Wood copying machine based on a router. Design features of copy milling machines

A manual or automatic stationary copy-milling machine for aluminum or other metal is a unit that allows you to create products that are as identical in shape as possible to the original specified sample.

1 Purpose of the copy-milling unit

The milling installations discussed in this article are optimal for producing copying work on a plane and in volume using appropriate copiers and volumetric models. They are also used for:

• performing simple milling work;
• engraving of all kinds of ornaments, shaped profiles, inscriptions, patterns and so on.

It is important that with a relatively simple and understandable design, such machines can produce truly complex ornaments, milling, using tools made from, products made of non-ferrous metals, cast iron and steel.

On industrial enterprises, engaged in small- and large-scale production, copy-milling installations make it possible to produce:

• metal blanks and models;
• blades of steam turbines and turbojet engines;
• various dies and cams;
• dies (forging and cutting);
• foundry and molds;
• propellers (crest) of swimming equipment.

The clear advantage of copy-milling units over universal ones is that they can drill holes for steel hinges, locks, handles, latches, and make frames for various geometric parameters for mirror surfaces and channels on aluminum and plastic profiles.

The described machines mill curved workpieces according to a prepared template using copying technology. It is thanks to this technique that the same shape of all finished parts is ensured. Moreover, the probability of an error by the worker servicing the unit is reduced to zero. That is, the notorious “human factor” does not have any effect negative influence to the production process.

To make a series of absolutely identical parts on a copying machine, it is allowed to use not only a template, but also any product that was made using it. At the same time, experts strongly advise additionally equipping the unit with a pantograph - a special mechanism that transmits the movement of the cutting tool along the profile of the installation head as accurately as possible.

2 Copy milling machine - operating principle

The units we are interested in process workpieces using a copier, which, through a special unit (copy mechanism), gives commands to various actuators of the machine. Moreover, the installation cutter and the part itself being milled recreate the surface specified on the copier in relative motion.

Movement along the contour of the slide and work table of the unit, as well as rotation of its spindle, are operations that are considered the main movement. And the secondary (auxiliary) actions include the following:

• adjustment movements of the copying finger, stops and tracer table;
• acceleration of the movement of the work table, spindle head and slide;
• spindle head clamp.

Copy milling is usually divided into two types:

• contour;
• volumetric.

When contouring, the copier curve is located perpendicular or parallel to the axis of the working tool. In the first case, the working surface with the part and the copier moves in the longitudinal and transverse directions along the curved line of the latter. In the second - only longitudinally. In this case, control over modifications of the curve becomes possible by moving the tracing finger and cutter vertically.

In volumetric milling, the workpiece has a spatially complex surface, which can be processed by performing parallel (two or more) moves of the work table. Essentially, in this situation we're talking about that contour milling is performed with each stroke. After each pass, the working tool relative to the part is shifted by the lateral feed rate perpendicular to the line. And then the next table move is performed.

For simple milling and engraving work, so-called “direct” copy-milling units are usually used. In them, the pantograph transmits movement to the instrument through a probe. On machines equipped with a pantograph, in addition, the scale of the workpieces being processed is reduced (in relation to the copier).

3 Design of a copy-milling machine - drawings, cutters for the unit

The most important working tool of such a unit is a cutter, which is designed to reproduce the surface or contour of the copier on the workpiece. The copier is more often called a master device. It is associated with a tracking mechanism designed to control the feed direction of the cutter. The specified connection can be:

• mechanical;
• pneumatic;
• hydraulic.

A copier is:

• photocell;
• special copying finger or roller.

And by copier we mean those made of metal, plastic, wood:

• outline drawing;
• spatial model;
• flat view template;
• reference workpiece.

The copier and the workpiece to be processed are mounted on a rotating table.

The actuator circuit of the unit is driven by an electric motor and a hydraulic cylinder. The actuator of the installation is understood as a differential, solenoid, spool, clutch with electromagnets or screw. A mandatory component of copy-milling equipment is a relay, which is included in the amplifier device of the machine. The relay can be:

• hydraulic;
• electromagnetic;
• electro-optical.

