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. In enterprises, this problem is solved using a device such as a copying machine. milling machine, which allows you to make copies of the original part in large series, is characterized by high speed, as well as the quality of the processing performed.

What is the milling process?

Copy-milling machines and any other equipment of the milling group can be found 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. Modern milling equipment can process parts of even the most complex shapes with high precision and productivity.

There are two main types of milling: counter (feed and rotation of the tool are in different directions) and down milling (the tool rotates in the same direction as the feed). The cutting part of the tools that perform milling is made of various materials, which makes it possible not only to successfully work on wood, but also to process (including grinding) even the hardest metals and alloys, artificial and natural stone.

Milling equipment is divided into two types: general purpose and specialized, which includes a copy-milling machine.

Capabilities of copy-milling equipment

The copying machine, which belongs to the milling group, is designed for copying and milling work with flat and three-dimensional parts. In addition, such a device can be used to engrave shaped profiles, apply inscriptions and patterns (even of high complexity) to products, and carry out light milling operations on wood and other materials.

Using tools with cutting parts made of various materials, parts made of cast iron are processed on copy milling machines, different varieties steel and non-ferrous metals. 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, due to which all finished products have the same shape and geometric dimensions. Conveniently, one template can be used to accurately manufacture a large batch of parts that will be completely identical to each other.

In order to copy the shape and dimensions of the template as accurately as possible, a copier (pantograph for a router) is installed on a copy-milling machine. The purpose of such a device is to accurately transfer all movements from the copy head to the cutting tool.

How does a copy milling machine work?

Copy-milling machines, as mentioned above, are used for planar (processing of profiles) and volumetric (processing of reliefs) milling. They use cutters as a working tool, which, when processing the contour or volumetric surface of a part, repeat the movements of the copier. The connection between the working element and the tracking system in manual machines is ensured by mechanical, pneumatic or hydraulic elements necessary to generate the force transmitted from the copier to the working element of the copy-milling machine.

The template on such machines is a flat contour or spatial model, a standard part or contour drawings, and the element that reads the shape and dimensions of the template is a copying finger or roller, a special probe, or a photocell. To make a template, you can use an aluminum sheet or a sheet of other metal, 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 round or rectangular rotary tables;
• machines, the feed on which is ensured by mechanical, electrical, hydraulic devices;
• photocopying equipment.

A homemade copying machine can be any of these types (including copying and grinding machines). You just need to find drawings on the Internet and select components.

According to the degree of automation and the method of fixing the workpiece, the following categories of copy-milling machines are distinguished:

• manual or tabletop, on which the workpiece is fixed mechanically(on these devices you can drill holes of various shapes in accordance with the template);
• automatic equipment of a stationary type, the workpieces on which are fixed using pneumatic clamps (such machines work with aluminum);
• automatic equipment of a stationary type with pneumatic clamps, on which a three-spindle head is installed (on these copy-milling machines, triple holes are simultaneously drilled, which does not allow the production of units of the two previous types).

How does a copy milling machine work?

As noted above, on a copy-milling machine the workpiece is processed using a master device - a copier. All movements of the copier along the contour or surface of the template are transmitted thanks to a special (copying) device to the working head of the machine in which the cutter is fixed. Thus, the cutting tool exactly repeats all the movements made by the copier used to equip the router.

The movements of the elements of a copy-milling machine during the processing of a part are divided into main (rotation and movement of the spindle when cutting the tool into the workpiece material, movement along the contour of the work table and slide) and auxiliary (movement of the spindle head, slide and table in accelerated mode, as well as installation movements made by the tracer table, the copying finger, the stops and the clamp that fixes the spindle head).

In copy milling machines working on aluminum, two tracking schemes can be implemented: simple action and feedback action. When implementing the direct action scheme, the working body of the machine makes movements due to the fact that it is rigidly connected to the copier. The reverse action scheme does not provide for such a connection and movements from the copier to the working element are transmitted not directly, but through a tracking system.

As mentioned above, contour and volumetric milling is performed on copy milling machines. When contour milling, the movements of the copier occur in a plane parallel or perpendicular to the axis of the tool. In the first case, the movement of the equipment working table can only be longitudinal, and the cutter and copying finger move vertically. In the second case, the table moves both longitudinally and transversely. In volumetric milling, the part is processed in stages - thanks to several movements of the table and tool performed in parallel planes.

