Do-it-yourself copying machine for woodworking

Factory or homemade machine?

The modern market offers the purchase of milling and copying machines of various levels of complexity and design. But it is not always possible to make such a purchase, and the cost of such woodworking equipment is quite significant. That is why craftsmen often raise the question of a homemade milling and copying machine, the production of which is less expensive than self-assembly. Now, if you have the appropriate drawings, materials and skills, you can make such equipment yourself.

It is clear that this type of homemade equipment cannot compete with factory-produced equipment in terms of its parameters and ease of use. But if performed reliably with a home-made machine, it is possible to make fairly high-quality copies of certain wooden objects.

It should be noted right away that it is almost impossible to install copying equipment on a factory milling machine, since this implies a radical re-equipment of the entire machine.

That is why you can make a copying machine for wood with your own hands only “from scratch”, using systems of rods, an electric motor and a special chuck in which the cutter that processes the workpiece will be held.

What does a copy milling machine consist of?

Nowadays, there are quite a lot of designs of home-made equipment for this purpose, depending on the drawing used and the tasks that will be performed on this equipment. A typical wood copier consists of the following basic elements:

• suitable sized work surface;
• supporting frame;
• device for installing the router.

The milling head must be equipped with a transmission mechanism with an electric motor, which can provide several operating speeds for a homemade wood milling and copying machine.

A large number of craftsmen who made such a machine with their own hands according to drawings note that as a result of copying, the finished part has a sufficient number of flaws. They appear during a change in the direction of operation of the cutter, trembling and vibration of the entire structure. In addition, inconsistencies also occur due to the curvature of the workpiece, which occurs when the internal stress increases as a result of the processing of the wooden workpiece.

It is almost impossible to eliminate the possibility of certain defects occurring in the process of manufacturing a homemade machine. To reduce them to a minimum, it is recommended to produce not universal, but narrow-profile machines with your own hands, on which it will be possible to produce and copy parts of one specific type.

Features of creating a copier yourself

Thus, when making copy-milling machines with your own hands, it is necessary to optimize them for processing specific parts that will be produced on it. Otherwise, various side effects may occur, which are often very difficult to correct.

A fairly important factor that must be taken into account when making a copier machine yourself is its size and total weight. The larger the products will be processed on it, the more massive the entire structure should be. This will enable the equipment to absorb vibrations that arise during the operation of the cutter. The guide axles must be made so that they have a significant margin of strength without bending under increased loads.

The optimal properties of a copy-milling machine for wood when making it yourself can be selected experimentally, since this depends on the design of the equipment and the purposes for which it will be used.

How to choose the power of wood milling machine equipment for your home workshop

The manual router is designed specifically for work in small workshops or on the road. It is difficult to process large batches of lumber on it; such a machine simply cannot withstand the volume of work. Bulk workpieces are easier to process on stationary machines.

A comment

Andrey Feofanov

Tool selection specialist at VseInstruments.ru

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“To create complex designs on wood, you will have to purchase several types of cutters. Some of them can be made independently, others can be purchased in specialized stores.”

Low-power machines are quite suitable for home and household use. For example, 400 W is enough for small jobs and drilling in soft wood. Machines of this power can be used for cutting grooves. The price of manual wood routers is low, however, the range of functions is very limited.

If you plan to expand the specifics of processing, then it is better to opt for a model with a power of at least 1 kW

With such equipment you can easily work on any type of wood. This is quite enough for household needs. For professional use, it is recommended to choose a machine with a power of at least 1.5 kW. It is not always possible to buy such a wood milling machine, because the price can reach several tens of thousands of rubles. With such a machine it will be possible to process large volumes of wood, as well as plastics, soft alloys, such as aluminum; it will “eat” any type of cutter. Remember that the time it takes to complete a task depends on the power.

Spindle rotation speed is a very important characteristic that affects the price of a wood milling machine; you should pay attention to this parameter when choosing equipment. Processing dry or wet wood of varying densities is most effective at certain speeds

The dimensions of the working platform and the distance from the spindle axis to the worktop determine the dimensions of the workpieces being processed. The accuracy and depth of processing of the part, as well as the ability to select the desired cutter, depend on choosing the right spindle for a wood milling machine.