By and large, any home craftsman with certain technical knowledge can study the drawings and make his own manual copying unit that will do an excellent job of milling operations.

4 Classification of copy-milling units

The entire range of such machines is divided into several different types:

• hydroficated;
• equipped with a pantograph that can function in two and three dimensions;
• photocopying;
• universal (they also have a pantograph placed in a vertical plane on a rotating sleeve);
• electrified;
• multi- and single-spindle with round or rectangular table.

Based on the type of clamping of the milled part and the degree of automation, the units are divided into three types:

• Automatic installations in which the profile is pressed by a pneumatic device. They are most often used for processing workpieces made of, and cannot be used for drilling triple holes.
• Tabletop (in other words, manual) machines. Also not suitable for triple holes, but capable of drilling using single hole patterns. To expand their functionality, it is possible to install a three-spindle attachment on a drill or machine. Tabletop units are equipped with a mechanical type clamp.
• Automatic installations with three-spindle attachment and pneumatic clamp. They are rightfully considered the most functional and widely versatile.

Very often in our lives there is a need to make a copy of some object, so the availability of copying equipment is a modern need for many enterprises. And we will not be talking about copy printing equipment, but about copy milling machines.

They serve to create objects that closely replicate the original design. The equipment makes it possible to produce parts in large quantities, ensuring high processing speed.

1 Features of milling

Milling is one of the methods of mechanical processing. The procedure allows for finishing, roughing and semi-finishing different surface blanks made of wood, plastic, cast iron, metal (ferrous and non-ferrous).

Milling has high productivity, making it possible to create objects of the required geometric shape.

Milling can be organized in two ways:

• down milling, in which the directions of feed and rotation of the cutter coincide;
• up milling, in which the feed is opposite to the direction of rotation of the cutter.

Using cutters equipped with modern cutting materials, Can carry out processing, replacing the grinding procedure.

A woodworking milling machine, including a mini modification, is used for processing the surfaces of planks, levers, covers, cases and brackets of simple configuration, and the surfaces of cabinet objects.

Allows you to apply 3D or 4D carvings. One of the most popular brands of domestic origin - Duplicarver.

Milling machines there are two categories:

• specialized;
• general purpose.

The last group is continuous milling equipment, non-cantilever, cantilever, longitudinal milling. The first group is copy-milling, key-milling, slot-milling, gear-milling, thread-milling. There are full and mini models.

1.1 Purpose of the machine

A copy milling woodworking machine is used to carry out copying work on a plane and in volume, to engrave patterns, inscriptions, ornaments, shaped profiles, as well as to implement simple milling tasks.

Despite the simplicity of the machine, it allows you to create incredibly complex patterns. It can be mini or full-size.

The equipment allows you to perform various milling operations using carbide and quickly cutting tool. Can make threads. The machines are used in small and large-scale production. Can work in 3D mode, if appropriate equipment is available, CNC. Duplicarver models are very popular.

The machine allows you to create:

• blanks and models;
• Press forms;
• various stamps;
• cams;
• forms.

The equipment can also be used for:

• drilling holes for metal hinges, handles, latches, locks;
• production of frames for mirrors;
• channels different sizes on profiles.

The Duplicarver wood milling machine allows you to mill curved parts by copying a template from which the shape of the future product is copied. Thanks to the use of templates excludes the influence of the so-called human factor, therefore the finished products have an identical shape. This is largely ensured by CNC.

Not only a template sample can be used in the work; subsequent products can be made according to the sample of the first one. To increase accuracy, the machine should be supplemented with a copying device called a pantograph.

He may have different designs, however, it has an important function - accurate transmission along the profile of the movement of the copy head to the cutting device. Therefore, high precision of the thread is achieved when applying it.

2 Machine design

The Duplicarver milling machine uses a carbide cutting tool – a milling cutter. It reproduces the surface or contour of the copier on the product.

This machine master device has a hydraulic, mechanical and pneumatic connection with a tracking system responsible for the direction of the cutter. On the one hand, it acts on the amplification device, on the other, it affects the executive body.

The copier is a flat template, outline drawing, reference part, spatial model. Copier - photocell, finger, roller or probe. Samples can be parts made of wood, plastic or metal. The copier and the workpiece being processed are located on a rotating table.