The direct action scheme can also be implemented through a pantograph, which allows you to reduce the size finished products relative 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, your homemade machine It is better to assemble a copy-milling type 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 according to a standard design, which includes a supporting structure - a frame, a work table and a milling head. The drive to ensure the rotation of the working tool is an electric motor that transmits movement through a two-stage mechanism, allowing two speeds to be obtained. The desktop of this homemade device can be adjusted in height.

Many of those who have made a copy-milling machine with their own hands note that when changing operating modes, such equipment begins to show a lot of shortcomings. The most common of these shortcomings are vibrations of the machine frame, curvature of the workpiece and its deflection, poor-quality copying, etc. To avoid such problems, it is best to make the copy-milling device highly specialized and immediately configure it to process workpieces of the same type. This is explained by the fact that it is almost impossible to take into account all the shortcomings that will arise in universal equipment when changing operating modes.

The size of a homemade copy-milling machine is of great importance, which must be selected depending on the size of the workpiece you are going to process on it. When processing large workpieces, significant vibrations arise, which only massive equipment can dampen. With such processing, serious loads are transferred to the guide axes of the machine, which must also be able to withstand it.

The first thing you need to do before making a copy-milling machine with your own hands is to decide on the tasks that you are going to solve with its help. The size of the work table, the method of securing the workpieces and template, and the direction of movement of the cutting tool will depend on this.

Depending on what parts you are going to make on your homemade copy-milling machine (as well as on the material for their manufacture), the power of the electric motor is selected. So, for engraving and other woodworking, an electric motor with a power of 150–200 W is quite suitable.

The probe and the working body of the machine are rigidly fixed to each other and installed above the work table so that the height of their location and their planes completely coincide. After installation, such a structure must move horizontally and vertically parallel to all sides of the desktop.

In the two videos below, another master talks about making a copy-milling machine with his own hands.

Milling is a type of mechanical processing of materials using a special cutting tool - a milling cutter. The method allows you to obtain a high level of accuracy and the degree of roughness of the processed surface. In addition, it is distinguished by significant productivity.

Surface processing is carried out by the method of up milling, when the rotation of the cutting tool is opposite to the direction of feed, and by down milling - a method in which the direction of rotation of the cutter and feed are identical. By using cutters with cutting edges made from modern super-hard materials, the grinding operation can be replaced.

Milling equipment is divided into universal and specialized. In the first case, these are general-purpose machines for performing longitudinal and continuous milling, with or without tools mounted on a console. The second contains a mechanism for cutting threads, splines, making gears and keyways, and pattern milling.

In production, there is often a need to produce several pieces, a batch, or even a series of identical parts. For this purpose, milling equipment equipped with a pantograph is used.

In the household, the functions of a milling machine are usually performed by a manual milling machine. To perform the maximum range of work, the milling cutter is equipped with a whole set of accessories. The main equipment is supplied with the equipment, additional equipment can be purchased or manufactured independently. These are a variety of stops, clamps, templates. But you can go even further and make a copier for milling volumetric parts.

Milling and copying equipment: operating principle

The operating principle of such a device is to clearly transmit the movements of the copy head through the holder profile to the cutting tool.

It is quite difficult to purchase a copy milling machine, so craftsmen make it with their own hands from scrap materials. Everything happens by trial and error. Therefore, experts advise first assembling a duplicate carver, and only then introducing it into mass production. As a rule, this stage is preceded by more than one serious adjustment and alteration.

Milling and copying equipment: areas of application

Copy milling machines can process not only flat, but also three-dimensional parts. With their help, along with simple milling operations, you can perform engraving, repeat drawings, patterns and inscriptions. The design of the machine is quite simple, and any craftsman can make it.

Copy-milling machines allow you to process not only wooden parts, but also cast iron, steel and plastic workpieces, as well as products made of non-ferrous metals. This is ensured by high-quality tools made of high-speed steel and hard alloys. The copying machine allows you to mill not only straight, but also curved surfaces. In this case, the details are completely identical.

Milling and copying equipment: design

The typical design of a copy-milling machine is completely simple. It consists of a work table and a guide system with clamps for attaching the router and copier.

Making a universal copy-milling machine at home is quite difficult, and there is no great need for it. For home use, equipment with highly specialized specialization is usually created.

