DIY

Carved iconostasis

Carved iconostasis They asked me here the other day to make a shelf for icons (iconostasis ). As always, open spaces help. I find a picture the customer likes.
Carved iconostasis Everything is not bad, but the shelf is angular, but you need a straight one on the wall. I think that's not a problem. I find the same, but direct.
< img class = "aligncenter" alt = "Carved iconostasis" src = "https://usamodelkina.ru/uploads/posts/2021-07/1626444913_006-000-01-ikonostas-2.jpg"/> I find drawing for CorelDraw (.cdr). If you take a closer look at the top picture (below I will show an increase in one place), it becomes clear that the details of the drawing were stupidly taken, placed them in a straight line and that's it. Quickie!
Carved iconostasis I will combine parts for aesthetics, well, I'll add my own … I open the found .cdr file in CorelDraw .
Carved iconostasis I translate it into .dxf format and open it in eDrawings from SolidWorks for checking.
 Carved iconostasis Next, I import the finished file into SoldWorks as a drawing of a new part. I select characteristics, layers and …
Carved iconostasis Carved iconostasis Carved iconostasis … ready (almost certainly)
Carved iconostasis From the general plan I select the necessary parts separately and save each part separately.
Carved iconostasis Carved iconostasis Now you can work with it. Dimensions don't matter yet. First, in the sketch, I combine each detail into a block . Left side mirror detail. Received 3 parts. I connect them directly in blocks using the collegiality and dot matching functions.
Carved iconostasis Function to spread the block helps to bring the big picture to editing. I remove the lines of contact of the past blocks. And I create blocks of parts again.
Carved iconostasis Now, you can freely move the created blocks as you like. I will try to reduce the vertical gaps in the sketch as much as possible by adding my own or extending existing patterns. Most likely a lot will have to be changed. In order not to draw too much, I will draw a center line in the center and delete, say, the right side. I'll work with one side and later mirror it around the axis.
 Carved iconostasis Locked the centerline. Then I start to move the blocks, set it as I need it. I connect a couple of points along the edge of the middle block with the centerline.
Carved iconostasis I align the lower points of the blocks horizontally.
< a href = "https://usamodelkina.ru/uploads/posts/2021-07/1626446324_006-000-01-ikonostas-16.jpg" rel = "prettyPhoto">Carved iconostasis I connect the blocks at the bottom points. There is still a gap between the top ones. I spread the block and save it before editing the sketch.
 Carved iconostasis Carved iconostasis Part of the vertical gap will have to be left, there will be stiffening ribs for the shelves themselves. For this, I will draw special holes. I can already see that I will delete part of the sketch and continue with another part of the sketch. This will have a greater effect of a single sketch field, rather than a composite one. Since the iconostasis will be mounted on the wall, I added a hole for fasteners.
Carved iconostasis Carved iconostasis Well, that seems to be all. Now I will mirror what I have drawn about the centerline. I'll add a couple of lines for the finished sketch and use Extrude Boss/Base to stretch it to 8mm. Birch plywood 8 mm thick will be used.
Carved iconostasis Carved iconostasis Carved iconostasis The customer asked for the distance between the shelves to be about 25 cm. I'll check.
Carved iconostasis We'll have to scale. That is, adjust the resulting sketch to the desired size. Therefore, I go into editing the sketch and use the scaling function to adjust the desired size to the desired size))))
 Carved iconostasis As always, there are troubles, where without them. With the change in dimensions, the dimensions of the seats for the shelves and stiffeners have also changed. And in order not to bother, I'll just delete them and draw new ones. It's easier this way.
 Carved iconostasis Now you need to draw the shelves. The sizes and distances of the bore holes are known. It's a matter of technology. First I drew the top one.
Carved iconostasis  Carved iconostasis Using the sketch of the top, I took it as a basis, drew the bottom. Large icons will be installed on the bottom, so I will increase the overhang. I'll also add a place for a lump.
Carved iconostasis Carved iconostasis I made a 2 mm recess in the shelf for the lump and I will install it collar.
 Carved iconostasis I took a piece from another craft and will install it. In my opinion they look normal. They will be cut on the 4th rotary axis.
