Wood is one of the main materials that people use in everyday life to make furniture, interior decoration, decorative architectural elements, household and garden supplies and much more.
Wood copying machine.
One or two things can be done hand tools or using woodworking equipment.
But how to process a large number of completely identical products with the least amount of labor and time? In this case, copying machines will come to the rescue. One of them is copying milling machine on wood.
The article discusses its structure and principle of operation, and also offers some advice to those who want to make the device themselves.
Copy-milling machines (CFS) are designed for processing wood parts using the copying method. Types of method:
- contour or 2-dimensional (2-D) milling;
- volumetric or 3-dimensional (3D) copying.
One method or another is used depending on the shape of the product being processed.
The main advantage of copying machines is that you can produce any number of parts with curvilinear contour, which are a copy of the original instance. They will all be absolutely identical. At the same time, the machine has the flexibility to switch to processing another part, just change the standard.
Therefore, their scope of application is quite wide: from small-scale production to mass production. Along with fairly large machines for industrial use, there are compact desktop devices. Copying machines are used in furniture production, woodworking shops, and carpentry workshops of individual entrepreneurs.
Often used as a working unit in small machines milling heads(milling cutter). Its rotation frequency is sufficient to ensure the required surface quality (no chips, splits, burrs).
Examples of processed products
Below is shown a far from complete composition of products manufactured using FSC:
- furniture parts - fronts, headboards, backs, legs of chairs and armchairs;
- interior items - fireplace surrounds, wooden panels, frames, stands;
- souvenir products - figurines, boxes, medallions;
- building structures - framing arched windows, filling paneled doors;
- architectural elements - bas-reliefs, decorative friezes and borders, window casings(slotted or relief), cornice carving;
- decorative fencing - elements of railings, balusters, screens with ornaments, fence details;
- wooden elements of the weapon - butt, fore-end;
- handles of gardening tools, for example, an axe.
As you can see, the listed parts have significant differences from each other, both in size and shape. If we group them according to the most common features, then it becomes obvious that To process parts belonging to the same group, your own design (layout) of the machine is required.
How the copier works
To replicate the product, one of the copies is used, which serves as a template. The head with the cutting tool (mill) is connected into one unit with a copy probe.
With 2-dimensional milling, the probe moves along the generatrix of the copied contour, and the rotating tool repeats this movement, resulting in a copy of the template.
When a volumetric part is milled, the copying tip scans the 3-dimensional model and forces the cutter to move along an equidistant (similar) path. The nature of the movements of copying machines is of 2 types:
- The template and the workpiece are stationary, the cutting head moves in the longitudinal direction, removing a certain amount of material in one double stroke.
- The template and the workpiece (one or more) rotate, and the cutter moves radially along the copier. As a result, it repeats the profile of the copied section. In this case, the cutting unit or part is evenly moved along the longitudinal axis of the product.
A particular type of copying and engraving work is the milling of drawings or ornaments according to a template, which is a pasted paper copy printed on a printer.
As a program for creating a drawing, you can use AVTOCAD, Compass, Word, Paint and others. To avoid tearing the paper, a soft insert (wood or plastic) is inserted into the copying tip.
Choosing the layout of a homemade machine
What you need to know when starting to develop your original device.
First of all, you should determine what parts it is intended for. Next, you should select the forming movements and the number of machine axes. To process flat parts using the contour copying method, 2 axes are sufficient: longitudinal and transverse movement. Parts with low relief require another movement (perpendicular).
However, if the terrain is steep, then the tool axis must be additionally rotated to ensure Better conditions for processing. That is, there are already 4 axes. In some cases, 5 or more axes will be required. When imagining the processing technology in your head, you should take into account everything possible situations. After the machine has been manufactured, it may be difficult to introduce additional movements.
Finally, the machine must be configured in such a way that control forces are minimal. This means that moving parts should be as light as possible. Think about which layout is better to choose: horizontal or vertical. Firstly, the convenience of work, as well as loading and unloading of workpieces, depends on this. Secondly, with a vertical arrangement, the chips fall directly to the floor or into a trough, and do not accumulate on the base or in the mechanisms of the machine.