Manufacturing of copy milling machine: materials

To create a duplicate carver at home with your own hands, you should draw a basic sketch, which will become a guide to further actions. In addition, you need to stock up on some materials. This:

1. Knee cemented polished shaft Ø 16 mm.
2. Linear bearings in the amount of 2 pcs.
3. Rail guides 900 mm long – 2 pcs. For ease of fastening, their length is taken as a multiple of 150.
4. Split linear bearings in the amount of 4 pcs. It is advisable to use bearings with a clamping screw to adjust the tightness of the fit on the guide.
5. Profile pipe 30×60 with a wall thickness of up to 3 mm.
6. Metal plate 900 mm long and 100 mm wide.
7. End posts in the amount of 2 pcs.
8. Moving element in the form of a plate – 1 pc.
9. Rocker arm for attaching the copier and router – 2 pcs. The length is chosen arbitrarily.
10. Movable couplings – 2 pcs.
11. Profile pipe 40×40 with a wall thickness of up to 3 mm.
12. Crown clutch for turning the part and template.

Making a copy-milling machine: tools

After this, you need to prepare a tool that will definitely be useful for assembling the machine structure. This:

• angle grinder;
• cutting and cleaning disc;
• welding machine;
• welding mask;
• petal disc or brush;
• self-tapping screws for fastening rail guides and moving elements;
• electric drill;
• screwdriver;
• measuring instruments: tape measure, caliper;
• center punch and scriber.

Making a copy-milling machine: step-by-step instructions

After everything is ready, the actual assembly of the copy-milling machine begins.

Step #1

It is necessary to cut two pieces 950 mm long from a 30×60 profile pipe to attach the rail guides. A margin of 50 mm is needed for installing limit switches in order to prevent linear bearings from slipping off.

Step #2

The 40×40 profile pipe needs to be cut into blanks for the base. Guided by the existing sketch, you need to cut two pieces of 1350 mm and two pieces of 900 mm.

Step #3

Small racks must be cut from the same pipe. Their linear size depends on the height of the subsequently processed parts.

Step #4

Now you need to remove the rust from the pipes. To do this, you can use a flap disc or brush.

Important! Before using the brush, pay attention to maximum quantity working speed on it and the grinder. The rotation speed on the brush must exceed the speed of the equipment.

Step #5

After this, we weld all the joints and clean the seams with a 6 mm thick cleaning wheel.

Step #6

Then it is necessary to ensure parallelism of the rail guides. To do this, you need to make the connection between the rack and the base of the rail guide detachable. It is necessary to take a washer according to the internal size of the rack, weld a nut to it and screw in the bolt. At this stage, the bolt is needed in order to install the nut and washer in the cavity of the stand pipe flush and in a strictly vertical position, and when welding it, do not damage the thread. This must be done with all four racks.

Step #7

Weld the posts to the base.

Step #8

At the base of the rail guide, at the junction with the racks, you need to drill holes: in the upper shelf for the bolt head, in the lower one for the thread.

Step #9

Install the rail guides on the base (30×60 pipe), pre-drilling holes, and secure with metal screws.

Step #10

Install the bases with rail guides and tighten with bolts.

Step #11

Check the parallelism of the guides. If it is missing, it is necessary to make adjustments by placing foil of different thicknesses on the racks under the guide.

Step #12

On the metal plate you need to mark and drill holes for attaching split linear bearings and end posts.

Step #13

After this, you need to make a movable element by welding 300 mm long rocker arms for the feeler gauge and router to a metal plate, then attach linear bearings to it.

Step #14

After this, the moving element must be placed on a polished shaft, along the edges of which the end posts must be installed.

Step #15

The entire structure must be installed on a metal plate 100 mm wide and the end posts must be secured with self-tapping screws.

Step #16

Then, split linear bearings must be installed on the metal plate on the bottom side.

Step #17

After this, the suspended structure is put on the rail guides with split bearings and the end switches are installed.

Step #18

Movable couplings are installed at the end of the rocker arms and a probe and a milling cutter are attached.

Step #19

In order for the workpiece and the part to rotate synchronously, it is necessary to connect them with couplings. A sprocket and crown are suitable for control. The copy milling machine is ready. The design achieved 5 degrees of freedom. Movement along the X axis is ensured by the movement of the structure along rail guides, movement along the Y axis is ensured by the movement of a moving element along a polished shaft, and movement along the Z axis is ensured by the movement of rocker arms.

