If you need to make a copy of an object made of wood or metal, copying equipment comes to the rescue; for this purpose it is used in many enterprises. In particular, copy-milling installations are designed to create objects that replicate the original sample as closely as possible.
Modern types of machines make it possible to perform work accurately and quickly in large quantities. Such installations are great for creating copying works on a plane and in volume using appropriate copiers and volumetric models. What is a milling machine? copying machine on wood, how it works and what its approximate price is, we will learn from the article.
Milling and copying equipment
Machines of this type are one of the ways machining to create the items you need geometric shape. The surface of the workpiece is processed in several stages - roughing, semi-finishing and finishing.
The scope of application of milling machines is very wide - these are shaped parts made of wood, plane milling, profile processing, volumetric milling of reliefs of objects and parts. Before you get into mass production, milling machines must undergo special certification to comply with all safety standards and regulations necessary during the work process.
Thanks to the method of template copying technology, the same shape of all parts is obtained and the error of the worker servicing the machine is reduced to zero, since the person does not influence the working process of the unit.
To produce a series of absolutely identical finished products it is necessary to use special templates or a product that was made based on it. Experts recommend equipping the unit with a pantograph. This is a mechanism that transmits movements to the cutting tool as accurately as possible along the head installation profile.
Processing the workpiece according to the copier through the copy mechanism gives a command to everyone actuators unit. The installation cutter and the part that is being milled recreate the surface specified on the copier in relative movement.
The main movements include the working table of a milling machine, movement along the contour of the slide, and rotation of the spindle. The secondary ones are:
- Moving the tracer table, the installation nature of the copying finger and stops.
- Acceleration of the movement of the spindle of the slide and the working surface of the table.
- Spindle head clamp.
Copy milling can be of two types:
- Outline.
- Volumetric.
Contour milling is different in that when processing wood the copier curve is located in a parallel or perpendicular axis working tool. In one case, the working surface with the workpiece and the copier moves only in the parallel or transverse direction of the copier, its curved line. They can also only move longitudinally, in which case the entire curve process is controlled by moving the tracing finger and cutter in vertical plane.
When the volumetric copying process is underway, the workpiece has a spatially complex surface. It is processed by two or more parallel strokes of the work table, with each stroke performing contour milling. The working tool of the machine that carries out the entire process, after each working pass forced to move relative to the part to the cross feed rate perpendicular to the line, then the table moves again.
Purpose of milling and copying units and their advantages
This equipment has long become indispensable for small furniture workshops. They help to mill straight and curved surfaces, drill holes, and make nests of various configurations in wood.
They are used for carving different breeds wood, for copying sculptures and flat-relief surfaces. Machines help to significantly improve the quality of processed products. The main advantages of copy-milling machines for wood include:
- Compactness.
- High strength.
- Long service life.
- High precision and reliability of machines.
Price for wood milling and copying machines
The equipment is designed for surface treatment soft and hard wood, so they are perfect for carpentry and model workshops.
Milling and copying units made in Italy G 60 - G 80 - G90 GRIGGIO, very popular in carpentry and furniture production. They are designed for milling curved and straight contours, nests, contours and grooves, drilling and countersinking holes in carpentry and furniture blanks. Excellent for processing furniture facades And door leaves. Worktable size - 750x600 mm, vertical travel of the worktable - 150 mm, spindle movement in the vertical plane - 80 mm, spindle rotates with a frequency of 9,000-18,000 rpm. Approximate price: 339,000 rubles.
Milling and copying machine VFK-810 (table rotation angle up to 45 o) - designed for milling curved and straight contours, nests, grooves, countersinking and drilling holes in furniture and joinery blanks. An important advantage is the high speed of up to 20,000 rpm, the ideal quality that the spindle gives. The lift of the table is 200 mm, its size, length - 1,000 and width - 800 mm. Approximate price - 274,000 rubles.
Milling and copying unit WINNER LH-1000 made in Taiwan - perfect option for the production of panel doors and other types of carpentry work. Such operations are the most complex and time-consuming, so even experienced master with high qualifications are not able to cope with such a task in a short time. It produces a paneled element in one pass; the multi-level spindle quickly changes the profile without rearranging the tool. Equipped with a special table with flat system coordinates, which gives high accuracy of all milling operations performed, as well as safety. The spindle rotates at a frequency of 9,000 rpm, the price of the machine is 1,246,463 rubles.
