Homemade copier from a router. Do-it-yourself copying machine for woodworking

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 makes it possible to produce copies of the original part in large batches and is characterized by high speed and 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 in 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. On modern milling equipment Parts of even the most complex shapes are processed 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 carry out processing (including grinding) of even the most hard 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

Copying machine, belonging to the milling group, is designed for copy-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 part from 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, molds, etc.

A copy-milling machine performs technological operations that are 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, thanks to which everything finished goods 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 an electric motor and a 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 rotary tables round or 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 desktop, on which the workpiece is fixed mechanically (on these devices you can drill holes various shapes according to 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, 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 feedback action. When implementing the scheme direct action the working part 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 of a homemade machine with an addition in the form of a video. 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 one must take into account all the shortcomings that will arise in universal equipment when changing operating modes, it is almost impossible.

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.

This is where a wood milling and copying machine will come to the rescue. 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

Machine cutting tool of this type– cutters of 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 the technological process of specific industries. 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 routers allow you to cut not only exact copies details, 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 are electronically controlled and use a laser meter as a probe.

Main types of copy routers

Devices of this type are in demand in a variety of industries, these are great helper for the home craftsman 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 ones desktop devices, intended 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 can be considered a simple desktop or stationary copying machine on a rotating frame with one working tool.

Factory equipment

Not everyone will undertake the production copy router on wood with your 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 of the 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 be the best assistant when it is necessary to mass produce 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 (numerical program controlled). 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 known to have more high cost, their acquisition 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 knot, you just need to make 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 important for the quality of work is the precision of the manufacture of the copier - the frame on which the cutting tool and probe are installed. 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.

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 and 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. Determining the dimensions of the working surface of the table.
6. Working surface 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 of various forms. Using templates makes your work easier.

Capabilities of copy-milling equipment

Copying group machines belong to equipment with cutters. Great option, when parts are processed that have surfaces with volume defined by planes. This design will allow you to engrave so-called shaped products, with inscriptions and patterns. Milling work involves 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 of various types form the connection between tracking systems and operation 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 of the 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. They are equipped with special rotary tables with a rectangular 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.

Ordinary actions and the use of feedback are the 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 products finished form 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 They are in no way inferior in quality. High accuracy and reliability are the main advantages of modern equipment.

2-3 is enough full-time education to get started with parts of any complexity.

All photos from the article

Wood copying and milling machines are universal units whose purpose is to copy products in two- and three-dimensional form. In other words, this equipment can copy flat finished products, and when using special copiers, also three-dimensional models.

Such devices are often used for engraving profiles and various decorative elements. They can also be used for ordinary, not very complex milling work.

What is copy-milling equipment

This equipment is unique because... with its relatively simple design, it is capable of copying complex products, even fine handmade ones.

In fact, the unit was designed for milling curved elements:

1. This is done by copying using templates. They allow you to perform the operation as accurately as possible, without the use of manual work. This property the unit guarantees that the manufactured elements will be identical in size and shape.
2. You can use one sample for all blanks or use ready-made products as a template.
3. When such parameters are not enough, it is possible to significantly increase the accuracy of the machine.

Note! The instructions recommend equipping it with a special copying device for this purpose. It is called a “pantograph” and serves to accurately communicate the movement of the copying unit (head) to the main device that processes the part.

When a template has many fine, elegant details, a pantograph machine is indispensable.

Unit design

Copy-milling units make it possible to process reliefs or profiles:

1. The workpieces are processed with a special tool - a milling cutter made of hard alloys.
2. It repeats in full the movements of the copier, which reproduces the outlines of the template.
3. The copier is equipped with an electronic or mechanical connection that has a tracking system and is responsible for the trajectory of the tool.
4. The copier can be a flat or three-dimensional sample, as well as a contour diagram or a reference model.
5. In this case, a special probe registers the contours of the part. This data is then reported to the tool.
6. In the most modern machines, the probe is replaced by a photocell, which has increased accuracy.

Note! The pantograph plays a vital role in the described units. It is equipped with a special guide “finger”.

It moves around the copier, while determining with maximum accuracy geometric parameters sample. The final size of the resulting copy depends on the proportions of the pantograph’s “shoulders.”

IN modern world Often there is a need to create a copy of something or reproduce and repeat something. For this purpose, many enterprises widely use copy-milling machines, which are designed to create products whose shape most closely matches the given original sample. They make it possible to produce parts in large quantities, while ensuring high speed of processing and manufacturing of each element.

Features of the milling procedure

Milling is one of the common machining methods. Using milling, roughing, finishing and semi-finishing of shaped and simple surfaces of workpieces made of steel, non-ferrous metal, cast iron and plastics is carried out. Milling is characterized by a high level of productivity, which allows the final result to obtain products of the correct geometric shape.

