Fix rendering/plotting of arcs with tiny angle and huge radius.

Fixes https://gitlab.com/kicad/code/kicad/-/issues/17343

(cherry picked from commit 4d66a8ebdb)

common/plotters/GERBER_plotter.cpp

@@ -879,19 +879,19 @@ void GERBER_PLOTTER::plotArc( const SHAPE_ARC& aArc, bool aPlotInRegion )
 
 
 void GERBER_PLOTTER::plotArc( const VECTOR2I& aCenter, const EDA_ANGLE& aStartAngle,
-                              const EDA_ANGLE& aEndAngle, int aRadius, bool aPlotInRegion )
+                              const EDA_ANGLE& aEndAngle, double aRadius, bool aPlotInRegion )
 {
     VECTOR2I start, end;
-    start.x = aCenter.x + KiROUND( aRadius * aStartAngle.Cos() );
-    start.y = aCenter.y + KiROUND( aRadius * aStartAngle.Sin() );
+    start.x = KiROUND( aCenter.x + aRadius * aStartAngle.Cos() );
+    start.y = KiROUND( aCenter.y + aRadius * aStartAngle.Sin() );
 
     if( !aPlotInRegion )
         MoveTo( start );
     else
         LineTo( start );
 
-    end.x = aCenter.x + KiROUND( aRadius * aEndAngle.Cos() );
-    end.y = aCenter.y + KiROUND( aRadius * aEndAngle.Sin() );
+    end.x = KiROUND( aCenter.x + aRadius * aEndAngle.Cos() );
+    end.y = KiROUND( aCenter.y + aRadius * aEndAngle.Sin() );
     VECTOR2D devEnd = userToDeviceCoordinates( end );
     // devRelCenter is the position on arc center relative to the arc start, in Gerber coord.
     VECTOR2D devRelCenter = userToDeviceCoordinates( aCenter ) - userToDeviceCoordinates( start );

common/plotters/HPGL_plotter.cpp

@@ -581,11 +581,11 @@ void HPGL_PLOTTER::Arc( const VECTOR2D& aCenter, const EDA_ANGLE& aStartAngle,
     EDA_ANGLE startAngle = -aStartAngle;
 
     // Calculate arc start point:
-    VECTOR2I cmap( aCenter.x + KiROUND( aRadius * startAngle.Cos() ),
-                   aCenter.y - KiROUND( aRadius * startAngle.Sin() ) );
+    VECTOR2I cmap( KiROUND( aCenter.x + aRadius * startAngle.Cos() ),
+                   KiROUND( aCenter.y - aRadius * startAngle.Sin() ) );
     VECTOR2D cmap_dev = userToDeviceCoordinates( cmap );
 
-    startOrAppendItem( cmap_dev, wxString::Format( "AA %.0f,%.0f,%.0f,%g",
+    startOrAppendItem( cmap_dev, wxString::Format( "AA %.0f,%.0f,%g,%g",
                                                    centre_device.x,
                                                    centre_device.y,
                                                    angle.AsDegrees(),

common/plotters/PDF_plotter.cpp

@@ -354,21 +354,21 @@ void PDF_PLOTTER::Arc( const VECTOR2D& aCenter, const EDA_ANGLE& aStartAngle,
     SetCurrentLineWidth( aWidth );
 
     // Usual trig arc plotting routine...
-    start.x = aCenter.x + KiROUND( aRadius * (-startAngle).Cos() );
-    start.y = aCenter.y + KiROUND( aRadius * (-startAngle).Sin() );
+    start.x = KiROUND( aCenter.x + aRadius * ( -startAngle ).Cos() );
+    start.y = KiROUND( aCenter.y + aRadius * ( -startAngle ).Sin() );
     VECTOR2D pos_dev = userToDeviceCoordinates( start );
     fprintf( m_workFile, "%g %g m ", pos_dev.x, pos_dev.y );
 
     for( EDA_ANGLE ii = startAngle + delta; ii < endAngle; ii += delta )
     {
-        end.x = aCenter.x + KiROUND( aRadius * (-ii).Cos() );
-        end.y = aCenter.y + KiROUND( aRadius * (-ii).Sin() );
+        end.x = KiROUND( aCenter.x + aRadius * ( -ii ).Cos() );
+        end.y = KiROUND( aCenter.y + aRadius * ( -ii ).Sin() );
         pos_dev = userToDeviceCoordinates( end );
         fprintf( m_workFile, "%g %g l ", pos_dev.x, pos_dev.y );
     }
 
-    end.x = aCenter.x + KiROUND( aRadius * (-endAngle).Cos() );
-    end.y = aCenter.y + KiROUND( aRadius * (-endAngle).Sin() );
+    end.x = KiROUND( aCenter.x + aRadius * ( -endAngle ).Cos() );
+    end.y = KiROUND( aCenter.y + aRadius * ( -endAngle ).Sin() );
     pos_dev = userToDeviceCoordinates( end );
     fprintf( m_workFile, "%g %g l ", pos_dev.x, pos_dev.y );
 

include/plotters/plotter_gerber.h

@@ -292,7 +292,7 @@ protected:
      * be initialized before calling it if needed.
      */
     void plotArc( const VECTOR2I& aCenter, const EDA_ANGLE& aStartAngle, const EDA_ANGLE& aEndAngle,
-                  int aRadius, bool aPlotInRegion );
+                  double aRadius, bool aPlotInRegion );
     void plotArc( const SHAPE_ARC& aArc, bool aPlotInRegion );
 
     /**

libs/kimath/include/trigo.h

@@ -193,8 +193,7 @@ bool TestSegmentHit( const VECTOR2I& aRefPoint, const VECTOR2I& aStart, const VE
  */
 inline double GetLineLength( const VECTOR2I& aPointA, const VECTOR2I& aPointB )
 {
-    // Implicitly casted to double
-    return hypot( aPointA.x - aPointB.x, aPointA.y - aPointB.y );
+    return hypot( (double) aPointA.x - aPointB.x, (double) aPointA.y - aPointB.y );
 }
 
 // These are the usual degrees <-> radians conversion routines

pcbnew/pcb_track.cpp

@@ -1355,7 +1355,10 @@ EDA_ANGLE PCB_ARC::GetAngle() const
 
 EDA_ANGLE PCB_ARC::GetArcAngleStart() const
 {
-    EDA_ANGLE angleStart( m_Start - GetPosition() );
+    VECTOR2I pos( GetPosition() );
+    VECTOR2D dir( (double) m_Start.x - pos.x, (double) m_Start.y - pos.y );
+
+    EDA_ANGLE angleStart( dir );
     return angleStart.Normalize();
 }
 
@@ -1363,7 +1366,10 @@ EDA_ANGLE PCB_ARC::GetArcAngleStart() const
 // Note: used in python tests.  Ignore CLion's claim that it's unused....
 EDA_ANGLE PCB_ARC::GetArcAngleEnd() const
 {
-    EDA_ANGLE angleEnd( m_End - GetPosition() );
+    VECTOR2I pos( GetPosition() );
+    VECTOR2D dir( (double) m_End.x - pos.x, (double) m_End.y - pos.y );
+
+    EDA_ANGLE angleEnd( dir );
     return angleEnd.Normalize();
 }