Copy milling machine made in China MX 5068. Its distinctive features are high speed up to 18,000 rpm, the spindle provides ideal quality, products do not require further processing. Vertical movement of the spindle from a pneumatic drive, rotation of the table by 45 o, increased dimensions of the work table - 805-600 mm, maximum thickness of the workpiece - 150 mm, machine weight - 440 kg, product price - 193,240 rubles.
Equipment such as a modern copy milling machine is different high accuracy and reliability in performing various types of work. In order to start working on it, 2-3 days of training is enough, after which you can create real masterpieces in wood.
Milling is one of the most common methods of wood processing. Using a milling cutter you can make parts of a wide variety of configurations.
The resulting product is characterized by high precision and surface cleanliness. indispensable in a home workshop, but often what is required is not a one-piece part, but several completely identical products.
Here on help will come wood milling and copying machine. This is a device that can create copies of a reference product, recreate a part according to a template, and some models even work according to drawings.
Distinctive features of copy routers
The cutting tool of this type of machine is milling cutters various shapes and designs. Actually, a copy-milling machine is a device with a movable cutter, the depth and angle of penetration of which is adjusted with a special probe.
The range of products that a copy milling machine can produce is very wide. Among other things, it should be noted:
- all kinds of furniture parts;
- carved and figured interior elements;
- profile frames for paintings and photographs;
- three-dimensional products with carvings (boxes, figurines);
- exterior elements (plinths, platbands, baguettes);
- decorative stair railings, fence details;
- handles for tools.
In addition, copy milling machines are used in technological process specific productions. On machines of this type they create wooden parts firearms (stock, forearm).
Machine device
Structurally, this machine consists of a frame on which a moving part is installed. In the simplest case, the moving part is a rigidly connected probe that moves along the surface of the model or template, and a cutting head that processes the workpiece. Devices with a mechanical connection are distinguished by ease of assembly; such a copying machine is easy to make with your own hands.
Note! Many models of copy milling cutters allow you to cut not only exact copies of parts, but also reproduce them on a certain scale. For this purpose, an additional device is used - a pantograph.
The pantograph can be mechanical (a rod system that allows you to change proportions) or an electronic mechanism that controls a pneumatic or hydraulic drive.
A measuring finger with a pointed or rounded end is used as a probe. Good results when working with large parts, it gives a roller feeler gauge. It is a rubberized wheel that rolls freely over the surface, following the contours of the reference part. More expensive models have electronic control, and a laser meter is used as a probe.
Main types of copy routers
Devices of this type are in demand in a variety of industries; they are an excellent assistant for home handyman working with wood. Given the high demand, manufacturers offer many types of machines that differ in purpose and technical characteristics.
Copy-milling machines are distinguished by the degree of automation and the method of fixing the workpiece. The most popular are simple desktop devices designed for the manufacture of small parts.
Stationary machines with pneumatic fixation of the workpiece are in demand. They perform a wide range of work and can process not only wood, but also metals. Automatic multi-spindle equipment is in demand in production, allowing it to simultaneously perform several operations.
Several groups of machines can be distinguished based on their design features:
- devices on a rotating frame that moves in a vertical plane;
- a machine with a pantograph that allows you to make enlarged or reduced copies of the template;
- multi-spindle devices with rotary tables;
- photocopiers.
A copy-milling machine is a complex device, however, if you have the skills to work with metal, it can be made in a home workshop. It’s hardly worth trying to recreate powerful factory equipment; you won’t need this for your home. The best device For a home workshop, a simple tabletop or stationary copying machine on a rotating frame with one working tool can be considered.
Factory equipment
Not everyone will undertake making a wood copy router with their own hands. Still, it’s difficult, the work will require skills and free time. If there is a need to acquire this useful machine in all respects, but there is no desire to tinker with drawings and parts, it is worth considering purchasing a finished factory product.
We must not forget that choosing any machine for a home workshop, copy milling is no exception, is a serious matter. It’s worth spending a little time comparing the main characteristics and choosing a device that is guaranteed to cope with the tasks. When choosing a machine, you should pay attention to the following:
- type of device, as a result, list of work performed;
- engine power, labor productivity and the permissible hardness of the processed material depend on it;
- brand and country of origin.
The price of a machine largely depends on its manufacturer. With approximately equal indicators, products from the European Union and the United States will be more expensive. The price of devices from Asian countries is much lower, but you have to be careful here; low cost does not always go hand in hand with quality.
Examples of manufacturers
Those who need a reliable machine for flat milling should pay attention to the products Italian company GRIGGIO. Machines of this trademark have a relatively low price and are good decision for creating shaped parts, skirting boards, platbands. With their help it is convenient to create facades of furniture panels and wooden doors.