Milling can be carried out in two ways: the procedure of up milling (against the feed), when the feed is opposite to the direction of rotation of the cutter, and down milling (along the feed), when the directions of rotation of the cutter and feed coincide. Using cutters that are equipped with modern cutting materials (mineral ceramics, synthetic super-hard), you can process materials that are hardened to high hardness, thereby replacing the grinding procedure.

Milling machines are intended for milling the surfaces of levers, strips, housings, covers and brackets of simple configurations, complex configurations of contours (such as templates, cams), surfaces of body parts. Milling machines are divided into two main categories: general-purpose machines and specialized machines. The first group includes longitudinal milling, cantilever, non-cantilever and continuous milling machines. The second category includes thread-milling, gear-milling, slot-milling, key-milling and copy-milling machines.

Purpose of a copy milling machine

Copy-milling machines are usually used to perform copying work in volume and on a plane, as well as in volume using three-dimensional models and corresponding copiers, for engraving various shaped profiles, patterns, ornaments and inscriptions, as well as for light milling work. The indisputable advantage of such units is that it is capable of performing with its own simple device incredibly complex patterns.

The machine can perform various milling operations on steel, cast iron and non-ferrous metals using high-speed and carbide tools in large- and small-scale production. On such machines, propellers of ships, blades of turbojet engines and steam turbines, impellers of hydraulic turbines, cutting and forging dies, press and casting molds, various cams, stamps, molds, metal models and blanks.

Such equipment is also used for drilling holes for handles, locks, latches, metal hinges, as well as making frames for mirrors and channels of any size on plastic and aluminum profiles, as in the video about copy-milling machines. On universal machines the processing procedure similar products is practically impossible.

A copy-milling machine is intended for milling curved parts using a copying technique according to a template from which the shape of the future product is copied. The use of templates allows us to eliminate the influence of the human factor during such a complex operation, and that’s all finished parts As a result, they have the same shape.

To make several completely identical products, you can not only use a single template, but also make all subsequent parts based on the first one. However, for the most accurate repetition, it is recommended to supplement the machine with a copying device called a pantograph. Its design can be different, but the function is the same in all cases - to more accurately transmit the movement of the copying head along the profile to the cutting device.

Design of copy milling machine

The copy-milling machine is designed for processing profiles (planar milling) or reliefs (volumetric milling) of products using a carbide cutting tool - a milling cutter. The cutter reproduces on the product the contour or surface of the setting device - the copier. The driving device of a manual copy-milling machine has a pneumatic, mechanical or hydraulic connection with a tracking system, which is responsible for directing the cutting tool, on the one hand acting on the amplifying device, and on the other influencing the executive body.

A flat template, a spatial model, a reference part, a contour drawing can act as a copier, and a probe, a copy roller or finger, or a photocell can serve as a copy device. Samples for copying can be made of metal, plastic or wood. The workpiece and the copier are mounted on a rotating table.

The executive body can be a spool, a screw, a solenoid, an electromagnetic clutch, or a differential. In the amplification devices of copy-milling machines, electromagnetic, hydraulic or electro-optical relays are used. The surface roughness of the workpiece and the accuracy of the profile depend on the speed of movement of the tracking device: roughness No. 6 and a profile accuracy of 0.02 millimeters are achieved. The actuator circuit is driven by a power hydraulic cylinder and an electric motor.

Copying at a specified scale is carried out using a special device called a pantograph. If you are interested in how to make a copy-milling machine yourself at home, then you can supplement it with this device. The pantograph has a structural guide pin, which is located on an axis and moves along the copier, a rotation axis and a tool spindle. When moving along the finger pattern on the workpiece, the spindle describes a geometrically similar figure. And the copying scale is determined by the proportions of the pantograph arms.

Types of copy milling machines

Based on the type of drive, the following main types of copy-milling machines are distinguished: with a pantograph, which is designed to work in 2 and 3 dimensions; universal devices with a pantograph, which is located on a rotating arm in a vertical plane; single and multi-spindle units with rectangular and round table; with mechanical feed, electrically and hydraulically, as well as photocopying.

There are several types of similar milling and copying machines, which differ in the level of automation and clamping of the workpiece being processed:

1. Manual or desktop copy-milling machine with mechanical profile clamping. With its help, you can drill holes of various shapes according to a template, however, for triple holes you will need a three-spindle attachment on a machine or drill.
2. Automatic (stationary) milling and copying machine with pneumatic profile clamping. Such machines also do not allow triple holes to be made for installing handles and, as a rule, are used for the production of aluminum structures.
3. Automatic (stationary) milling and copying machine with pneumatic profile clamping and a 3-spindle attachment for drilling triple holes.

Operating principle of a copy milling machine

Processing of products on a copy-milling machine is carried out using a master device (copier), the action of which is caused through copier corresponding movement relative to the workpiece of a special cutting tool. Through the copying device, the copier acts on the executive bodies, while the workpiece and cutter are recreated in relative motion surface that is specified on the copier.