Dust extraction - when processing wood, an exhaust volute is an irreplaceable thing. Sometimes, for such purposes, ordinary vacuum cleaners are used, which are attached at a certain angle to the frame.

Dimensions and weight of the machine - for an amateur, a compact desktop model is suitable, which is installed on a workbench, and after use it is put away in the pantry. If you have a workshop, it is more advisable to assemble a full-fledged wood milling machine on a bed with your own hands. If you plan to work on a construction site, choose a manual router.

A comment

Andrey Feofanov

Tool selection specialist at VseInstruments.ru

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“The manual electric top-type milling cutter can be stationary or submersible. Fixed models are cheaper, however, less functional. In such a tool, the cutter cannot move relative to the device body.”

Much more convenient to use is a plunge router, the drive motor of which is mounted on special guides and can move along them along with the working attachment during processing. The design of plunge-type milling machines also has a special spring, which ensures the lifting of the working attachment after processing has been completed with its help.

If, in the process of purchasing top-type milling cutters, you choose which one is better, then you should definitely pay attention to submersible models, which are perfect for both professionals and beginners

What should be considered when designing a machine?

When creating a drawing of a wood copying machine and designing it, you need to do everything depending on the parts that will be made on it.
So, in order to mill long workpieces or perform engraving work, a completely different method of securing the workpieces and the type of work table are required. Also, the power of the electric motor required for high-quality work, which ensures the rotation of the cutter, depends on the parts manufactured and copied on the machine. But in most cases, a 150-220 W DC motor is sufficient for processing wood parts.

To ensure maximum accuracy of copying parts, the device holding the router and the copying probe must be secured to each other as firmly as possible. At the same time, their planes, together with the height above the working surface, must coincide completely.

The created rigid structure must be installed on the table surface in such a way that it is able to move in horizontal and vertical planes.

Thus, it is not very difficult to make a copying machine yourself for making various parts from wood, so many people can cope with such work. But you need to remember that if you make such equipment yourself, it will only be suitable for the production of products of a certain type. Otherwise, only modern universal factory-made equipment will do.

Classic design

Industrial machines have a rather complex design, especially CNC versions, which can carry out processing automatically. The required product can also be obtained using copying equipment. The classic design is represented by a combination of the following main components:

1. The bed acts as a base and connecting element. The structure is made using metal, the individual elements are connected by welding. The bed can have different heights. Each craftsman chooses his own height when making a homemade structure.
2. The headstock and tailstock are also an integral part of the machine. The headstock is used to house the gearbox and drive, as well as the electric motor. The tailstock is used to fix the workpiece, which makes it possible to produce longer products.
3. The main rotation is received by the workpiece. It is transmitted from an electric motor through a drive.
4. The tool rest also allows for high-quality processing. It is worth securing the cutting area to eliminate the possibility of injury to your hands or contact with a foreign element.
5. Leading and driven centers used to secure the workpiece.

A homemade copier for a wood lathe also allows for high-quality processing of workpieces.

DIY making

Industrial versions of machines are expensive. That is why many are considering the possibility of assembling the machine with their own hands. Recommendations for carrying out the work are as follows:

1. First, you should develop or download a drawing according to which the assembly will be carried out. As a rule, a drawing of a conventional lathe is taken, which is modified to accommodate the installation of a copier.
2. Work begins with the creation of the bed. This will require corners, as well as sheets of metal. The connection of individual elements is carried out using a welding machine. It is worth considering that screw connections are characterized by less rigidity. The bed must be strong and resistant to vibration.
3. The main component is the electric motor. In order to increase the functionality of the equipment, an electric motor with a power of 200-250 W at 1500 rpm is installed. If you plan to process large workpieces, then a more powerful motor is installed. The motor should be protected from environmental influences.
4. To fix the workpiece, a faceplate is attached to the output shaft. It has several sharp elements that it hits. Due to the sharp elements, rotation is transmitted, but fixation is carried out due to the tailstock with centers.