The VFK-810 milling machine with a table rotation angle of 45 degrees is perfect for those who are interested in making furniture. Her distinctive feature– high rotation speed of the cutter (up to 20,000 rpm), which guarantees excellent surface quality of the finished product.
The Chinese MX 5068 unit has comparable characteristics at a much lower price. It boasts a cutter rotation speed of up to 18,000 rpm and uses a pneumatic drive for table rotation and tool movement.
Those who are planning to take up carpentry seriously should pay attention to a milling unit made in Taiwan. WINNER LH-1000 will become best assistant if necessary, serial production of similar parts. A special feature of the machine is a multi-level spindle, which allows you to perform several operations at once in one pass and create a product of the required profile without the need to rearrange the cutting tool.
CNC copy milling machines
A separate type of copy-milling machines are devices with CNC (computer numerical control). These machines are more complex to manufacture, but have a number of significant advantages compared to simple models:
- ability to work in fully automatic mode without operator participation;
- stable high quality manufactured products;
- ease of setup and programming;
- Possibility of integration into a computer system.
CNC devices are obviously more expensive; their purchase is advisable for large manufacturing enterprises.
Homemade copy router
Factory-made devices are expensive; designing a homemade wood copying machine will help you get out of this situation. It is unlikely that it will be able to compete with purchased models in terms of power and reliability, but the price advantage is guaranteed.
There is an opinion that the easiest way is to make a copying machine from an existing ordinary wood milling machine. It is a bad idea. The fact is that these two devices have very little in common, only the type of cutting tool; everything else will have to be radically altered. It is much easier to design and manufacture a machine from scratch.
You should start by choosing the layout of the future device. A drawing will help simplify the process.
Note! There is no need to try to create your own device; a drawing of any type of router is easy to find on the Internet.
By the way, it is not necessary to follow it exactly; the dimensions can be easily adjusted to suit your needs.
There are a number of requirements for a copy milling machine. Among other things, it should be different:
- heavy and stable frame;
- precisely manufactured guides;
- the ability to adjust the angle of inclination of the tool;
- ability to scale products.
Working tool simple machine will serve manual frezer. Such a solution will significantly simplify the design, since there is no need to design this complex unit; it is enough to just make a reliable fastening. Its configuration is selected based on the size and shape of the router.
The basis of any machine is the bed. It must be reliable and stable. One of the main problems of a homemade copying machine is the inaccuracy of the output product caused by vibration and backlash. Errors during assembly can affect the accuracy of the manufactured part, which will lead to a large percentage of defects.
No less influential on the quality of work is the precision of the manufacture of the copier - the frame on which it is installed. cutting tool and dipstick. It must ensure accurate transfer of force from the probe to the tool and prevent vibration of the cutter.
Those who like to work with wood, who plan to make furniture for themselves or to order, should definitely get this useful tool. It will significantly expand the capabilities of your home workshop and give you a chance to make money from your hobby. The purchased device will become the basis home production, and a homemade machine will help you try out a new business without major investment.
Making a simple copying machine with your own hands at first glance seems like an easy task. There are many photos of finished structures on the Internet that impress with their originality and ease of manufacture. Many people are eager to do something like this. But when the homemade copying machine is assembled, it turns out that not everything is so smooth.
Copying machines come with milling and turning. In terms of prevalence, the first place is occupied by milling and copying machines. They are more functional and allow you to get not only round copies, but also free-form copies. They will be discussed in this article.
The biggest problem with a home-assembled milling and copying machine is backlash and vibration. Many home craftsmen complain that when copying a sample, the resulting product has many inconsistencies and flaws that appeared when changing the direction of the molding cutter and shaking supporting structure. In addition, they add to the trouble of bending and bending of the workpiece, associated with an increase in internal stress due to wood sampling. Therefore, when making a copying machine, it is impossible to immediately avoid all the shortcomings. As a rule, after assembly it is necessary to bring the structure to acceptable parameters for some time.
In any case, it is better to make a homemade copying machine not universal, but narrow-profile, that is, optimized for the manufacture of specific products that you need. For example, to effectively produce a wooden part of a gun, a propeller screw, and three-dimensional text, different technical solutions, and if they are combined in one machine, then there may be side effects, which will be difficult to fix. Therefore, it is more practical to assemble machines for a specific task. This approach will avoid many difficulties and unjustified costs.
The size of the machine is also an important factor. The larger the workpiece you plan to process, the more massive the structure should be. Vibrations transmitted from the cutter drive must be absorbed by the mass of the machine's supporting structure. And the guide axles must not only withstand the load, but also have a margin of safety so that they do not bend. At independent design For a milling and copying machine, the optimal parameters for the smooth running of the cutter are selected experimentally.