 Carved iconostasis Carved iconostasis I almost forgot about the stiffeners. Quickly drew and installed on the assembly.
< img class = "aligncenter" alt = "Carved iconostasis" src = "https://usamodelkina.ru/uploads/posts/2021-07/1626447932_006-000-01-ikonostas-34.jpg"/> Carved iconostasis The next step is to lay out the details on a sheet, write a control program and cut out.
Here is the cutting process:
Carved iconostasis Carved iconostasis By the chips (if you can call it that), you can determine the degree of wear of the cutter. In the photographs, it is (shavings) in the color of plywood. When it starts to darken, that is, the material burns, then the cutter is dull and will soon break. This is with thin cutters, in the photo 1.5 mm. With cutters larger than 4-5 mm, it is more difficult. They have a tighter shank, and when such a cutter is blunt, you get a lot of smoke! Well, and accordingly, the effort to move and wear of the machine's lead screws significantly increases.
When I was building my machine, I laid in the basic wiring diagram the ability to track the current consumption of the spindle. Often saves! For different materials (wood, plastic, metal), you need to set an acceptable value for a specific cutter in the control program. If the feed during cutting is high (specifically for a specific cutter), then goodbye to the cutter. Well, and accordingly, if you specify the feed with a small value (in the G-code, the working feed G01, the feed has the value F with the value), then you can stretch the cut of the simplest part for a week/month …..
Carved iconostasis So, the first sheet is ready. You can remove finished parts and cuttings. Shavings in the form of flour estimate from the working area just into the corner. The photographs show the storage of this “flour” in the far right corner.
Carved iconostasis Carved iconostasis Carved iconostasis Here are the finished parts from the first sheet. A total of 2.5 sheets of 500 * 300 mm will be used. Since the working area of ​​the machine is less than some parts, then I just half these parts, cut them, then put them into one.
Carved iconostasis After a little cleaning of the working area, I fix a new plywood sheet and re-set the machine coordinates for this sheet. The photo shows that I put spacers under the workpiece (sheet) (large scraps from past work). This is so as not to spoil the working area, otherwise it can be quickly spoiled.
Carved iconostasis I am starting to manufacture parts for the turning group. Fortunately, there is only one type of them and the number is small. To do this, I install the 4th pivot axis. Immediately I set “zeros” for Y and Z.
Carved iconostasis I also set the counter center, clamp the workpiece into the chuck of the pivot axis and press it with the center. I set “0” on the X-axis.
Carved iconostasis I run the control program and in three passes (two roughing and one finishing) I get the first part.
 Carved iconostasis Carved iconostasis Carved iconostasis I set the connecting jumper too thin and as a result, during the first roughing of the second part, the first one breaks off. The managing director was tweaked for the future. And in this case, I just shift the center closer to the cartridge. The photographs show that the pivot axis and the center are centered on a special groove of the desktop when fastening. This excludes displacement “at an angle” and along planes (except for a plane along the installation of workpieces).
Carved iconostasis And here is the result of editing the control program with handles. For one installation of the workpiece, 4 finished parts at once. All that remains is to trim the tails. Frequency of processing norms !, you don't even have to grind.
 Carved iconostasis I start assembling the halves. Before this bar with sandpaper, I cleaned the surfaces from fringe. So far, vertical shelves are used only for screeds, well, how can it be without a clamp. After the surface of the parts has dried, I will go through an orbital sander.
Carved iconostasis I glued a decorative fence and kerchiefs to the shelves for rigidity.
 Carved iconostasis I glue the bottom shelf assembly, wait for it to dry (there are not an infinite number of clamps).
Carved iconostasis After the bottom glue has dried, I mount the top one. And I'm waiting for it to dry again.
Carved iconostasis The last touch remains – cover. Several almost empty (maximum 3/4) bottles of non-aqueous stain (this is what some say) stagnated, I merged everything into one, diluted with acetone and got this color.
 Carved iconostasis I have everything. All good!

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