knifeblock.scad

   1 // -*- C -*-
   2
   3 // properties of the knives
   4 nknives = 3;
   5 widths = [15.5, 15.8, 19.0];
   6 handlelenbase = 75;
   7 handlelendelta = [-15, 0, 10];
   8 locations = [-35, 0, 40];
   9 bladew = 5; // 2.5
  10 maxhandledepth = 45;
  11
  12 templatescale = 27.2 / 19.6;
  13
  14 coverlonglen = 120; // xxx
  15 covershortlen = 70; // xxx
  16
  17 // other tuneables
  18 front = 5;
  19 back = 5;
  20 height = 50;
  21 minsidein = 4;
  22 minsideout = 4;
  23
  24 frontbackslop = 0.25;
  25
  26 screwbackdepth = 6.0 - 1.0;
  27 screwdia =       4.0 + 0.5;
  28 screwcsinkdia =  9.8 + 1.0;
  29
  30 screwabove = 15;
  31
  32 coverthick = 2.4;
  33 coverside = coverthick;
  34
  35 covertopwing = 15;
  36 covertopwingbase = 20;
  37 coveredge = 3;
  38
  39 pegstem = 3.5;
  40 peghead = 10;
  41 pegstemheight = 2;
  42 pegheight = 9;
  43 peglen = 12;
  44
  45 recessblockwidth = peghead + pegstem*3;
  46 recessblockheight = peglen + pegstem*1.5;
  47
  48 pegsloph = 0.5;
  49 pegslopv = 0.5;
  50 pegslopl = 0.5;
  51
  52 pegdepthproportion = 0.67;
  53
  54 // computed
  55 side = minsidein + screwcsinkdia + minsideout;
  56 totaldepth = front + maxhandledepth + back;
  57
  58 minkx = locations[0] -         widths[0]        /2;
  59 maxkx = locations[nknives-1] + widths[nknives-1]/2;
  60
  61 minx = minkx - side;
  62 maxx = maxkx + side;
  63
  64 pegrecess = pegdepthproportion*totaldepth - 0.5*peglen;
  65
  66 module ImportTemplate(w,k,t) {
  67   fn = str("knifeblock-knives-t",k,t,".dxf");
  68   echo(fn);
  69   translate([0,0, -w/2])
  70     linear_extrude(height=w)
  71     scale(templatescale) import(file=fn, convexity=100);
  72 }
  73
  74 module Knife(k){
  75   ImportTemplate(bladew, k,"bl");
  76   hull(){
  77     ImportTemplate(widths[k], k,"hl");
  78     translate([-100,0,0])
  79       ImportTemplate(widths[k], k,"hl");
  80   }
  81 }
  82
  83 module DoKnife(k){
  84   translate([locations[k],0,0]){
  85     rotate([0,90,0])
  86       translate([-(handlelenbase + handlelendelta[k]),0,0])
  87       Knife(k);
  88   }
  89 }
  90
  91 module DoKnives(){
  92   for (k=[0:nknives-1])
  93     DoKnife(k);
  94 }
  95
  96 module ScrewHole(){
  97   translate([0,-50,0])
  98     rotate([-90,0,0])
  99     cylinder(r=screwdia/2, h=150, $fn=40);
 100   translate([0, totaldepth-front - screwbackdepth, 0])
 101     rotate([90,0,0])
 102     cylinder(r=screwcsinkdia/2 / (sqrt(3)/2), h=100, $fn=6);
 103 }
 104
 105 module PegTemplate(){
 106   for (mx=[0,1]) for (my=[0,1]) {
 107       mirror([mx,0,0]) mirror([0,my,0])
 108         polygon([[-0.1,      -0.1],
 109                  [pegstem/2, -0.1],
 110                  [pegstem/2, pegstemheight/2],
 111                  [peghead/2, pegheight    /2],
 112                  [-0.1,      pegheight    /2]]);
 113     }
 114 }
 115
 116 module AtSides(){
 117   translate([minx,0,0])                 child(0);
 118   translate([maxx,0,0]) mirror([1,0,0]) child(1);
 119 }
 120
 121 module BlockPegSlot(){
 122   translate([recessblockwidth/2, pegrecess - 0.5*peglen, -height]){
