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 batches, differs 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 on almost any industrial enterprise. This is explained by the fact that the milling operation is one of the most common methods used to perform machining. This technology allows you to perform a wide range of roughing, semi-finishing and finishing operations with simple and shaped workpieces made of ferrous and non-ferrous metals, and to work on wood and plastic. On modern milling equipment Parts of even the most complex shapes are processed with high precision and productivity.
There are two main types of milling: counter-milling (the 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 perform processing (including grinding) of even the most hard metals and alloys, artificial and natural stone.
Milling equipment is divided into two types: general purpose and specialized, which includes a copy-milling machine.
Capabilities of copy-milling equipment
Copying machine, belonging to the milling group, is designed for copy-milling work with flat and three-dimensional parts. In addition, such a device can be used for engraving shaped profiles, apply inscriptions and patterns (even of high complexity) to products, 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 turbojet engine blades and steam turbines, propellers for ships, cutting and forging dies, impellers for hydraulic turbines, molds for pressing and casting, compression 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 it is possible to achieve the following characteristics finished product: 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 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 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, having the desire, having spent not so much time, effort and financial resources, you can make such equipment yourself.
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.
Lathes are specialized equipment used for making wood products. It is on such a machine that furniture legs, door handles, balusters and other wood products are made. There are many models of modern lathes with different prices.
Models of wood lathes
Exists large number different models lathes, they can be divided into the following types:
- Standard machines, depending on the product, processing on such a device is carried out in the center, in a special chuck or faceplate. The equipment design includes an electric motor, a steel frame, cutters, chucks and a control system.
- Copying tools, with their help, produce the same type of wood products, in large quantities. Manually operated devices are cheaper and will profitable option for small productions.
- Milling machines, on which wood processing is done along the axis of the product. The work is done using a milling cutter and a circular saw.
- Machines for twisted flutes; the equipment can carry out standard operations, as well as figured cutting on the sides of products. Electronic control significantly simplifies the work, and the ability to simultaneously process two products increases productivity and saves time.
Copy wood lathe Proma DSL-1200
The lathe is designed for processing wooden products, turning profiles and decorative parts. A characteristic feature of the device is presence of two incisors. One is installed on a steady rest and is used for processing round workpieces, removing up to 10 mm of material in one pass. Using this cutter you can make round workpieces of different diameters. The settings are set on a special device.
The second cutter is installed in the copying carriage and turns the parts according to the copying machine. The original fastening allows you to quickly prepare the machine for work.
For the manufacture of long products, the delivery set includes a steady rest, which is mounted on guide rods as a support and prevents deflection of the long workpiece. By installing a faceplate, the machine will allow you to process multi-faceted products.
Specifications:
- Voltage - 380V.
- Center height - 215 mm.
- Weight - 395 kg.
- Dimensions - 2105x1000x1225 mm.
Price - 255803 rub..
4-spindle copy lathe T4M-0
Model T4M-0 is equipped with a horizontal sanding unit, which is capable of processing 4 workpieces simultaneously using a copier (lace legs of tables and chairs, musical instruments).
- The cast bed and balanced parts eliminated vibration, increasing the processing speed of large workpieces.
- The shaft is installed automatically at the beginning of the cycle and returns to its original position after processing is completed.
- Pneumatic clamping on spindles.
- Adjustable shaft feed speed.
- Smooth adjustment of spindle speed using a block.
Specifications:
Additional equipment:
- 7.3 kW motor.
- Inventory rotation speed control.
- Expansion of working space up to 1500 mm.
Price - 49,700 rub..
Copy wood lathe CL-1201
The CL-1201 machine is used in manufacturing industries for turning rounded products with a diameter of up to 1200 mm and processing cylindrical parts. Wide possibilities for processing are provided by clamps: faceplate, chuck, centers.
Features of the lathe:
- The heavy spindle is equipped with a device that controls the rotation speed, which allows high-quality processing of workpieces based on weight, dimensions, and type of wood.