The principle of operation of a milling and copying machine is as follows: a milling cutter for sampling wood and a probe are installed on a movable frame, which is used to guide the original. The frame lowers to wooden blank, and the milling cutter removes excess wood. The whole point of the design is to ensure simultaneous movement of the cutter and probe in three planes, as well as rotation around the transverse axis. For this purpose, metal guides or wooden hinge systems are used. Wood absorbs vibrations better, is easier to process and has a lower cost. The video at the bottom of the page shows a homemade copying machine for creating flat-relief images and three-dimensional inscriptions with in a non-standard way movement in space. Moreover, this design provides for a twofold reduction in scale. You can download the drawings of the milling and copying machine in one archive at the bottom of the page.
Now making a copy of, for example, a three-dimensional inscription will not be difficult. You can also make a template for creating 3D text yourself. To do this you will need a printed sketch, a couple of cardboard sheets, glue and a stationery knife. We glue the sheet with the sketch and the cardboard together so that the paper does not wrinkle. After drying with a point stationery knife Carefully cut out the letters exactly according to the sketch. A template height of 2 mm is usually enough to prevent the probe from slipping.
Download the copying machine diagram
New entries:
Copy-milling machine “Duplicarver”
The “Duplicarver” copy-milling machine is designed for wood carving, copying sculptures and flat-relief products.
Today it has no analogues on the Russian market in terms of price-quality parameters, and has received wide recognition among professionals and those who are just beginning to master carving.
The machines meet the requirements Technical regulations customs union TR CU 010/2011 “On the safety of machinery and equipment” and have a declaration of conformity registered in Federal service for accreditation (Rosaccreditation) under the Ministry of Economic Development of the Russian Federation.
Registration number of the declaration of conformity: EAEU N RU D-RU.AB93.V.06056
Our company produces three models of machines.
Duplicarver-1 and Duplicarver-2 allow you to perform two types of threads.
- Volumetric or sculptural carving.
The main type of carving performed on these machines. You will be able to make copies of various sculptures, both simple and complex.
- Flat relief carving. It can be different door panels, panels and other products with a relatively shallow pattern depth. At the same time, the dimensions of the products are limited only by width, and their length can be any, within reasonable limits, of course.
Duplicarver-3 retained all the capabilities of Duplicarver-2 and acquired completely new ones.
Now it is possible to produce long volumetric threads.
- Long volumetric thread.
Do-it-yourself copy milling machine for wood
The most typical objects of carving are gun butts, table legs, balusters stair railings, long lamps, tall figurines and any other objects whose size corresponds to the working capabilities of the machine.
The working tool of the machine is a high-quality milling cutter produced in Germany. The control system allows you to smoothly change the rotation speed of the cutter from 10,000 to 30,000 rpm.
The machine works very reliably and accurately. You can master the techniques of working with it quite quickly, within a few days. The machine gives real pleasure from the results of its work. The payback period for the machine is one month. Start browsing our website with a photo gallery of works, watch video clips, and you will get an idea of the capabilities of the Duplicarver copy-milling machine.
A wood copying and milling machine is a universal equipment designed for copying products in two- and three-dimensional formats. This unit can copy a finished two-dimensional product, as well as using special copiers and three-dimensional models.
In addition, the technique is often used to engrave profiles and a wide variety of decorative elements. You can also “entrust” simple traditional milling work to a copy-milling machine for wood, which it can handle on a par with traditional milling machines.
This technique is inherently unique, since with its rather primitive device it is able to copy enough complex designs, including very thin handmade.
Such machines can be found at a variety of enterprises, including large industrial facilities with large-scale production.
The copy-milling unit specializes in milling curved parts.
This is done by copying a template.
Do-it-yourself copying and milling machine for wood
It is the templates that make it possible to make the process as accurate as possible, eliminating manual work and, accordingly, the human factor. This feature of the technology guarantees that the resulting parts will be identical and their shape will be the same.
In this case, the master can use either one template for all parts, or use already manufactured parts as a template.
In fact, every part produced on such equipment can act as a sample, which confirms the amazing accuracy of the technology.
If this is not enough for you, you can improve the accuracy of your machine.
To do this, you should equip it with a special copying device. It is called a pantograph and is designed to transmit extremely accurately the movement of the copy head to the main device processing the workpiece. If the template has many “fine” details, it makes sense to select a copy-milling machine for wood, which has a pantograph as an option.
Design Features
This unit allows you to process profiles or relief.
