In the presence of a milling machine, work on inserting loops, forming complex holes, recesses, woodcarving, etc. is really simplified. But this does not mean at all that it is necessary to have professional and expensive equipment: it is enough to have a simple manual device.
The only thing you need is to be able to handle wood and use power tools. In addition, you need to have a desire, otherwise there will never be a result without it. Those who have no desire to work simply buy furniture or hire craftsmen to, for example, install a new door and embed locks. Any work, especially with a power tool, requires certain knowledge, and especially safety precautions.
The milling device is intended for processing both wood and metal. With its help, it is possible to form recesses or holes of any configuration. This greatly simplifies tasks such as tapping hinges and tapping locks. To do this with a chisel and an electric drill is not so easy, and it takes a lot of time.
There are stationary milling devices and portable (manual). Manual electric cutters are considered universal devices, with the help of which, in the presence of nozzles, it is possible to perform operations for various purposes, it is enough just to change the position of the part in relation to the device or vice versa.
Stationary devices are used in factories or factories where mass production of wood or metal products is established. Under such conditions, the cutting nozzle is stationary, and the workpiece moves along the desired path. When using a hand tool, on the contrary, the part is fixed motionless and only then it is processed, although there are parts that require fixing a hand tool. This is provided for in the design, therefore, it is considered more universal. This is especially true when you need to process a large number of parts, and it is not possible to use a stationary machine.
Homemade milling machine - a horizontal platform with a hole in the center, from below to which a manual fixture is attached. There are many types of milling machines, but for use at home or for starting a business, universal models are more suitable. As a rule, they are equipped with a set of cutters and various devices for performing various kinds of operations. The only thing is that with a manual router, simple operations can take much more time than with a stationary machine.
With the manual milling device it is possible to:
- Make grooves or recesses of arbitrary shape (curly, rectangular, combined).
- Drill through and non-through holes.
- Process ends and edges of any configuration.
- Cut out complex shapes.
- Carry out drawings or patterns on the surface of parts.
- Make a copy of the details, if necessary.
Copying parts is one of the functions of any electric milling machine. The presence of such functions makes it possible to simplify the production of the same type of furniture or the production of identical parts that are not related to the production of furniture. This is one of the main advantages of this tool. As a rule, for the production of parts of the same type, it is necessary to install copy machines that are designed to perform only one operation, which is not always profitable, especially in small enterprises.
Getting Started and Caring for the Instrument
To understand how this device works, you should familiarize yourself with its main parts and their purpose.
Composition and purpose of the main nodes
The manual milling fixture consists of a metal case and a motor, which is located in the same case. A shaft protrudes from the body, on which various collets are put on, serving as adapters. They allow you to install cutters of various sizes. A cutter is inserted directly into the collet, which is fixed with a special bolt or button, which is provided on some models.
The main elements of a manual milling device and their purpose. The design of the milling fixture provides a metal platform, which has a rigid connection with the body. It is attached to the body with two rods. From outside the plate has the smooth covering providing smoothness of the movement in the course of work.
The manual milling fixture has some characteristics that can be adjusted:
- Due to the handle and scale setting the depth of milling. Adjustment is carried out in increments of 1/10 mm.
- By adjusting the speed of rotation of the cutter.
At the initial stages, when the tool is mastered, it is better to try to work at low or medium speeds. Although you should always remember that the higher the speed, the better the work. Especially when it comes to responsible, visible areas that cannot be masked.
In addition to these levers, there is also a button for turning the product on and off, as well as a lock button. These elements are considered the main ones that ensure the quality and safety of work. There is also a parallel stop, which contributes to ease of use. It can be rigidly fixed or with the ability to adjust the shift of the working area, in the direction from the center.
Caring for your handheld router
Usually, a factory product falls into the hands of a person tested and lubricated, so no additional measures should be taken. Only in the process of its operation it is necessary to monitor its cleanliness and serviceability. At the same time, it should be regularly cleaned of dust and change the lubricant, if the passport says so. Especially lubrication is needed for moving parts. Alternatively, you can use aerosol lubricants, but you can get by with the usual ones, such as Litol. The use of thick lubricants is not recommended, as chips and dust stick to them. If aerosol lubricants are used, then this factor can be eliminated.
