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 Block(){
 122   sidemidx = minsideout + screwcsinkdia/2;
 123
 124   difference(){
 125     hull() mirror([0,0,1]) {
 126       translate([minx, 0, 0])
 127         cube([maxx-minx, totaldepth-front, height]);
 128       for (x=[minx + front/2, maxx - front/2])
 129         translate([x, -front/2, 0])
 130         cylinder(r=front/2, h=height, $fn=30);
 131     }
 132     for (x=[minx + sidemidx, maxx - sidemidx]) {
 133       translate([x, 0, -screwabove])
 134         ScrewHole();
 135     }
 136     for (yshift=[-1,1])
 137       translate([0, yshift * frontbackslop, 0])
 138         DoKnives();
 139   }
 140 }
 141
 142 module BlockPrint(){ ////toplevel
 143   rotate([0,0,90])
 144     Block();
 145 }
 146
 147 module CoverTemplate(){
 148   linear_extrude(height=coverthick)
 149     polygon([[minx, 0],
 150              [maxx, 0],
 151              [maxx, coverlonglen],
 152              [maxx - coverside, coverlonglen],
 153              [minx, covershortlen]]);
 154 }
 155
 156 module CoverSide(len){
 157   translate([0, 0 ,0]) {
 158     rotate([90,0,90])
 159       linear_extrude(height=coverside)
 160       polygon([[0,                      0],
 161                [0,                      totaldepth],
 162                [covertopwing,           totaldepth],
 163                [covertopwingbase,       coverside + coverthick],
 164                [len - covertopwingbase, coverside + coverthick],
 165                [len - covertopwing,     totaldepth],
 166                [len,                    totaldepth],
 167                [len,                    0]]);
 168     cube([recessblockwidth, recessblockheight, totaldepth]);
 169   }
 170 }
 171
 172 module Peg(){
 173   echo("peg angle slope (must be <1)",
 174        (peghead-pegstem)/(pegheight-pegstemheight));
 175   dx = pegsloph;
 176   dy = pegslopv;
 177   rotate([90,0,0]) {
 178     linear_extrude(height=peglen-pegslopl) {
 179       intersection(){
 180         translate([-dx,-dy,0]) PegTemplate();
 181         translate([-dx,+dy,0]) PegTemplate();
 182         translate([+dx,+dy,0]) PegTemplate();
 183         translate([+dx,-dy,0]) PegTemplate();
 184       }
 185     }
 186   }
 187 }
 188
 189 module CoverPegSlot(coverlen){
 190   translate([recessblockwidth/2, 0, -1]){
 191     linear_extrude(height= 1 + pegrecess + 0.5*peglen){
 192       PegTemplate();
 193     }
 194   }
 195 }
 196
 197 module Cover(){
 198   difference(){
 199     union(){
 200       CoverTemplate();
 201       AtSides() { CoverSide(covershortlen); CoverSide(coverlonglen); }
 202     }
 203     AtSides() { CoverPegSlot(); CoverPegSlot(); }
 204   }
 205 }
 206
 207 module CoverAligned(){
 208   translate([0,-front,-height])
 209     rotate([-90,0,0])
 210     Cover();
 211 }
 212
 213 module Demo(){ ////toplevel
 214   %Block();
 215   DoKnives();
 216   color([0,0,1]) CoverAligned();
 217 }
 218
 219 Demo();
 220 //Cover();
 221 //Peg();