Additionally, due to the movable couplings, the probe and the milling cutter can move left and right along the axis of the rocker arm, and it is possible to move the template and the workpiece simultaneously. This makes it possible to process parts of almost any shape.

Copy-milling machines for metal in mass and serial production

Metal copying and milling machines are used in mass production. With their help, ridge propellers for ships, jet engine turbines, pump impellers, dies for forging and press production, and blanks for mechanical and foundry production are manufactured. In everyday life, metal copying equipment is practically not used.

Pantograph for a router: design features

To scale copying processes, there is a special device called a pantograph. It facilitates the manufacturing processes of parts with curved surfaces and allows you to produce ornaments and patterns of any complexity in a reduced form. The cost of such a device is quite high. But making a pantograph at home with your own hands is quite possible.

Pantograph for a router: principle of operation

The schematic diagram of a pantograph looks quite simple. It is a square divided in half. All joints are hinged, so all sides are movable, and the square easily turns into a rhombus when impacted. The zero point, located in one of the corners of the square, is fixed rigidly. Relatively, its design can be modified, turning into a rhombus. A cutting tool is installed in the middle of the square. A copier is fixed diagonally in the opposite corner of the square. The distance from the zero point to the cutter is a certain value A, and to the copier 2A. This gives a 2:1 scale. The linear size of the long and short sides of the pantograph should also differ from each other by 2 times.

Pantograph for a router: materials

In order to make a pantograph with your own hands, you will need the following materials:

1. Square metal profile 12×12
2. Bearing 180201.
3. Bushings for the outer race of the bearing.
4. Pins according to the internal size of the bearing and M12 thread.
5. Nut M12.
6. Bolts M6×45
7. Nuts M6.
8. Bushing for securing the copier.
9. Profile pipe 40×40
10. Hinge of a metal-plastic window.
11. Dye.
12. Masking tape.
13. Metal plate.
14. Screw for fixing the copier.

Pantograph for router: tool

In addition to the materials listed, you will need the following tools:

• Manual milling machine.
• Angle grinder.
• Welding machine.
• Wrenches.
• Measuring tool.

Pantograph for a router: step-by-step instructions for making it yourself

Let's proceed to the actual production of the pantograph.

Stage No. 1. Workpiece cutting

It is necessary to mark and cut the square profile according to the calculated dimensions. For convenience, you can use masking tape and a metal plate. The tape will allow for clear markings, and the plate will help make an even and high-quality cut. The blanks for the platform for the router must be cut at a right angle, and the sections of the profile for the connecting rods must be beveled for maximum fit of the bearing sleeve.

Stage No. 2. Drilling technological holes

All workpieces must be chamfered and holes Ø 6.2 mm drilled for further connection into the structure.

Stage No. 3. Welding the platform for the router

After this, you need to weld the platform for the router.

Stage No. 4. Manufacturing of connecting rods

It is necessary to make something like a jig on the board and firmly fasten all the parts to be welded. To do this, a hole is drilled in the board, and the bearing in the bushing is clamped with a bolt, the square profiles of the connecting rods are secured with clamps. First you need to insert two washers between them and fasten them with bolts. After this, all joints of the structure are scalded and cleaned. Then you need to cut the bearing sleeve between the square profiles on each connecting rod. M6 bolts, washers and bearings must be removed. It is necessary to weld a mount for the router onto the frame, and an extension for scaling onto the short connecting rod at the point opposite the zero point. The connecting rods can be painted to give an aesthetic appearance.

Stage No. 5. Making a unit for attaching a copier

Now you need to machine two bushings with an internal diameter similar to the size of the copier. Drill a hole on the side and cut a thread to install the screw that secures the copier. After this, you need to cut two pieces of 12x12 squares 20-30 mm long and weld them on the side between the bushings. The size between squares should be 12 mm.

Stage No. 6. Manufacturing of the bearing lifting mechanism

It is necessary to manufacture a bearing lifting unit. To do this, the zero point finger must be welded onto a piece of 12×12 profile and secured to a 40×40 profile pipe using a loop from a metal-plastic window. The profile pipe will serve as a place for attaching the pantograph to the table with a clamp.