Processing is carried out with a special tool made of hard alloys. We are talking about cutters. The cutter completely repeats the movements of the copier - a device that reproduces the contours of the template. This master device is equipped with a mechanical or other connection with a tracking system responsible for the trajectory of the tool.
What can perform the functions of a copier for such a machine?
This can be a three-dimensional or flat sample, an outline drawing or a reference model. A special probe actually traces the contours of the workpiece, which are transferred to the tool. In some modern units, instead of a probe, a photocell can be used, which is characterized by increased accuracy.
Pantograph – important element copy-milling machine for wood.
Its design includes a special guide pin. It moves along the copier, accurately capturing any geometric features of the figure. In this case, the proportions of the pantograph arms determine the relative size of the final result.
Classification of copy milling machines
Today it is possible to divide all the machines on the market according to many parameters.
The following units can be distinguished by drive type:
- Copying machines with two- or three-dimensional pantograph;
- A universal unit located on a rotating arm;
- Equipment equipped with a round or rectangular table;
- Copiers with electric, hydraulic or mechanical feed.
- Photocopying units.
There are also such units that differ from each other in their level of automation:
- Manual desktop type machine with mechanical clamp.
- Automatic copy-milling machine equipped with pneumatic clamp.
- Stationary automated machine with pneumatic clamp and three-spindle attachment.
conclusions
Copy-milling machines occupy a place of honor in the woodworking industry.
Without them, manufacturing a part with complex relief would take a lot of time. With the advent of such technology, labor productivity on an enterprise scale increases tenfold.
This is why purchasing such a machine can be a very valuable investment for a craftsman.
COPYER a, m. copyier germ. copyen, Kopiershablone. A part of a copying machine that transmits movement to a tool that reproduces on a workpiece a given surface profile corresponding to the profile of the copier. SIS 1985. Copier processing. Leping 1,738. || How does the cutlet machine mechanism work?
The disk with the pistons rotates, the piston rods rest against the copier below, as if rolling on the copier either uphill or downhill. Therefore, the pistons themselves either rise above the protrusions of the copier, or fall under the action of a spring. The copier can be rotated 180° using the handle.
PIO 1997 2 43. - Lex. SIS 1979: copy/…
Copier`Big Encyclopedic Polytechnic Dictionary`
copier`Russian orthographic dictionary`
kop\’ir, -a
Russian spelling dictionary. / Russian Academy Sci. Institute rus.
Homemade copying machine
V. Vinogradova. - M.: “Azbukovnik”. V. V. Lopatin (executive editor), B. Z. Bukchina, N. A. Eskova and others. 1999.
Copier'Efremova's Explanatory Dictionary'
A part of a copying machine that transmits movement to a tool that reproduces the workpiece specified by a template, drawing, etc. profile.
(German: Kopierschablone) - detail copier, having a shaped profile (shaped ruler, cam, washer, etc.).
Big Encyclopedic Polytechnic Dictionary 2004
Copier
Page 1
The copying device consists of a copier mounted on the movable part of the device, along which the roller of the drive bracket, fixedly mounted on the vertical guides of the machine, slides from below.
The copier works as follows. Both cavities communicate with each other, for which a hole is made in the piston. The hydraulic cylinder rod is tl tr fastening, and the cylinder tzd 1 is fastened.
Copying devices are made either in the form of adaptations to existing machines (lathes, milling, etc.), or are organically built into them and form copying machines or semi-automatic machines.
The copying device can be mechanical, electromechanical, or hydraulic, and the rotation of the spindle unit and table can be single or double index.
Copiers can also be installed on horizontal milling machines.
The copying device (Fig. 73) is used for processing shaped surfaces with fairly high accuracy.
The copying device of this machine works using the inductive method.
Pattern copiers can achieve accuracy down to 0.02 mm.
Do-it-yourself copy-milling machine - we create reliable equipment!
The copier consists of three separate parts: the copier posts (right and left), the sensor slide, and the sensor. The copier stands are installed on the support body and can be moved along the support guides to install the copier when setting up the machine.
The copier is designed for longitudinal and transverse copying. To do this, a special holder with a roller is attached to the turret head, which rests against the copy ruler. The copy ruler is installed at the required angle to the horizontal and secured in this position.
Copiers of this type (Fig.
6.25) are equipped with two piston engines: with an inclined washer 6 - for the driving movement and 5 - for the follower movement.
Copiers can be rationally used on rotary machines. Single-column rotary machines model 1541 from the Sedin plant, as well as new domestic machines, are equipped with copying devices. Foreign companies Schiess, Frorip, Gidings, Webster and Bennett and others manufacture machines of appropriate designs that allow the installation of copying devices.