The executive body of the Duplicarver machine is a differential, electromagnetic clutch, solenoid, screw, spool. Electro-optical, hydraulic or electromagnetic relays can be used in amplifying devices.

The speed of movement of the tracking device determines the accuracy of the profile and the surface roughness of the product. An accuracy of 0.02 mm and a roughness of No. 6 can be achieved. The Duplicarver machine is driven by an electric motor and a power hydraulic cylinder.

A pantograph, which allows you to copy products to a specified scale, has a guide pin located on an axis and moving along the copier, as well as a tool spindle and an axis of rotation.

When the finger moves along the copier, the spindle on the workpiece describes the required geometric shape. The scale of the pantograph is determined by the proportions of the shoulders. Additionally, CNC can be used.

2.1 Types of copy milling machines

By type of drive:

• photocopying, hydro- and electrified, with mechanical feed;
• multi- and single-spindle units with round and rectangular tables;
• universal devices with a pantograph located vertically on a rotating arm;
• with pantograph necessary for functioning in 2 and 3 dimensions.

There are mini and full versions. Such devices can be equipped with CNC.

You can also identify other groups of devices that differ in workpiece clamping and level of automation:

• tabletop or manual homemade machine with mechanical clamping of the profile allows you to drill holes different shapes using a template;
• automatic machine with pneumatic profile clamping - most often used for manufacturing aluminum structures; may have CNC;
• an automatic machine with pneumatic profile clamping and a 3-spindle attachment necessary for drilling triple holes (other devices do not have this capability); may have CNC.

These can be mini or full-size machines.

2.2 Making a machine yourself

A homemade copy milling machine can be made at home with your own hands. Of course, such mini equipment will not be able to work at the same level as industrial designs, but it is quite capable of creating high-quality copies.

A homemade CNC woodworking copy milling machine can be made using a rod system, an electric motor with a clamping chuck necessary for the cutter.

The typical design of a do-it-yourself device is:

• Desktop;
• supporting frame;
• milling head.

Do-it-yourself desktop copy milling machine for wood carving with CNC must be optimized for specific purposes, which need to be achieved, for example, for threading. Understanding what parts are to be processed, you should perform calculations of size, power, and so on. Then a self-made machine will allow you to carry out the necessary tasks.

2.3 Operation of the Duplicarver copy-milling machine (video)

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 processing methods. 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 copier curve is located at parallel to the plane and perpendicular to the cutter axis when the installation uses contour copying.

Design features of the machine

In order to understand how to make a copy-milling machine for wood, you should take a closer look at it 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, 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. Concerning executive body, then it is a differential, electromagnetic clutch, solenoid, screw or spool. If we are talking about a machine with an amplifying device, then 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 copying and milling machine will have a pantograph, which is a special device that ensures copying at a specified scale.

If you plan to manufacture the machine yourself, then this node can be included in the design. It has a guide pin located on the axis. Its movement is directed towards the copier. As the finger moves, the spindle describes a similar geometric figure on the workpiece. The copying scale will be determined by the proportions of the pantograph arms.

Manufacturing Features

Rather than purchasing ready-made equipment, it is 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 electric motor and traction systems.

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 must be prepared for the fact that when copying 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. The height and planes above the work surface must match.

Finally

As a copier for the machine, you can use contour drawings, a flat template, a spatial or reference model. Most simple design The copier requires 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.

Copying equipment always comes to the rescue if you need to produce a specific part according to a template within small batches. Copy-milling machines are used both in enterprises that produce products on a large scale, and in small workshops, and in household There is always a job for a wood copying machine. Industrial designs of copying equipment can produce parts in almost unlimited quantities, but we will focus on models that can be assembled with your own hands and budget machines for small-scale furniture production.

Design of copying and milling machines

A copy-milling machine is a universal device that is designed for making copies of a wide variety of parts. The machine can operate in both two-dimensional and three-dimensional formats. In the first case, copying is made from a template, in the second - from a finished product. The more accurately the machine is made, the more accurate the copy will be, and the accuracy of the machine, as in all means of processing materials, and the rigidity of the power and working structures.