Most attention is paid to the production of the copier. This is what distinguishes a lathe from a copying machine.

Creating a copier

The copier is used to produce similar products. Due to its use, the productivity indicator is significantly increased. Among the features associated with creating a copier, the following points are noted:

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.

Classification of lathes with a copier

The machines are widely used in the woodworking industry. Important aspects of the classification are process manufacturability and design features. There are many different models available, which can be divided into four categories:

• Classic. A cutter is used as a cutting tool. The machines are not designed for large-scale mass production.
• Copying. They work according to templates that make the task easier when creating similar variants. In small-scale production, models with manual control are in demand.
• Milling. We are in demand for the production of volumetric and flat workpieces.
• CNC. Units with numerical control are required in large quantities when supplying expensive models.

Copy wood lathes are equipped with improved characteristics and are therefore in demand for use in workshops.

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. These types of units can be used both for large-scale production and for the production of small batches.

For example, such devices can be used to 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.

What is copy-milling equipment

The pantograph is the most important element of the machine.

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

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

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

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

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

Unit design

The photo shows a desktop device with mechanical clamps.

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

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

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

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

Duplicarver machine

The units of this brand are of the highest quality.

The most popular brand of copy milling machines are the Duplicarver units:

1. Its cutting tool is a cutter made of hard alloys, which reproduces the contour or surface of the copier on the workpiece.
2. It has a mechanical, hydraulic or pneumatic connection with a tracking system that determines the direction of movement of the cutter. The cutter acts on the reinforcing device and affects the actuator.
3. The copier can be a flat or spatial template, a contour diagram, or a reference sample. The copying device can be a finger, a photocell, a probe or a roller. This unit and the workpiece are placed on a rotating work table.
4. The executive body of the unit can be a solenoid, differential, screw, electromagnetic clutch, spool. The amplification units use a hydraulic, electro-optical or electromagnetic relay.
5. The speed of movement of the tracking device determines the level of accuracy of the profile (up to 0.02 mm), as well as the degree of roughness of the part.

The executive unit of the device, consisting of an electric motor and a cutter.

1. The machine is driven by an electric motor and a hydraulic power cylinder.
2. The pantograph, which makes it possible to repeat products on a given scale, has a tool spindle and an axis of rotation, as well as a guide pin. It is placed on an axis and moves along the copier.
3. During this movement, the spindle on the part describes the desired geometric configuration. The pantograph, thanks to the proportion of its shoulders, determines the scale of copying.

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 few designs of this equipment, its typical, most common form will be presented.

The components of such a unit are as follows:

• working 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.

A fairly common disadvantage of 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.

Classic machine design

The machines are equipped with a sophisticated design system. These include CNC models that operate in an automated mode. Such devices are obtained by using drawings and a copying device. The classic design consists of five nodes:

• The main element is a metal frame; individual parts are connected by welding. The bed has different heights, so when creating a homemade machine, this particular parameter is selected.
• The front and tailstock are needed to store the box, drive and electric motor. The rear one fixes the workpiece to obtain dimensional parts.
• An electric motor and drive rotate the workpiece.
• A tool rest is needed for the best quality work. The cut site is protected to prevent injury.
• The master and slave centers secure the part.

A homemade lathe-copier for wood makes it possible to carry out high-quality cutting of workpieces no worse than production models.

Recommendations for creating a machine

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.

Do-it-yourself duplicarver drawings video

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 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.

Short description

Copy-milling machines (CFS) are designed for processing wood parts using the copying method. Types of method:

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.

Examples of processed products

Below is shown a far from complete composition of products manufactured using FSC:

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 processing parts belonging to the same group requires its own design (layout) of the machine.

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:

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.

However, if the terrain is steep, then the tool axis must be additionally rotated to provide better 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).

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.

Milling and turning copying machine for wood

The purpose of this type of machine is the processing of wooden products, turning profiles and decorative blanks. A distinctive feature of this type of equipment is 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 workpieces 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.

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.