- The spindle can change the direction of rotation, providing good processing of wood of any density.
- The lathe is controlled and configured from a portable console, which, at the user’s request, can be placed on the front or rear column.
- The stability of the machine is ensured by a frame made of steel, and the rear columns are made of cast iron. This ensures minimal vibration during operation and improves the quality of processing.
- The base allows you to process workpieces up to 1270 mm long, and to increase it you can use additional sections up to 1270 mm.
- The copying mechanism is included in the basic package, which significantly expands the possibilities.
- The milling attachment allows you to produce longitudinal grooves along the entire length of the workpiece.
- The mobile support moves over the entire surface of the part. Control is carried out by a flywheel. The processing depth is adjusted by lever
- With the help of a tailstock, the machining accuracy of long parts increases.
- The degree of protection of the machine is IP54, the engine is reliably protected from overheating and overload, and electronic parts are protected from moisture and dust.
The standard package includes:
- Copier and template holder.
- Knife support 254 mm.
- Mounting washer 254 mm.
- Rotating center.
- 2 straight cutters
- Chisel stand.
- Mobile rest.
- Devices for regulating spindle speed.
Price - 153588 rub..
Copy wood lathe CL-1201A
The device is manufactured by the Austrian company Stomana, which has been supplying equipment for more than 20 years. The device is designed for processing wood and rounding products up to 1270 mm long, made of materials of different densities. The copier is supplied in a basic configuration; it is used to produce products according to the sample.
Included in delivery lathe includes:
- Copier and stand for templates.
- Knife support.
- Mechanism for applying spiral channels.
- Rotating center.
- Leading center with a diameter of 20 mm.
- Fastening washer.
- 2 incisors.
- Stand for lunette.
Copy wood lathe KTF-7
The KTF-7 turning device is used for processing wood on stationary and rotating workpieces. Equipment uses disc milling tool, which increases productivity and service life. This scheme allows you to obtain parts that cannot be made on a conventional lathe:
- Profile polyhedra.
- Surfaces with helical profile.
- Profile grooves on the product.
Work on a turning device is carried out according to a template with automatic feeding of the workpiece, in two passes. When moving forward, roughing occurs; when moving backwards, finishing occurs. Semi-automatic operation increases productivity and the number of irregularities on the wood surface during processing. The device is equipped with a mount for a hand cutter.
Specifications:
- Voltage - 380V.
- The maximum length of the part is 1200 mm.
- Center height - 215 mm.
- Weight - 740 kg.
- Dimensions - 2100x900x1049 mm.
Wood is one of the main materials that people use in everyday life for the manufacture of furniture, interior decoration, decorative architectural elements, household and garden supplies and much more.
Wood copying machine.
One or two things can be done with hand tools or using woodworking equipment.
But how to process a large number of completely identical products with the least amount of labor and time? In this case, copying machines will come to the rescue. One of them is 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 (CFS) are designed for processing wood parts using the copying method. Types of method:
- contour or 2-dimensional (2-D) milling;
- volumetric or 3-dimensional (3D) copying.
One method or another is used depending on the shape of the product being processed.
The main advantage of copying machines is that 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, in 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.
How the copier works
To replicate the product, one of the copies is used, which serves as a template. The head with the cutting tool (mill) is connected into one unit with a copy probe.
With 2-dimensional milling, the probe moves along the generatrix of the copied contour, and the rotating tool repeats this movement, resulting in a copy of the template.
When a volumetric part is milled, the copying tip scans the 3-dimensional model and forces the cutter to move along an equidistant (similar) path. The nature of the movements of copying machines is of 2 types:
- The template and the workpiece are stationary, the cutting head moves in the longitudinal direction, removing a certain amount of material in one double stroke.
- The template and the workpiece (one or more) rotate, and the cutter moves radially along the copier. As a result, it repeats the profile of the copied section. In this case, the cutting unit or part is evenly moved along the longitudinal axis of the product.