Copiers can be mechanical, electrical or hydraulic. Holder 6 with copier 7 is fixed in the turret socket, and body 2 is fixed in the side support tool holder.
The cutter / processes the shaped profile.
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Wood craftsmen sometimes face the need to create the most accurate copy of a product. For this purpose, many enterprises today use copy-milling equipment. With its help, you can produce parts in impressive quantities, while achieving impressive processing speed and excellent quality.
Purpose of the machine
Milling is one of the traditional ways processing. Using this approach, it is possible to process simple and shaped surfaces of varying cleanliness. Milling machines are suitable for the corresponding processing of slats or, for example, levers, which can have simple or complex contour configurations.
Principle of operation
Processing of products is carried out using a copier, the actions of which are set by the copier. Through the copier, the latter acts on the executive bodies; the cutter from the workpiece recreates the surface that is specified on the copier. The operating principle of a copy-milling machine for wood is based on the rotation of the spindle, which is the main movement. The sled and table move along the contour. During milling, the spindle head moves.
The basis of the work is the movement of the sled
Auxiliary movements are the movement of the slide and its acceleration, the table, the spindle head and the installation movement of the tracer table. The cutter and the copy probe are connected to each other very rigidly. In this case, the first transmits the movement of the probe. If its movement deviates, this causes misalignment relative to the cutter.
Volumetric processing
Programmed milling and copying machines for wood can operate on the principle of volumetric and contour motion. The tracer curve is located in a parallel plane and perpendicular to the axis of the cutter when the machine uses contour copying.
Design features of the machine
In order to understand how to make a copy-milling machine for wood, you should become more familiar with its design features. Such installations are designed for processing profiles or reliefs of products using a carbide cutting tool called a milling cutter. It forms a contour or repeats the surface of the master unit - the copier. It has a mechanical, pneumatic or hydraulic connection with a tracking system responsible for guiding the cutting part.
On the one hand, the effect is on the amplification device, while on the other, on the executive body. When making a copy-milling machine for wood, you can use a flat template, a reference part, or a spatial model as a copier.
The copying device will be a probe, a finger, copy roller or photocell. You can make samples for copying from different materials, namely:
- wood;
- plastics;
- metal
When manufacturing a copy-milling machine for wood, the copier and the workpiece are fixed on a rotating table. As for the executive body, it is a differential, electromagnetic clutch, solenoid, screw or spool. If we're talking about about a machine with an amplifying device, the design involves the use of hydraulic, electromagnetic or electro-optical relays.
The accuracy of the profile and the surface roughness of the product will depend on the speed of movement of the tracking unit. The actuator circuit is driven by an electric motor and a hydraulic power cylinder. A wood copy-milling machine will have a pantograph, which is special device, providing copying at a specified scale.
If you plan to manufacture the machine yourself, then this unit can be included in the design. It has a guide pin located on the axis. Its movement is directed towards the copier. During the movement of the finger, the spindle describes a similar geometric figure. The copying scale will be determined by the proportions of the pantograph arms.
Manufacturing Features
What to buy finished equipment, it’s better to make a copy-milling machine for wood, homemade installation will cost less. However, it will not be able to compete with the factory model in terms of performance and quality of copies. It is very difficult to adapt a copier to an industrial model. This applies to reworking the entire apparatus. Therefore, it is easier to assemble a homemade machine from scratch when using an electric motor and a rod system.
As for the motor, it must have a chuck for the cutter. A manual copy-milling machine for wood will include the following components:
- milling head;
- supporting frame;
- desktop.
The latter can be adjusted in height, and the milling head will work in tandem with an electric drive motor and a two-stage attachment mechanism. With its help it will be possible to provide two speeds of the milling shaft.
Manufacturing of narrow-profile equipment
You should be prepared for the fact that when copying the final product may have some flaws and inconsistencies. They appear when the cutter changes direction, the supporting structure shakes, and vibrations.
Curvature and bending of the workpiece only adds to the trouble. This is caused by an increase in internal stress due to material sampling. You can avoid shortcomings by making a narrow-profile machine. It should not be made universal.
The size of the unit is also an important factor. The more massive the products you plan to process, the larger the structure should be. Vibrations transmitted from the cutter drive must be absorbed by the mass of the supporting structure. The guide axes will undergo loads. They must have a margin of safety. It is important to choose a node that will not sag.
