.0, 1.0);

    // Shell with thickness larger than box — should still produce valid geometry
    auto result = shell(box, 0, 0.6);

    EXPECT_TRUE(result.is_valid());
    // May produce fewer faces if some faces collapse, but shouldn't crash
    EXPECT_GE(result.num_faces(), 0u);
}