Stage No. 7. Pantograph assembly

The bearings must be installed in the bushings and secured securely by tightening the square profiles of the connecting rods with M6 bolts. Using your fingers, you need to assemble the connecting rods into a single structure. Secure the pantograph to the table with a clamp and install the router. The device is ready for use.

Cutting tools for milling work: copy cutters

Copy cutters are a tool on which, in addition to the cutting part, there is a bearing. Its size is equal to the diameter of the cutting part of the cutter. The bearing can be located both in the upper and lower parts of the cutter. This is how the tool is classified. It is worth considering that the marking indicates the position of the bearing in the usual placement of the cutter - with the shank up.

They are used to perform copying work according to a template. When using a cutter with an upper bearing, the template is located on top of the part; if with a lower bearing position, then from the bottom.

Working with a hand router involves the use of any cutters. It's safe. The only thing is that when using a cutting tool with an upper bearing, you should pay attention to the overhang of the cutter so as not to damage the workbench.

Milling on a woodworking machine involves using cutters only with a lower bearing position. This is due to the fact that a cutter with an upper bearing position has an open rotating cutting part in the workpiece area. Careless movement may result in serious injury. Such cutters are used on machines only in special cases with maximum compliance with safety regulations.

Copy-milling machines are unique equipment with the help of which the most complex work is performed on the production of identical parts. But for working at home, you can make simple analogues of such equipment and devices that will help in your home or small business.

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 large number exactly identical products with the least amount of labor and time? In this case, copying machines will come to the rescue. One of them is a copy-milling machine for 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 (KFS) 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 it is possible to produce any number of parts with a curved contour, which are a copy of the original copy. 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.

Milling heads (milling cutter) are often used as a working unit in small machines. 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 carvings;
• 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 general characteristics, it becomes obvious that To process parts belonging to the same group, your own design (layout) of the machine is required.

The principle of operation of the copier

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 volume 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 best conditions for processing. That is, there are already 4 axes. In some cases, 5 or more axes will be required. When imagining processing technology in your head, you should consider all 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 an important factor affecting the quality of processing (the height of the ridges from the cutter decreases).

Some examples

Pantograph

Photo 1: machine for cutting letters.

Used for flat threads. Its design is based on a geometric figure - a 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 rotating attachment points for 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 milling cutter installed 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 the devices discussed above are manually controlled, that is, despite the increase in productivity, the person remains chained to the mechanism. This type of work is quite monotonous and tedious. In mass and large-scale production, copy milling machines equipped with numerical control are used. program controlled(CNC). 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, making a CNC copying machine yourself is something out of the realm 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 the artistic decoration of a country estate, outbuildings, playgrounds and other structures. Jewelry work, it would seem, will be done effortlessly and with high quality.

Designed to create various products, the shape of which practically does not differ from the given sample. The essence of using these units is that they allow you to create selected elements in large quantities, while providing greater processing speed.

Features of the use of the unit

The milling operation is one of the most common options used in material processing. A copy-milling machine for wood can perform functions such as roughing, semi-finishing or finishing processing of shaped and simple surfaces of workpieces.

This operation is characterized by its very high productivity. Thanks to this, this unit allows you to obtain parts with the correct geometric shape.

Milling methods

In order to carry out this process, you can use one of two existing methods:

• The first method is the counter milling procedure. When using this method, the feed of the element is opposite to the movement of the cutter.
• The second method is down milling, the essence of which is that the part and the cutter move in the same direction.

Currently, materials such as mineral ceramics, synthetic, and superhard are used as materials for the manufacture of cutters. However, it is worth saying that the use of such high-quality substances for the manufacture of cutters can replace the grinding procedure. But this is not very relevant for a wood milling and copying machine, since the material is initially quite soft.

It is also worth noting that there are two types of such machines:

1. The first group is general purpose units.
2. The second category is specialized devices.

Copy-milling equipment belongs specifically to the second category of machines.

General description of the copy-milling device

A wood milling and copying machine is used to perform copying-type work in volume as well as on a plane. In addition, the device is also used for work using three-dimensional models. To perform such operations, appropriate copiers are also used.

This unit can also be used to perform engraving operations, applying patterns, ornaments or various inscriptions. The greatest advantage of a wood milling and copying machine is that, with its rather simple structure, it is capable of performing a large number of different complex operations.