Before you make a copy-milling machine for wood with your own hands, you must design the equipment and determine the type of parts that you plan to form. For engraving work and milling long products, different work tables will be required, and the method of securing workpieces must be individual. The power of the electric motor, which is responsible for rotating the cutter and is installed on the machine, will depend on the material of the parts being manufactured.
For milling and engraving wooden products the motor will be enough direct current at 200 W. But to implement the copying procedure, the device and the copying probe are connected to each other. Height and planes above work surface must match.
Finally
As a copier for the machine, you can use contour drawings, a flat template, a spatial or reference model. The simplest design of a copier involves the presence of a supporting frame, which acts as a base. During assembly, you should prepare the milling head, work table and electric drive.
The dimensions of the table can be selected individually and depend on the tasks. It is also important to take into account the size of the work space. You must determine the power of the electric motor taking into account the planned loads. This part of the structure will rotate the cutter.
Both in production and at home, there is often a need to produce a part whose shape and dimensions are completely identical to the original sample. At enterprises, this problem is solved using a device such as a copy-milling machine, which allows you to produce copies of the original part in large series, differs high speed, as well as the quality of the processing performed.
What is the milling process?
Copy-milling machines and any other equipment of the milling group can be found on almost any industrial enterprise. This is explained by the fact that the milling operation is one of the most common methods used to perform machining. This technology allows you to perform a wide range of roughing, semi-finishing and finishing operations with simple and shaped workpieces made of ferrous and non-ferrous metals, and to work on wood and plastic. Modern milling equipment can process parts of even the most complex shapes with high precision and productivity.
There are two main types of milling: counter (feed and rotation of the tool are in different directions) and down milling (the tool rotates in the same direction as the feed). The cutting part of tools performing milling is made of various materials, which makes it possible not only to successfully work on wood, but also to process (including grinding) even the hardest metals and alloys, artificial and natural stone.
Milling equipment is divided into two types: general purpose and specialized, which includes a copy-milling machine.
Capabilities of copy-milling equipment
The copying machine, which belongs to the milling group, is designed for copying and milling work with flat and three-dimensional parts. In addition, such a device can be used to engrave shaped profiles, apply inscriptions and patterns (even of high complexity) to products, and carry out light milling operations on wood and other materials.
Using tools with cutting parts made of various materials, parts made of cast iron, different types of steel and non-ferrous metals are processed on copy milling machines. Such devices for producing parts in small and large batches successfully produce blades for turbojet engines and steam turbines, propellers for ships, cutting and forging dies, impellers for hydraulic turbines, molds for pressing and casting, compression molds, etc.
Performed on a copy milling machine technological operations, practically inaccessible to universal equipment. The operating principle of such a machine is based on the copying method, for which a special template is used. The use of a template eliminates the human factor when processing even the most complex parts, due to which all finished products have the same shape and geometric dimensions. Conveniently, one template can be used to accurately manufacture a large batch of parts that will be completely identical to each other.
In order to copy the shape and dimensions of the template as accurately as possible, a copier (pantograph for a router) is installed on a copy-milling machine. The purpose of such a device is to accurately transfer all movements from the copy head to the cutting tool.
How does a copy milling machine work?
Copy-milling machines, as mentioned above, are used for planar (processing of profiles) and volumetric (processing of reliefs) milling. They use cutters as a working tool, which, when processing the contour or volumetric surface of a part, repeat the movements of the copier. The connection between the working element and the tracking system in manual machines is ensured by mechanical, pneumatic or hydraulic elements necessary to generate the force transmitted from the copier to the working element of the copy-milling machine.
The template on such machines is a flat contour or spatial model, a standard part or contour drawings, and the element that reads the shape and dimensions of the template is a copying finger or roller, a special probe, or a photocell. To make a template you can use aluminum sheet or other metal sheet, plastic or wood. The template and the workpiece are located on the rotating work table of the machine.
The working body of copy-milling equipment comes into motion thanks to such structural elements, such as a screw, spool valve, solenoid, differential or magnetic clutch. Relays installed in the amplification devices of copy-milling machines can be electromagnetic, hydraulic or electro-optical.
The quality of the workpiece (surface roughness, accuracy of shape and size) depends on such a parameter as the speed of movement of the tracking device. In this case, the following characteristics of the finished product can be achieved: roughness – No. 6, profile accuracy – 0.02 mm. The main elements of the executive circuit of such equipment are Electrical engine and hydraulic cylinder.
A pantograph installed on copy-milling equipment ensures copying at a given scale. The pantograph structure consists of a guide pin, its axis, a tool spindle and a separate axis of rotation. The spindle and guide pin are located on the same rail, the ratio of the arms of which determines the copying scale.