A particular type of copying and engraving work is the milling of drawings or ornaments according to a template, which is a pasted paper copy printed on a printer.
You can use AVTOCAD, Compass, Word, Paint and others as a program for creating a drawing. 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 the processing technology in your head, you should take into account everything possible situations. After the machine has been manufactured, it may be difficult to introduce additional movements.
Finally, the machine must be configured in such a way that control forces are minimal. This means that moving parts should be as light as possible. Think about which layout is better to choose: horizontal or vertical. Firstly, the convenience of work, as well as loading and unloading of workpieces, depends on this. Secondly, with a vertical arrangement, the chips fall directly to the floor or into a trough, and do not accumulate on the base or in the mechanisms of the machine.
The milling head should be selected as high-speed as possible. This is 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 router mounted on a pantograph 
Drawing 3 - carriage for installing a router on a flat-bed copier
Video: presentation of a homemade copying machine
Do-it-yourself CNC copying machine - is it possible?
All devices discussed above have manual control, that is, despite the increase in productivity, the person remains chained to the mechanism. This type of work is quite monotonous and tedious. In mass and large-scale production, copy-milling machines equipped with computer numerical control (CNC) are used. All work on such equipment comes down to loading blanks and removing finished products. As an example, the photo shows a similar machine.
A copying machine differs from a conventional CNC milling machine by the presence of a programming system. A traditional CNC machine operates from a control program compiled by the operator in a system, for example, ARTCAM, according to a 3-D model, which is developed at the design stage by a design engineer. If the product was created by a sculptor or designer, it must first be digitized, that is, a 3-D model must be created. This work is performed by a software engineer.
On a CNC copying machine, the control program is compiled by the system itself. When installing a copied product, an additional CNC attachment probes the part and creates its 3-dimensional model, from which a control program is automatically generated. Considering the high cost of components, problems with purchasing a CNC system, 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.
Copier for wood lathe with manual router
We suggest you make your own copier with minimal costs according to time, the machine can be started in " industrial production» turned parts by evening. The “cutting tool” will be a manual milling cutter; the technical characteristics of the parts being manufactured depend on technical characteristics wood lathe. Despite the fact that the copier is made using plywood, it can produce up to hundreds of products from one copier, you will agree that this quantity is quite enough to fulfill most wholesale orders.
The device does not look exactly “attractive” from a design point of view, but we did not set such a task for ourselves. We tried to make our “equipment” as simple to manufacture and more or less reliable as possible. Which is what happened in the end. How is a copier made? Let's get to know him better.
Copier device
An ordinary hand-held milling cutter is used for the cutting tool; the specific model does not matter. Place the router on the support platform, our platform dimensions are 500×200 mm, made of sheet plywood 12 millimeters thick. You can slightly increase or decrease the linear parameters of the site depending on the size of the hand cutter. On the site, make holes for the cutter to exit and holes for installing mounting bolts. In order to completely eliminate unauthorized spontaneous movements of the cutter during operation, we advise you to install additional stop bars around the perimeter on the site, secure the bars with self-tapping screws, the length of the screws is selected taking into account the thickness of the fixing bars.
The router needs to be installed between the stop bars, check that it is securely fixed, any vibrations are completely eliminated. The far end of the platform should “ride” along the pipe the entire length of the wood lathe, we used a Ø 25 mm pipe, you can use other pipes for making. The main thing is that they can withstand the weight of the router without bending, that they are absolutely flat and have a perfectly smooth surface. Secure the ends of the pipe with two wooden blocks; in our case, 80x35 mm blocks were used. Screw the bars to the body of the lathe using metal screws; you do not have to cut threads for the bolts. If your machine design does not allow you to fasten the bars in this way, then solve this problem in your own way.
Installation of the main structural elements of a homemade copier
Strong advice - do not rush during the manufacture of equipment; turned parts for a copier do not forgive even the slightest violations not only of technology, but also of the location of the working axes. It follows from this that the axis of the pipe along which the milling cutter will move must be perfectly parallel to the axis of rotation of the lathe. We naturally found that the axis of the pipe coincided with the axis of the machine, but this condition is not necessary. The main thing is that the cutting tool of the cutter in its lowest position coincides with the axis of the machine, and this parameter can be adjusted by the level of the copier.