The essence of the work

It should be noted that the ability of the device to work with various materials depends on the alloy from which the cutter is made. Operations can be carried out not only on wood, but also on steel, cast iron, and non-ferrous metals. To do this, it is necessary to use carbide as the material for the cutter, as well as provide a high number of revolutions per minute. This kind of units can be used both for large-scale production and for the production of small batches.

For example, such devices can produce things such as ship propellers, turbojet engines, steam turbines, various shapes, molds, and wood blanks.

It is worth noting that models of a CNC copy-milling machine for wood are produced. The purpose of this type of device is to perform the milling operation of curved parts. To perform such a task, these machines use a pattern copying method. The use of this method helps eliminate the human factor. This is very important, since a person is not able to create two perfectly identical things, unlike a machine. As a result of the mechanization of the process, that is, the use of machine tools, it became possible to conveyor production of various parts and elements with a curved shape and absolutely identical dimensions.

DIY machine

Today it is possible to purchase such a device on the market. However, the possibility of creating a homemade wood milling and copying machine cannot be ruled out.

Since there are quite a lot of designs for this equipment, its typical, most common form will be presented.

The components of such a unit are as follows:

• work surface;
• supporting frame or bed;
• milling head.

It is important that the working surface of the equipment has the ability to be adjusted in height, and that the milling head is equipped with an electric drive. In addition, a two-stage mechanism must be connected to it, the task of which is to provide two different speed levels of the milling head.

Quite a common drawback homemade devices is that they are not able to create an exact copy of the product. The reasons for this are most often trembling, vibration, as well as a change in the direction of the cutter. It will not be possible to avoid all flaws, and therefore, in order to minimize their presence, experts recommend creating a narrowly focused equipment model, rather than trying to make it universal.

When making a copy-milling machine for wood with your own hands, you need to create a drawing and design all the parts in such a way that in the future it will be convenient to work with workpieces of the selected size. For example, there are two types of work - milling long workpieces or engraving. These two operations require that the method of fastening the workpiece, as well as the work surface, be completely different.

This is not the only reason why you need to think things through in advance. The second thing that anyone who creates a machine on their own will have to face is the choice of an electric motor. Depending on the density of the material with which you will need to work, it is necessary to select the power of this product. If we talk about working with wood, then most often a motor with a power of 150 to 220 W is enough.

Another feature that must be observed is the most durable fastening of the copy probe and the device that holds the cutter. These two small details are very important, since the accuracy with which the machine can reproduce the model from the sample will depend on this.

Milling and copying machine for wood "Duplicarver"

The purpose of this equipment is to perform operations such as wood carving, copying sculptures and flat relief objects. The main advantage of this particular device is that it has the best price-quality ratio. And its characteristics are suitable for both professional work and beginners.

These devices can perform wood carving in two ways:

1. Volumetric or sculptural carving. This operation is the main one for this machine. It allows you to create exact copies of models from wood materials.
2. Flat relief carving. This type of work includes carving door panels, panels, or any other workpieces that have a shallow image depth.

Milling and turning copying machine for wood

The purpose of this type of machine is processing wooden products, turning profiles and decorative blanks. Distinctive feature This type of equipment requires the presence of two cutters at once. One of them is mounted on a steady rest and is intended for processing round wood blanks. This cutter is capable of removing up to 10 mm of material in one pass of the part. Settings for this element are configured on a special device.

The second cutter is mounted in the copy carriage, and its main purpose is to turn blanks according to the sample. In order to ensure comfortable work with long elements, the unit has a steady rest that can be attached to the guide rod. It is used as the main support to prevent the long workpiece from bending. It is also possible to install a part such as a faceplate. This allows you to process parts with a large number of edges.

A copy-milling machine is used to create copies of products made of wood or other material of a certain shape. Such machines are used on large and small industrial enterprises, as well as at home to create various parts. Next, we will describe the operating principle of such a machine and give recommendations on how to make it yourself.

1

Milling equipment with a copying unit is used for mechanical processing of various planes. By using quality machine You can reproduce copies of three-dimensional forms, engrave, make patterns, drawings. Its main feature is its simplicity of design, while it can perform a rather complex list of works.

