In order to ensure the normal operation of the milling machine, it is necessary not only to handle the device used correctly, but also to correctly use, in other words, devices for So that this tool has the ability to form a workpiece in accordance with the requirements of the master (that is, cutting off the edges and other places of the material where it is needed, and not where “it happened so”). So, it is precisely to give the processed material a clear planned shape that the farm uses “devices” for a manual milling machine.

The difficulty of making homemade devices

Often, manufacturers themselves complete their products at the production stage; however, unfortunately, not every company will be able to please consumers with a complete set of all necessary tools. And why do this if at any time you can make a suitable tool with your own hands in a garage. This can be done even without a preliminary drawing: their design is so primitive that even a novice master can cope with such work. To make a parallel stop or any other part, it is enough to have a drawing of this device and a minimum set of tools. But if you want to make a homemade table for a hand router, you definitely can’t do without a drawing. You need to calculate everything correctly, indicate the dimensions of the table, and then get to work.

How to work with a hand router?

Before carrying out milling work on wood, you need to make sure of the following:

• Is the cutter secured in the collet?
• Does the additional device installed on the workbench correspond to its power and speed?
• Is the required milling depth set (when working with submersible devices, this indicator is measured using a special immersion limiter).
• When working with it, make sure that a guide ring or bearing is installed that provides the desired trajectory of the device (the thickness of the cutter should be no more than three millimeters).

We pay attention to supports for parts when performing work.

When considering the question “how to work with a hand router,” it is also necessary to note that the part you are processing must always have some kind of support. For example, before the engine is turned on, the edge of the sole or bearing is pressed against a guide piece or template. Only then does the master turn on the machine and begin milling.

Below we will look at what types of tools there are for a router and what makes them special.

Rip fence

The rip fence is one of the few devices that is already included with every router. Therefore, there is simply no need for their independent development and production. As for the functions, with the help of the mentioned element it is possible to make a reliable stop for the material being processed, thereby ensuring the linear movement of the cutter relative to the base surface. The latter can act as a straight edge of a part, a guide rail or a table.

With this attachment for a hand router, you can quickly process edges and mill various grooves, holding the material almost in the “dead center” position.

Guide rail

This tool has similar functions to the previous one. Like the rip fence, the guide rail ensures extremely smooth, straight-line movement of the device. Working with a manual wood router using a guide rail can significantly reduce the time spent on processing a particular part. In addition, using the specified equipment, you can install the mechanism at almost any angle relative to the edge of the table.

In some cases, the design of the tools in question provides for the presence of special elements that facilitate the performance of certain operations (for example, this may be the function of cutting holes at the same distance opposite each other).

Copy rings and templates

Devices for a hand router, such as copying rings, are a round plate with a protruding shoulder that can slide along the surface along the template, thereby ensuring the exact trajectory of the cutter. Often this element is attached to the base of the workbench. There are several ways to install it:

• Screwing the ring into a threaded hole.
• Installation of special antennae of the device into the holes on the sole.

If you have such a device for a manual router as a template, you can also achieve more accurate and efficient work. The designated

the element directly on the workpiece itself, after which both parts of the device are pressed against the machine using clamps. Upon completion of the work, experts recommend checking the condition of the ring - see whether it is securely pressed against the edge of the template or not.

Another feature of the tool in question is the ability to process not the entire edge, but only its corners. At the same time, some devices for a hand router allow you to make curves of four different radii at once. Thus, the process of cutting material using a template is an excellent way to cut grooves for a part.

Compasses

These homemade devices for a manual router are designed to move the entire machine in a certain circle. The design of this tool includes a main part (a compass consisting of one rod), attached at the end to the base of the router, and a secondary part - a screw with a pin inserted into the hole of the machine. The value is set directly by the offset of the machine relative to the device design. Before starting work, you must carefully secure the tool to the base and make sure that the router is in good condition and is functioning normally. It is worth noting that the most effective and easiest to use is the compass that has not one, but two rods.

Most often, this instrument is made of transparent plexiglass. A small metric scale is additionally applied to its surface. It is worth noting that some models of compasses can have a circumference of up to 150 centimeters. Using this device, you can easily make a round tabletop for several people.

However, let's return to the principle of operation. Using an angular lever with a precise scale, copying is carried out on the workpiece. In this case, here you have the opportunity to center the ring directly under the cutter. The angle arm, which is complemented by a special support plate, also ensures precise edge milling.

The entire structure of this device consists of a base plate, a set of probes and a chip protection device.

Devices for copying identical devices and parts

This characteristic refers to a set of tools consisting of an angle lever and special copying probes, which are needed for the manufacture of a batch of identical parts. Most often, such equipment is used in cases where there is a need to replicate small-sized wooden devices. But before you start working with such a router, you need to prepare the angle lever scale in advance (division value is 1/10 mm).

Once the scale is set, you will be 100 percent sure of the correct centering of the thrust ring under the cutter, the location of which depends on the values ​​​​set on the angle lever. Also, this adjusting element can be equipped with a support board and a special mechanism that protects the surface of the device from chips. The use of such parts will significantly speed up and secure the processing of product edges.

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

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

1 Features of milling

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

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

Milling can be organized in two ways:

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

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

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

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

Milling machines come in two categories:

• specialized;
• general purpose.

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

1.1 Purpose of the machine

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

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

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

The machine allows you to create:

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

The equipment can also be used for:

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

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

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

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

2 Machine design

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

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

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

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

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

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

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

2.1 Types of copy milling machines

By type of drive:

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

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

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

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

These can be mini or full-size machines.

2.2 Making a machine yourself

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

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

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

• Desktop;
• supporting frame;
• milling head.

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

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

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. 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, 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, 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 is set in motion thanks to such structural elements as a screw, spool valve, solenoid, differential or electromagnetic 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 various types of drives. 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 desktop, on which the workpiece is fixed mechanically (on these devices you can drill holes of various shapes in accordance with the template);
• automatic equipment of a stationary type, the workpieces on which are fixed using pneumatic clamps (such machines work with aluminum);
• automatic equipment of a stationary type with pneumatic clamps, on which a three-spindle head is installed (on these copy-milling machines, triple holes are simultaneously drilled, which does not allow the production of units of the two previous types).

How does a copy milling machine work?

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

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

In copy milling machines working on aluminum, two tracking schemes can be implemented: simple action and 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 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 according to a standard design, which includes a supporting structure - a frame, a work table and a 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. 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

Milling copying 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

It is necessary to cut small racks 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 the maximum number of working revolutions 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 frezer.
• Angle grinder.
• Welding machine.
• Spanners.
• 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 is 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.

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 in 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. Using a high-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. Typically, 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 a simple template in two dimensions, a standard version with a clamping profile is sufficient, but to produce and drill three-dimensional holes, the machine must be equipped with a pneumatic clamping unit, a drill and drill or other drilling installation. Depending on the configuration and capabilities, it can work not only with wood, but also with plastic, cast iron and other non-ferrous metals. To do this, the machine is equipped with powerful and durable cutters for various materials, and copying equipment is improved for certain shapes.

Do-it-yourself machines are often used in the home 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 a medium-diameter metal pipe as a guide. 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 milling cutter 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.