 123     rotate([-90,0,0]) linear_extrude(height=totaldepth){
 124       PegTemplate();
 125     }
 126   }
 127 }
 128
 129 module Block(){
 130   sidemidx = minsideout + screwcsinkdia/2;
 131
 132   difference(){
 133     hull() mirror([0,0,1]) {
 134       translate([minx, 0, 0])
 135         cube([maxx-minx, totaldepth-front, height]);
 136       for (x=[minx + front/2, maxx - front/2])
 137         translate([x, -front/2, 0])
 138         cylinder(r=front/2, h=height, $fn=30);
 139     }
 140     for (x=[minx + sidemidx, maxx - sidemidx]) {
 141       translate([x, 0, -screwabove])
 142         ScrewHole();
 143     }
 144     for (yshift=[-1,1])
 145       translate([0, yshift * frontbackslop, 0])
 146         DoKnives();
 147     AtSides() { BlockPegSlot(); BlockPegSlot(); }
 148   }
 149 }
 150
 151 module BlockPrint(){ ////toplevel
 152   rotate([0,0,90])
 153     Block();
 154 }
 155
 156 module CoverTemplate(){
 157   linear_extrude(height=coverthick)
 158     polygon([[minx, 0],
 159              [maxx, 0],
 160              [maxx, coverlonglen],
 161              [maxx - coverside, coverlonglen],
 162              [minx, covershortlen]]);
 163 }
 164
 165 module CoverSide(len){
 166   translate([0, 0 ,0]) {
 167     rotate([90,0,90])
 168       linear_extrude(height=coverside)
 169       polygon([[0,                      0],
 170                [0,                      totaldepth],
 171                [covertopwing,           totaldepth],
 172                [covertopwingbase,       coverside + coverthick],
 173                [len - covertopwingbase, coverside + coverthick],
 174                [len - covertopwing,     totaldepth],
 175                [len,                    totaldepth],
 176                [len,                    0]]);
 177     cube([recessblockwidth, recessblockheight, totaldepth]);
 178   }
 179 }
 180
 181 module Peg(){
 182   echo("peg angle slope (must be <1)",
 183        (peghead-pegstem)/(pegheight-pegstemheight));
 184   dx = pegsloph;
 185   dy = pegslopv;
 186   rotate([90,0,0]) {
 187     linear_extrude(height=peglen-pegslopl) {
 188       intersection(){
 189         translate([-dx,-dy,0]) PegTemplate();
 190         translate([-dx,+dy,0]) PegTemplate();
 191         translate([+dx,+dy,0]) PegTemplate();
 192         translate([+dx,-dy,0]) PegTemplate();
 193       }
 194     }
 195   }
 196 }
 197
 198 module CoverPegSlot(coverlen){
 199   translate([recessblockwidth/2, 0, -1]){
 200     linear_extrude(height= 1 + pegrecess + 0.5*peglen){
 201       PegTemplate();
 202     }
 203   }
 204 }
 205
 206 module Cover(){
 207   difference(){
 208     union(){
 209       CoverTemplate();
 210       AtSides() { CoverSide(covershortlen); CoverSide(coverlonglen); }
 211     }
 212     AtSides() { CoverPegSlot(); CoverPegSlot(); }
 213   }
 214 }
 215
 216 module CoverAligned(){
 217   translate([0,-front,-height])
 218     rotate([-90,0,0])
 219     Cover();
 220 }
 221
 222 module Demo(){ ////toplevel
 223   %Block();
 224   DoKnives();
 225   color([0,0,1]) CoverAligned();
 226 }
 227
 228 Demo();
 229 //Cover();
 230 //Peg();