The pipe is fixed in the blind holes of the bars; before fixing it, you need to put two bars on it, on which the bearing platform of the router will be installed. An important condition is that the bars for the platform should slide easily along the guide pipe, but wobbling is prohibited. Check this parameter and, if necessary, manually lap the pipe and bars. Then attach the router support pad to the bars and install the router on it. Check the smoothness of sliding again, making sure that there is no wobble at all. Don’t be afraid of such “strict” requirements for gliding quality. If you have a pipe with a normal surface and completely flat, then achieving smooth sliding is not difficult.
Installation of a horizontal bar
This is the second “working” element of a homemade copier; in terms of installation accuracy, you must comply with all the above requirements. The profile template of the parts is attached to the horizontal bar. A 70x30 mm block is quite suitable for manufacturing; it is attached with self-tapping screws to vertical wooden posts; fix the posts in any convenient way to the lathe bed. The upper edge of the horizontal bar must be parallel to the axis of the machine and be flush with it. If the copier becomes temporarily unnecessary, the block is easily removed, the installation platform for the router is tilted to the rearmost position and lathe on wood can be used for its intended purpose.
Attach a vertical stop to the working platform of the router; we made it from thin plywood; you can use more durable materials, even metal. This part will move along the copier during turning and set the spatial position of the cutter; fasten the copier as firmly as possible. There is a direct relationship in terms of thickness: the thinner it is, the more accurately the dimensions will be taken from the template. But there is another dependence - a copier that is too thin makes it difficult to move the device along the template, choose golden mean. The height of the copier needs to be adjusted after final assembly machine, during adjustment all the listed conditions must be observed. One more thing. If you have a copier made of plywood, then you need to make it removable; this will allow you to quickly replace a worn-out copier with a new one while turning a large number of similar products.
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Copier stop |
How the template is made
There's nothing new here. Draw the outline of the part to be turned on a strip of plywood or OSB board, check all the dimensions again and carefully cut out using an electric jigsaw. The edges must be sanded to remove nicks and irregularities. Attach the template to the horizontal rail with self-tapping screws; when fixing, observe all installation dimensions.
Some features of turning
You will have to move the device only with two hands, otherwise it may jam on the pipe. Another problem is that the radii of curvature of turned parts are limited by the diameter of the cutter; this must be kept in mind when choosing the profile of turned parts. Practice shows the dependence of the feed speed on the diameter of the cutter: the smaller the diameter of the cutter, the less the feed should be and vice versa.
700 rub
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Making a lathe copy with your own hands is not the most difficult task. But in order to achieve the desired result in terms of quality and efficiency, you will have to make some efforts. You will need a detailed drawing, a copy template and several hours of free time. We offer you a version of a copier machine based on a hand milling cutter as a cutting tool.
The proposed copier for your lathe requires little financial, time and labor costs. This is why it attracts a large number of craftsmen who need a copier for a lathe.
The cutting device will be a hand router. At the same time, the operational capabilities of the copier directly depend on the characteristics of the turning equipment itself.
You should not count on the attractiveness of the design of a device you create yourself, since its main task is to create copies according to a template without unnecessary energy consumption.