Copy milling machine

Such equipment has a simple operating principle. A special copy probe is connected to the working plane. Next, he uses mechanical movements to create contours from the template or part. A wood or metal cutter is attached to the working plane, depending on the purpose of the machine, which repeats the movements of the copy probe. In addition to these parts, the standard machine is also equipped with a cutter clamping system or milling unit, an electric motor and a guide system. Usually the equipment for simple work on wood or plastic consists of three main elements:

• working surface with a supporting element and frame;
• milling cutter or milling machine with a clamping mechanism;
• copying unit (pantograph) and copying probe.

Depending on the type of copy milling machine, it can work in two or three dimensions. To create simple template in two dimensions, the standard version with a clamping profile is sufficient, but for the production and drilling of three-dimensional holes, the machine must be equipped with a pneumatic clamping unit, a drill and a drill or other drilling unit. Depending on the configuration and capabilities, it can work not only with wood, but also with plastic, cast iron and other non-ferrous metals. For this purpose, the machine is equipped with powerful and durable cutters under various materials, and copying equipment is being improved to fit certain shapes.

Do-it-yourself machines are often used in households for drilling key holes, producing frames, or creating grooves in wooden or metal parts.

2

Today, there is a large amount of copy-milling equipment of various designs with certain operating features. Their cost is usually quite high, so many hobbyists make such devices with their own hands. The homemade version, of course, will differ from its industrial counterparts, but if certain conditions are met, it will cope with its functions perfectly.

Self-made copy milling machine

The standard layout of a homemade machine consists of a working surface, a supporting structure and a milling head, which is equipped with an electric motor with a drive to enable the head to operate at two speeds. Thus, to do the installation yourself, you will need a set of certain equipment and tools, namely:

• main frame made of wood or metal;
• wooden plywood or panel, bars, boards and slats;
• fasteners in the form of bolts, nuts, screws or nails;
• milling installation;
• a set of keys, a saw or a hacksaw for working with parts;
• guide system and metal pipes;
• electric motor with drive or manual drive;
• drills and drilling rig (for more complex options).

Instead of a wooden or metal frame, you can use a ready-made milling machine as a base, but attaching a copying device to it is much more difficult than making the machine from scratch. In this case, you will have to almost completely redo the milling machine, and this will require more time and additional equipment.

3

The basis for making a machine with your own hands will be manual. Secure it to a wooden support made of thick plywood (at least 12 mm thick). Several holes are also made in the support for fasteners and a router holder. Additionally, you should build a frame and make several bars that are installed along the edges of the support; they will hold the device during operation.

Manufacturing of milling unit

We use it as a guide metal pipe medium diameter. We install a carriage with a router inserted into it on the pipe. We attach a bar to the carriage, which plays the role of a copy probe, after which it is necessary to fix the horizontal beam on which the main template is attached. A machine made according to this principle can be used to process and create copies of simple household products, for example, door handles, locks, furniture legs. The milling unit with the motor is inserted inside the carriage and connected to the power supply. The template is fixed on the support, and the copy probe moves along it.

The router is powered, the carriage moves manually, so that the working head follows the movements of the probe. To create more complex models, it is necessary to connect additional working heads and install a drive with a belt drive. Now it is possible to connect a homemade installation to software, but this will require a CNC and additional equipment and tools. Such a homemade machine will cope with its everyday functions quite well.

4

The practice of using homemade copy-milling machines of various types shows that the final part made on such equipment has certain inconsistencies with drawings and shapes and some manufacturing defects in the form of chips and curvatures. These defects are caused by constant vibrations of the machine and movements of the working head. It is very difficult to get rid of them at home.

Do-it-yourself copy-milling machine

To avoid such shortcomings in the operation of home-made equipment, we recommend making highly specialized machines rather than universal equipment. That is, before starting work on making a machine with your own hands, you need to decide what specific parts you plan to use it for. This way you can optimally select the weight and dimensions of a hand-assembled copy-milling machine. It is important to remember that the larger the size of the parts to be processed, the more powerful and heavier the working unit must be.

For large parts, additional holders and a more massive support are needed; this will allow maximum dampening of vibrations that will occur during operation. In addition, it is better to use an electric drive instead of a manual one and ensure that the guides have a sufficient margin of safety. Remember that the type of working surface determines the smooth movement of the cutting equipment in different planes, and therefore the final result.