The main movements are rotation of the spindle, movement of the table and slide along the contour, and movement of the spindle head when cutting. Auxiliary movements - acceleration of movement of the slide, spindle head and table, installation movements on the table of the tracer table, stops, copying finger and clamping of the spindle head.

Aluminum copy-milling machines are capable of operating according to 2 tracking schemes: action with feedback and simple action. The copy probe and the cutter in the simple-action scheme are rigidly connected to each other, and the movement of the probe along the copier is transmitted to the cutter. The deflection of the trace probe in the feedback circuit causes a mismatch in the position of the trace probe relative to the cutter.

The result of such a mismatch is sent to a special tracking system, which issues a signal to the actuator to adjust the tool path. In this case, there is no rigid connection between the cutter and the copier, and the copier does not perceive the cutting force, but only transmits it executive bodies corresponding signal.

There are two types of copy milling - volumetric and contour. When contour copying, the copier curve can be placed in a plane that is parallel or perpendicular to the axis of the cutter. In the first case, the table with a copier and the workpiece moves in the longitudinal direction; control of the change in the curve is accomplished due to the vertical movement of the cut-in and the carbon finger. In the second case, the table with the copier and the workpiece moves in the transverse and longitudinal directions according to the shape of the curved line of the copier.

The complex spatial surface of the workpiece during volumetric copying is processed with a cutter sequentially, through several parallel table strokes, that is, contour copying is performed with each working stroke. At the end of the pass, the cutter is shifted relative to the workpiece perpendicular to the line by the amount of the transverse feed, then the next working stroke occurs.

There are also direct-action copy-milling machines, in which the milling probe transmits movement through the pantograph. Such machines are mainly used for light engraving and milling work. When using a pantograph, in addition to copying, it is possible to reduce the scale of workpieces in relation to the copier. The movement of the copy probe along the copier, which is installed on the machine table, is transmitted to the spindle, which, when processing the workpiece, describes a contour similar geometrically to the copier.

Do-it-yourself copy-milling machine

Currently, the market offers milling and copying machines of the most different designs and level of difficulty. However, it is not always possible to buy one, and the price of a copy-milling machine is quite high. Therefore, we often face the question of how to make a copy-milling machine at home.

Undoubtedly, homemade machines cannot fully compete with industrial models, but they are still functional and allow the production of high-quality copies. I would like to immediately make a reservation that the copying device should be adapted to industrial milling device It will be very difficult, and this concerns, first of all, a radical redesign of the entire apparatus. Therefore, the easiest way to assemble a homemade copy-milling machine is practically “from scratch” using a rod system and an electric motor with a clamping chuck for the cutter.

There can be many designs of copy-milling machines. Typical design The apparatus is as follows: the machine structurally consists of a work table, a supporting frame and a milling head. The working surface can be adjusted in height, milling head equipped with an electric drive motor and a two-stage transmission mechanism that provides two speeds of the milling shaft.

Many homeowners complain that when copying a product, the resulting part has many flaws and inconsistencies that appeared when changing the direction of the cutter, vibration and trembling supporting structure. Adding to the trouble is the sagging and curvature of the workpiece, which is associated with an increase in internal stress due to the removal of wood. It is impossible to avoid all the shortcomings when making a homemade copy-milling machine. It is simply recommended to make the copying machine narrow-profile, and not universal.

A homemade copy-milling machine should be optimized for the production of specific products that you need. For example, for efficient manufacturing The wooden part of the gun and the screw for the propeller require different technical solutions; they cannot be combined in one machine, and side effects that are difficult to correct may occur. Thus, it is more practical to assemble machines for some certain tasks. This approach can save you many costs and difficulties.

An important factor is the size of the machine. The larger the product you plan to process, the more massive the design should be. It is necessary that the vibrations transmitted from the cutter drive are absorbed by the weight of the machine's supporting structure. Loads must be supported by guide axes, which must also have a safety margin and not bend. The optimal parameters when designing a copy-milling machine with your own hands are selected experimentally, this ensures smooth operation of the cutter.

When designing a copy-milling machine, determine the type of parts you will produce. To perform engraving work and to mill long products, a different work table and a method for securing workpieces with a template on it are required. Freedom of movement in different planes of the cutting tool depends on the type of work table.

The power of the electric motor, which rotates the cutter and is installed on a homemade copy-milling machine, depends on the parts being manufactured and their material. For engraving and milling wooden products A 150-200 watt DC electric motor is sufficient.

To ensure an accurate copying procedure, you need to rigidly connect the copying probe and the device to each other, securing the cutting tool in it. In this case, their height and planes above the desktop must coincide completely. The created rigid structure should be installed above the desktop in such a way that it can move in the vertical and horizontal planes along the axes that are conventionally created by the sides of the desktop.

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