The milling head should be selected as high-speed as possible. This is important factor, affecting the quality of processing (the height of the scallops from the cutter decreases).
A few examples
Pantograph
Photo 1: machine for cutting letters.
Used for flat threads. Its design is based on geometric figure- parallelogram. One of the properties of this mechanism is that the nodal points describe equidistant curves during movement. Moreover, if the link is lengthened, then its end point will travel a greater distance. This property allows the mechanism to be used for scaling.
The photo shows that the total length with the copying tip at the end is approximately 2 times longer than the side of the parallelogram. This means that the mechanism is magnifying. If you copy a shape with a tip, the cutter will reduce it by 2 times. This will reduce copier errors. Do not forget that the drawing or template is enlarged.
To make a pantograph you will need a purchased router and several dry boards. Apparently it doesn't get any cheaper.
Machine with plane-parallel mechanism
Photo 2: contour milling
The scope of application is also contour milling.
Unlike a pantograph, a curvilinear trajectory is obtained by adding two mutually perpendicular movements. The 3rd axis is used to insert the cutter into the thickness of the part. The weight at the opposite end of the swing frame is designed to balance the system.
Please note a small design flaw: It is better to install the load on a threaded rod to allow for adjustment.
Volume milling machine
Photo 3: volumetric milling
At the bottom of the frame there are 2 rotary units fastening the copier and the workpiece.
The milling head is mounted on a balanced swinging frame, which during operation moves along mutually perpendicular guides.
Instead of linear bearings or sliding bushings, as in the previous device, roller carriages are used here. The advantage of the design is the open base, which makes chip removal easier.
Duplicarver-2
Photo 4: machine for flat-relief and sculpture carving
Serial machine for flat-relief and sculpture carving. An example of simplicity: they say about such structures - two sticks, two rolling pins. Has 5 controlled axes:
- 4 turns (side arms, rotating frame, head, work tables);
- lateral movement of the head.
Longitudinal movement is obtained by adding two rotations: levers and frame. A German milling cutter with a power of 500 W and a spindle speed of 10 - 30 thousand revolutions per minute is used as a power head. Easily carried by one person (weight - 28 kg).
Duplicarver-3
Photo 5: processing of long-length volumetric threads
2 more rolling pin guides (an additional linear axis) have been added to the previous machine, and the rotary work tables are located vertically. As a result, it became possible to process long volume threads.
Below are some drawings that may be useful in making a homemade device.
Drawing 1 - pantograph device
Drawing 2 - diagram of a router mounted on a pantograph 
Drawing 3 - carriage for installing a router on a flat-bed copier
Video: presentation of a homemade copying machine
Do-it-yourself CNC copying machine - is it possible?
All devices discussed above have manual control, that is, despite the increase in productivity, the person remains chained to the mechanism. This kind of work is quite monotonous and tedious. In mass and large-scale production, copy-milling machines equipped with computer numerical control (CNC) are used. All work on such equipment comes down to loading blanks and removing finished products. As an example, the photo shows a similar machine.
A copying machine differs from a conventional CNC milling machine by the presence of a programming system. A traditional CNC machine operates from a control program compiled by the operator in a system, for example, ARTCAM, according to a 3-D model, which is developed at the design stage by a design engineer. If the product was created by a sculptor or designer, it must first be digitized, that is, a 3-D model must be created. This work is performed by a software engineer.
On a CNC copying machine, the control program is compiled by the system itself. When installing a copied product, an additional CNC attachment probes the part and creates its 3-dimensional model, from which a control program is automatically generated. Considering the high cost of components, problems with purchasing a CNC system, make it yourself copying machine with CNC - something out of science fiction. It’s easier to make a CNC milling machine (not a copying machine), although not everyone can handle this either.
For those who are going to start their own business, making crafts from wood, as well as for professional cabinetmakers, a self-made copying machine will be of great help. It can be successfully used for decoration country estate, outbuildings, playgrounds and other structures. Jewelry work, it would seem, will be done effortlessly and with high quality.
When milling, copying devices are used, i.e. pantographs, which have a high cost. You can assemble a pantograph for a router with your own hands.
