CAM: Linking - Tolerance in get_linking_moves()

src/Mod/CAM/CAMTests/TestLinkingGenerator.py

@@ -82,6 +82,20 @@ class TestGetLinkingMoves(PathTestUtils.PathTestBase):
                 solids=[blocking_box],
             )
 
+    def test_path_blocked_by_solid_with_tolerance(self):
+        blocking_box = Part.makeBox(1, 10, 10)
+        blocking_box.translate(FreeCAD.Vector(5, -5, 0))
+        with self.assertRaises(RuntimeError):
+            generator.get_linking_moves(
+                start_position=self.start,
+                target_position=self.target,
+                local_clearance=5,
+                global_clearance=11,
+                tool_shape=self.tool,
+                tolerance=1.1,
+                solids=[blocking_box],
+            )
+
     def test_plunge_to_zero_depth(self):
         """Test that plunge moves correctly go to Z=0 (regression test for depth==0 bug)"""
         start = FreeCAD.Vector(0, 0, 1)  # Start below clearance

src/Mod/CAM/Path/Base/Generator/linking.py

@@ -62,7 +62,7 @@ def check_collision(
     # Create direct path wire
     wire = Part.Wire([Part.makeLine(start_position, target_position)])
     distance = wire.distToShape(collision_model)[0]
-    return distance < tolerance
+    return distance < tolerance and not Path.Geom.isRoughly(distance, tolerance)
 
 
 def get_linking_moves(
@@ -74,6 +74,7 @@ def get_linking_moves(
     solids: Optional[List[Part.Shape]] = None,
     retract_height_offset: Optional[float] = None,
     skip_if_no_collision: bool = False,
+    tolerance: float = 0.001,
 ) -> list:
     """
     Generate linking moves from start to target position.
@@ -121,7 +122,7 @@ def get_linking_moves(
     # Try each height
     for height in heights:
         wire = make_linking_wire(start_position, target_position, height)
-        if is_wire_collision_free(wire, collision_model):
+        if is_wire_collision_free(wire, collision_model, tolerance):
             cmds = Path.fromShape(wire).Commands
             # Ensure all commands have complete XYZ coordinates
             # Path.fromShape() may omit coordinates that don't change
@@ -170,4 +171,4 @@ def is_wire_collision_free(
     if not solid:
         return True
     distance = wire.distToShape(solid)[0]
-    return distance >= tolerance
+    return distance >= tolerance or Path.Geom.isRoughly(distance, tolerance)