In addition, the copy milling machine can perform template engravings, production decorative elements, and sometimes the device can replace a milling machine.

The simplicity of the device, and at the same time the efficiency of copying, have made copy-milling machines indispensable in the manufacture of curved and complex parts. Another good property of the machines is their independence from the level of professionalism of the operator. The versatility of the machine can be achieved using replaceable elements, attachments and copying heads.

Milling and copying machine, characteristics

The main problem with a milling and copying machine can be inaccuracy, which is associated with vibrations and backlash. A do-it-yourself copy-milling machine for wood, assembled at home, is most often susceptible to such shortcomings. The slightest play can affect the quality of the copy, and to avoid it, it is necessary to use rigid structures and strong frames, regardless of the type and thickness of the wooden workpiece.

That is why such machines, assembled at home, cannot always boast of versatility. With a clearly defined scope of work, it is much easier to achieve rigidity and accuracy from the structure. The bed of a copy-milling machine should be as heavy as possible in order to dampen the slightest vibrations that may affect the accuracy of the work.

Therefore, the following characteristics must be mandatory for such equipment:

Only such a machine will work fully and accurately.

CNC copying and milling machine

A CNC machine is a type of copying equipment. Like manual copy-milling machines, they can very accurately copy a given part, and the use of software methods provides many advantages over manually controlled models:

CNC machines are quite complex and functionally rich devices, fully controlled by automation. In addition, it is possible to integrate the control system of a CNC machine into a computer control system, which will further increase the functionality and speed of operation of the equipment.

Copy milling machine, price

Copy-milling machines for wood can have a fairly wide price range, which depends on the level of equipment and purpose of the machine. The device can be equipped with the most different systems, both manual control and electrical tracking systems.

Many models of such machines use high-precision sensors, which can be electrical contact or inductive. Naturally, the equipment affects the prices of the machines. If we take the desktop models we are interested in, the most inexpensive and most popular on the market are YILMAZ, Star, and Duplicarver. IN manual version These models cost about 50 thousand rubles.

Therefore, having carefully thought through your requirements for the machine, it is quite possible to make such a machine yourself using drawings or your own design. Several designs that are presented in the photo may lead to correct solution and another useful and simple machine will appear in your arsenal.

The milling machine is useful both in enterprises and in living conditions. The main thing is to decide in advance what type of equipment you need to purchase. After all, the unit is available in several varieties, each of which has its own parameters. The choice depends on the purpose of the device and the required results.

In production or home workshops, sometimes you have to create parts with specific patterns in shape and size. Copy-milling machines are devices that allow you to solve a problem in an enterprise environment. Processing is guaranteed to take place with high speed, accuracy when using copy milling machines.

Specifications

Each model has its own specific numbers for parameters. Next specifications important for models of any kind:

1. Electric motor power and speed.
2. Maximum vertical movement of the table.
3. Transverse movement of the table.
4. Longitudinal travel of the table.
5. Determination of dimensions by work surface table.
6. The working surface of the table of the product that is being copied.
7. Diameter of the largest circle.
8. Copy scale.

The machines are equipped additional tools, contributing to the creation various forms. Using templates makes your work easier.

Capabilities of copy-milling equipment

Copying group machines belong to equipment with cutters. An excellent option when processing parts that have surfaces with volume and defined planes. This design will allow you to easily engrave so-called shaped products, with the application of inscriptions and patterns. Milling work involve light processing of wood and metal.

Metal tools are equipped with cutters based on different materials. This makes it possible to process various substrates:

• Cast iron.
• Steel, different grades.
• Metal, colored.

One of the areas of application is large- and small-scale production of parts with different characteristics.

Copying machines are capable of performing operations that are inaccessible to owners of conventional universal devices. The basic principle of operation is copying, which uses templates. Even the processing of highly complex forms takes place without the human factor. The geometric plan parameters of the parts remain the same. Large batches of parts are also produced based on one template.

Special copiers are installed on the machine to make the result of the work even more accurate.