Making a pantograph
A milling cutter equipped with a pantograph allows you to repeat parallel lines of the workpiece during work. This procedure facilitates the production of shaped parts, various ornaments and patterns. In addition, using a pantograph you can make various inscriptions on metal and wooden plates.
It’s not difficult to make a homemade pantograph; you just need 4 ruler levers. Three such levers should be long, and one should be short. In addition, you will need to make several holes in them to mount the axles.
The axles will be used to install the mechanism and attach the rod. The axial mechanism is a pin with a cap at the end. The copying part should resemble a compass element in which the stylus is attached. Such a rod part can be made from the tip of a plastic knitting needle. Such a tip will glide gently during operation and will not damage the original part.
You will also need an axis on which the entire mechanical part of the device will rest. It must be equipped with a heel that acts as a stop. The last or outer guide will act as a fastener for the entire structure using a special boss.
Such a boss should be made of an aluminum cylinder. In its lower part you need to attach 3 stings, which can be made from small furniture nails. These nails will be used to secure the base to the plate being processed.
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Completion of work
The next step is to assemble the copying mechanism for the router. To do this, you need to prepare the following components:
- 4 rulers;
- 8 brass bushings.
Rulers should be made of plexiglass or plastic, their thickness should be 4-5 mm. You can also use plexiglass as a material for making rulers. Next, the marking of these linear parts is carried out. This process should be approached very carefully, since the slightest error in dimensions can lead to incorrect operation of the pantograph.
Holes are drilled on the marked markings. In this case, their alignment must be maintained. To achieve this, you need to put all the rulers together and drill holes in them at the same time.
Then you need to insert brass bushings into the prepared holes. When installing them, a slight tension should be observed: this will help the bushings to stay more tightly in the rulers. In order to secure the axial parts in the bushings, you need to make special clamps. They can be made from hardened steel wire, the diameter of which should be 1-1.5 mm.
Then the boss is assembled. Blind holes are made in its lower part, which can be punched with a core. The nails must be installed in such a way that they protrude from the body of the boss by 2-3 mm.
Having prepared all the necessary parts of the pantograph, they are assembled.
During this process, you need to ensure that all moving parts move smoothly and easily.
In this case, all prepared holes should be marked. According to this marking, you can scale the manufactured copy of the part.
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. We will learn from the article what a wood milling and copying machine is, how it works and what its approximate price is.
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 reliefs of objects and details. Before going 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 copying mechanism gives a command to all actuators of the 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 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 the 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, are 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 - ideal for making paneled doors and other types of carpentry work. Such operations are the most complex and time-consuming, so even experienced master with high qualifications is not able to cope with such a task for a short time. It produces a paneled element in one pass; the multi-level spindle quickly changes the profile without rearranging the tool. It is equipped with a special table with a flat coordinate system, which provides 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 is a high speed of up to 18,000 rpm, the spindle provides ideal quality, the 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 execution various types works In order to start working on it, 2-3 full-time education, after which you can create real masterpieces in wood.
Copy-type equipment is used in cases where parts need to be manufactured according to a specific template within a small batch. In some cases, a copy-milling machine is used in large-scale production, just like the CNC version. This is due to the fact that the machine in question is capable of creating products whose shape most closely matches the original sample, like CNC machines, the movement of the cutter is set automatically. main feature, which a copy-milling machine has – high processing speed.
Purpose
Often, a copy-milling machine is used to perform volumetric and plane processing; its operation is similar to those on which the CNC system is installed. At the same time, special models allow wood processing to be carried out in volume when a volumetric model is used as a copier. In the woodworking industry, volumetric processing allows:
- create ornaments and various inscriptions.
- engrave shaped profiles.
- create complex patterns, the edges or planes of which are located in different planes.
The woodworking machine in question is often used in furniture production. Many decorative parts that have complex shape, are created using a similar machine.
Principle of operation
The possibility of significantly accelerating the production process of complex products is determined by the operating features of the copy-milling machine. As with metal processing, woodworking uses cutting tool called "cutter".
The main points of the work include:
- The cutter creates a contour or surface that is specified using a copier.
- The connecting link between the cutting tool and the tracking device is a mechanical, hydraulic, pneumatic system. A woodworking machine most often has mechanical system feeding and control.