Moving along the contour of the template, the finger sets in motion the rack, which rotates freely on an axis. Accordingly, on the other side of the rack, the machine spindle makes identical movements, processing the workpiece. On do-it-yourself copy-milling machines, such a device will also not be superfluous; its presence significantly increases the functionality of the equipment.
Types of copy-milling machines
The equipment of a copy-milling machine may include drives various types. Based on this parameter, the following are distinguished:
- equipment with a pantograph (suitable for processing parts in 2–3 dimensions);
- devices with a copier mounted on a rotary rack moving in a vertical plane;
- single- and multi-spindle machines equipped with round or rotary tables rectangular shape;
- machines, the feed on which is ensured by mechanical, electrical, hydraulic devices;
- photocopying equipment.
A homemade copying machine can be any of these types (including copying and grinding machines). You just need to find drawings on the Internet and select components.
According to the degree of automation and the method of fixing the workpiece, the following categories of copy-milling machines are distinguished:
- manual or tabletop, on which the workpiece is fixed mechanically(on these devices you can drill holes of various shapes in accordance with the template);
- automatic equipment of a stationary type, the workpieces on which are fixed using pneumatic clamps (such machines work with aluminum);
- automatic equipment of a stationary type with pneumatic clamps, on which a three-spindle head is installed (on these copy-milling machines, triple holes are simultaneously drilled, which does not allow the production of units of the two previous types).
How does a copy milling machine work?
As noted above, on a copy-milling machine the workpiece is processed using a master device - a copier. All movements of the copier along the contour or surface of the template are transmitted thanks to a special (copying) device to the working head of the machine in which the cutter is fixed. Thus, the cutting tool exactly repeats all the movements made by the copier used to equip the router.
The movements of the elements of a copy-milling machine during the processing of a part are divided into main (rotation and movement of the spindle when cutting the tool into the workpiece material, movement along the contour of the work table and slide) and auxiliary (movement of the spindle head, slide and table in accelerated mode, as well as installation movements made by the tracer table, the copying finger, the stops and the clamp that secures the spindle head).
In copy milling machines working on aluminum, two tracking schemes can be implemented: simple action and action with feedback. When implementing the direct action scheme, the working body of the machine makes movements due to the fact that it is rigidly connected to the copier. The reverse action scheme does not provide for such a connection and movements from the copier to the working element are transmitted not directly, but through a tracking system.
As mentioned above, contour and volumetric milling is performed on copy milling machines. When contour milling, the movements of the copier occur in a plane parallel or perpendicular to the axis of the tool. In the first case, the movement of the equipment working table can only be longitudinal, and the cutter and copying finger move vertically. In the second case, the table moves both longitudinally and transversely. In volumetric milling, the part is processed in stages - thanks to several movements of the table and tool performed in parallel planes.
The direct action scheme can also be implemented through a pantograph, which allows you to reduce the size of finished products in relation to the size of the template used (scale). Most often, such an additional device, which is easy to make yourself, is installed on machines used for engraving and light milling work.
Another variation of a self-made machine
How to make a copy milling machine with your own hands
Many home craftsmen would like to purchase a copy-milling machine to equip their workshop, but the cost of such equipment is quite high. Meanwhile, if you have the desire, and without spending a lot of time, effort and financial resources, you can make such equipment with your own hands.
Naturally, homemade copy-milling equipment cannot be compared with professional ones in terms of power, reliability and functionality, but such machines can also make high-quality copies, work with wood and process workpieces from other materials. Many people try to attach a copying device to an existing one, but this is impractical, since it would require redoing almost the entire machine. As practice shows, it is better to assemble your homemade copy-milling machine from scratch, selecting the appropriate components for this.
The photo below shows an example homemade machine with a video supplement. The creator of the machine narrates the story in English, but in principle everything is quite clear even without translation.
The easiest way to make a copy-milling device with your own hands is by standard scheme, which includes load-bearing structure– frame, work table and milling head. The drive to ensure rotation of the working tool is an electric motor that transmits movement through a two-stage mechanism, allowing two speeds to be obtained. Desktop of this homemade device can be adjusted in height.
Many of those who have made a copy-milling machine with their own hands note that when changing operating modes, such equipment begins to show a lot of shortcomings. The most common of these shortcomings are vibrations of the machine frame, curvature of the workpiece and its deflection, poor-quality copying, etc. To avoid such problems, it is best to make the copy-milling device highly specialized and immediately configure it to process workpieces of the same type. This is explained by the fact that it is almost impossible to take into account all the shortcomings that will arise in universal equipment when changing operating modes.