Machine device

The main purpose of the machines is milling, planar and volumetric type. The main working tools are the so-called cutters. They are responsible for processing the contour or volumetric surface of the part. The copier movements are repeated. Elements various types form a connection between tracking systems and operations authorities:

1. Mechanical.
2. Pneumatic.
3. Hydraulic.

Such elements form the force received by the working body from the copier.

The device works with templates – spatial and contour models in a plane. Standard parts or outline drawings are also used. The cutter is read:

• Photographic elements.
• Probes for special purposes.
• Roller, finger mechanisms.

Template sheets are made using aluminum and any other metals, wood or plastic.

Processing of parts and templates takes place on a working machine, with rotation.

The use of the following parts begins the movement of the working body:

1. Coupling electromagnetic element.
2. Differential part.
3. Solenoid.
4. Spool-type valve part.
5. Screw design.

Relays are mandatory devices for copiers; they are placed on the reinforcing parts. They can be of several types: with electromagnets, hydraulic, electro-optical type.

The speed at which the tracking device moves is a parameter that determines the quality finished part. For finished products you can achieve the following parameters:

• Profile accuracy up to 0.02 millimeters.
• Roughness – No. 6.

The hydraulic cylinder together with the electrical circuit become the main elements for the actuator circuit of such equipment.

Copying at a given scale is ensured by a pantograph. It also has a design consisting of several parts:

1. Separate rotation axis.
2. Tool spindle.
3. Guide pin axis.
4. The finger itself.

One rack accommodates the spindle along with the guide pin. The ratio of the shoulders at the staff determines the copying scale.

The rod begins to move when a finger is moved along the template. At the next stage, free axial movement is carried out. On the other side of the slats, the movements are identical, using a machine spindle. The latter will be needed when making tools yourself. The functionality of the device increases.

Types of copy-milling machines

Copying machines are equipped with equipment different types. This parameter allows you to select the following groups of devices:

• Photocopy varieties.
• Machines in which the feed is carried out by hydraulics or electrics, mechanics.
• Varieties with one or several spindles. Equipped with special rotary tables, with a rectangle or circle shape.
• When using a copier. When securing the latter, a rotary rack is used. It itself moves vertically along the plane.
• With the addition of pantographs. Helps process parts in 2-3 dimensions simultaneously. Many people choose the Dekel GK 21 model.

Acceptable self-creation masters of machines belonging to one of the groups described above. All that remains is to find the drawings along with the necessary components.

1. Equipment in a hospital, fully automatic. The kit includes springs that act as pneumatics, with a three-spindle type head. Simultaneously drills triple type holes.
2. Stationary machines, when pneumatics, represented by springs, are responsible for fixation.
3. Handheld or tabletop, using mechanical method fixation.

Principle of operation

The part that sets the characteristics during processing becomes copiers. The head at the table is the main tool for work, accepting movements on the working surface, contour. The repetition of movements is carried out using parts with cutters.

The work of the main elements is carried out with the main and auxiliary movements. The main thing is that when the spindle rotates and moves, the tools cut into the workpiece materials, and a table with a slide moves along the contour.

There are several types of auxiliary movements:

• Accelerating the movement of the table and slide.
• Moving installations, from tables with copying fingers, stop mechanisms, clamping.

Normal operations, use feedback– two main types of circuits, the implementation of which is allowed for devices. A rigid connection with the copier is the basis of the simplest scheme, the direct variety. There is no connection when the movement is reversed. The tracking device transmits movements.

When a contour or volume is milled, machines of this type are ideal. If contour milling is used, it is assumed to use a plane that is parallel or perpendicular to the tool. The second case involves moving the table along or across. Volumetric version of work - when the part is processed in stages. When moving, several planes are used at once.

The pantograph also allows you to implement a direct scheme. It reduces the size of finished products compared to templates. Self-production devices will not cause any trouble if necessary.

Conclusion

For carpentry and model shops, copying machines are ideal because they allow metal and wood to be processed to the same extent. The main thing is that the surface is soft enough. Models brought from Italy have become popular. But Taiwanese and Chinese installations are in no way inferior in quality. High accuracy and reliability are the main advantages of modern equipment.

2-3 days of training is enough to start working with parts of any complexity.