- The copier can be a flat template, a previously created reference model, a spatial model, a photocell, or a contour drawing. In some cases, such machines are equipped with CNC, which makes them highly versatile.
- The samples that act as a template can be made of metal, wood, plastic or other material.
The copy milling machine works as follows: a sample is installed various types, a tracking device is connected to it, which through a certain type of connection transmits the required force to the cutting tool.
Classification
- wood pantograph for router. this option can work in 2 or 3 dimensions;
- universal type, which is also called a pantograph, having a rotating arm. as a rule, the sleeve is located in a vertical plane;
- There are design options that have several spindles to speed up the processing process;
- with mechanical, electrical, hydraulic feed;
- photocopy type of contour transfer for guiding the cutting tool.
Woodworking machines also differ in their level of automation. production process. In this case, CNC is installed quite rarely, since the template processing method does not require a Numerical Program Control system to indicate the trajectory of the cutting tool.
Making a machine with your own hands
There are a huge number of copy-type woodworking machines, which are known as pantographs, have a CNC system ( universal option, which allows processing using a copier or program). However, not everyone can purchase such equipment, which is associated with its very high cost. The addition of CNC makes the equipment available only to large manufacturers, when the payback period for the equipment will be less than 5 years. That is why many people ask the question - how to make a machine with your own hands?
Before you start work, it is worth remembering that do-it-yourself machines are significantly inferior to industrial models. At the same time, it is impossible to make a CNC version yourself. Also, many note that converting a regular milling version into a copying version with your own hands is also very difficult, and, often, it is easier to start from scratch. It is not difficult to make a pantograph yourself, but there are still certain difficulties in this process.
There are many schemes by which you can create a copy-milling machine with your own hands. Typical option, as a rule, consists of the following elements:
- Desktop;
- supporting frame;
- milling head.
To carry out the procedure for changing the cutting mode, the height of the table changes; the head with the cutter has electric drive, which sets the cutting tool in motion, the system often includes a transmission mechanism for changing speeds.
The pantograph itself can be made as follows:
- Made of wood. You can create such a pantograph with your own hands, but it will have low processing accuracy, since the wooden parts are connected using a loop. Fastening with loops is characterized by backlash.
- Drawing pantograph made of metal - allows you to create copies at various scales, but cannot be used to create three-dimensional copies.
When creating a machine with your own hands, you should take into account that many parts may have flaws and discrepancies in size. This situation is associated with vibration and trembling of the base, which is quite difficult to avoid. When changing the direction of movement of the cutter, errors are also possible. Due to the internal stress of the wood workpiece, the workpiece may become distorted. Therefore, it is recommended to create such equipment only for narrow-profile production, when the machine will be designed to create one part. It is almost impossible to avoid the problems under consideration, however, provided that the same part is processed, gradual improvement of the design is possible.
All photos from the article
A wood turning and copying machine is a machine that is widely used in factory woodworking for replicating products of a certain configuration that corresponds to a given sample. This equipment allows you to process any parts with high accuracy and speed. However, production machines with their large dimensions will be difficult to locate in a small private workshop.
Copying equipment in woodworking
Many carpentry enthusiasts, gradually expanding their tool base and improving their skills, come to the idea of assembling a wood copy lathe with their own hands. After all, with the help of this device it is possible to make an exact copy of any piece of furniture and carry out restoration work.
Note!
In most cases, of course, the main factor that encourages people to “reinvent the wheel” is high price for a finished factory product.
The operating principle of a wood copying machine is quite simple:
- The workpiece of the required size is clamped in a horizontal position.
- Starting the device, forcing the workpiece to rotate around its axis.
- In turn, the movable cutter also removes excess wood, turning the blank into a product of the desired shape.
Structurally, a copying device for lathe woodworking consists of a whole series of parts connected to each other, so there will be a lot to work on.
Personal assembly of equipment at home
Lathe
In order to assemble a small copying machine for wood with your own hands, you will need to make some effort and patience, as well as invest financially (about 7-7.5 thousand rubles). But this is several times less than the costs that await you if you purchase a ready-made option.