The device of a machine with a copier
- To begin with, to create a lathe with a tracer, you will need a hand router. Choose its type yourself, depending on the planned work;
- The router is mounted on a support platform with dimensions of approximately 50 by 20 centimeters. It can be made from sheets of plywood 12 mm thick;
- At your request, the copying machine can have a larger or smaller platform. The dimensions largely depend on the parameters of the selected router;
- On the support platform, make holes through which the routers will come out;
- Holes for fastenings are also made here. It is optimal to use bolts as fasteners;
- Thrust bars located around the perimeter and fixed with self-tapping screws will provide protection against accidental movements of the cutter when processing products;
- Having installed the cutter support between the bars, make sure that it is securely fixed and there is no vibration or play;
- The far end of the support platform must be able to move along the guide pipe along the entire length of the turning equipment;
- Use a guide pipe with a diameter of 25 millimeters, or adapt it to your machine parameters;
- The main condition when choosing pipes is that they must cope with the loads from the weight of the router, not sag, and maintain an even, smooth surface;
- Secure the ends of the pipes with a pair of wooden blocks of a suitable size;
- The bars are mounted to the machine body with self-tapping screws or through bolts.
Installation of structural elements
In order for the lathe with a copier to work efficiently, and the copying process does not raise quality issues, do not rush in any case. It is precisely the rush that prevents craftsmen from making a really good copier for a lathe with their own hands.
Having studied the drawing on the basis of which you decided to build a copier with your own hands, stick to the suggested dimensions. If you make even a small error, the copying technology may be completely disrupted and the working axes may be disrupted.
To prevent anything like this from happening, follow a few important rules.
- The axis of the pipe intended for moving the router must be exactly parallel to the axis of rotation of the machine.
- The coincidence of the pipe axis and the machine axis is also an important plus, although this condition is not mandatory.
- The main point is the coincidence of the router in the lowest position with the axis turning device. This parameter is controlled and changed as necessary due to the level of placement of the copier.
- Fix the guide pipe through the blind holes of the wooden blocks. But immediately before fixing, place two bars on the pipe on which you plan to install the supporting platform.
- The wooden blocks for the load-bearing platform must move very easily, or rather slide along the guide pipe. If loosening is noticed, the copying unit will have to be redone.
Many fear the moment when increased demands are placed on gliding. But making a machine with such operating parameters is not difficult if you use an even, smooth pipe.
Horizontal bars
The next step is to install the horizontal block of wood, which is the second most important operating component of your tracer lathe.
- Adhere to similar precision requirements as in the operations described above;
- The horizontal beam is connected to the workpiece profile template;
- To make a block with your own hands, you can use a workpiece measuring 7 by 3 millimeters and fix it with self-tapping screws to the vertical posts;
- The wooden stands themselves are mounted to the lathe bed using any method convenient for you;
- Make sure that the top edge of the horizontal element is parallel to the axis of the machine and is located at the same level;
- If at some point you don’t need the copying functionality, you can easily remove the block with your own hands, fold the mounting platform onto the edge of the machine and use the turning unit for its intended purpose without a copier;
- A vertical stop is mounted to the milling table. A sheet of thin plywood is quite suitable here. Although if you require a more durable structure, use steel sheets;
- This element is used to move around the copier when sharpening parts. It sets the spatial position for the working milling cutter. Therefore, the copier should be fixed as securely as possible;
- Thickness plays an important role. The thinner the vertical stop is, the more accurately the lathe can copy your template. But even if the stop is too thin, the device begins to move according to the pattern with certain difficulties. Therefore, the optimal way out of the situation is to find an intermediate option;
- If you use plywood to make a copier, be sure to consider using a removable design. This will allow you to easily dismantle the copier when it wears out and replace it with a new one with minimal time investment.
Sample
Last but not least important element a lathe with a copier function is the copy template itself. It is not difficult to make, but the configuration completely depends on the parameters of the products that you want to obtain using your machine.
- Take a sheet of plywood or OSB board;
- Apply markings on the sheet according to the contours of the future product that you want to turn on a lathe;
- Be sure to compare all dimensions with the required parameters;
- Use an electric jigsaw to carefully cut the blade along the contours, cutting out the required part;
- Sand the edges with a sander or regular sandpaper. The template should not have any irregularities, burrs or nicks;
- Secure the resulting template to the horizontal rail using self-tapping screws;
- Carry out fixation strictly in accordance with the installation parameters.
Using drawings and video instructions, you can easily make a fairly efficient, productive copy lathe unit yourself. You just need a little patience and time.
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