Lubrication also requires a sole - a smooth part of the body. Regular lubrication will ensure the desired smoothness of movement.
Despite this, the purchased item should definitely be checked for build quality and the presence of lubrication.
Unfortunately, not all manufacturers, and especially domestic ones, care about build quality. There are cases when, after the first hours of operation, screws or screws are unscrewed from the product, as they were not tightened properly.
Rotation speed adjustment
The operation of any tool is associated with certain conditions related, first of all, to the nature of the material being processed. It can be plywood, composite material or regular wood. Depending on this, the rotation speed on the electrical appliance is set. As a rule, the technical data sheet always indicates the operating parameters of the device, depending on the technical characteristics and characteristics of the surfaces being processed, as well as the cutters used.
Processing speed indicators when using various cutters. Cutter fixation
The first thing the work begins with is the installation and fixing of the cutter. At the same time, one should adhere to the basic rule - all work is carried out with the cord removed from the outlet.
The cutter is set according to certain marks, and if they are absent, then to a depth not less than ¾ of the length of the cutter itself. How to install the cutter on a specific model, you can find out from the instructions, which must be present in the technical documents for the device. The fact is that each model can have its own design features and it is not possible to talk about this in the article.
Installing the cutter on the device before starting work. There are models both simple and more "advanced", as they say. Some models have a shaft rotation lock button, which makes it easier to install the cutter. Some, especially expensive models, are equipped with ratchets. So it’s impossible to describe specifically the process of installing the cutter, and it doesn’t make sense, since everyone who is familiar with the operation of such devices will figure it out at the moment.
Milling depth adjustment
Each model has its own maximum cutting depth. At the same time, it is not always the maximum depth that is required, but a certain depth, which is set before work. Even if the maximum depth is required, then, in order not to overload the device, the milling process is divided into several stages, changing the milling depth in steps. For adjustment, special stops are provided - limiters. Structurally, they are made in the form of a disk located under the bar, on which stops of various lengths are fixed. The number of such legs can be from three to seven, and this does not mean that the more of them, the better. It is better if it is possible to adjust each of the legs, even if their number is minimal. To fix this stop in the optimal position, you should use the lock, in the form of a flag.
The milling depth adjustment process is as follows:
Thus, the workpiece is milled to a predetermined depth. On high-quality expensive models, there is a wheel for fine-tuning the depth of milling.
With this wheel, you can more accurately set the depth without violating the previous setting. This wheel (green in the photo above) allows you to adjust the depth in a small way.
Cutters for manual milling tools
A milling cutter is a cutting tool that can have an intricately shaped cutting edge. As a rule, all cutters are designed for rotational movements, therefore they have a cylindrical shape. The shank of the cutter, which is clamped in the collet, has the same shape. Some cutters are equipped with a thrust roller, so that the distance between the cutting surface and the workpiece remains constant.
Milling cutters are made only from high-quality metals and their alloys. If you need to process soft woods, then HSS cutters will fit, and if you need to process hard wood, then it is better to use HM cutters from harder grades.
Each cutter has its own technical characteristics, which provide it with high-quality and long work. The main indicator is the maximum speed of its rotation, which should never be overestimated, otherwise its breakdown is inevitable. If the cutter is dull, then you should not try to sharpen it yourself. Sharpening of cutters is carried out on special, expensive equipment. After all, it is necessary not only to sharpen the cutter, but also to maintain its shape, which is no less important. Therefore, if the cutter, for some reason, has become dull, then it will be cheaper to buy a new one.
The most popular cutters
There are cutters that are used in the work more often than others. For example:
Groove molds are designed to create recesses in an arbitrary place on the workpiece. There are simple cutters, monolithic, made from a single piece of metal, and there are type-setting. Type-setting cutters consist of a shank, which serves as the basis for a set of cutting elements. By selecting cutting planes and installing them on the shank, using washers of various thicknesses, it is possible to form an arbitrary relief on the surface of the workpiece.
A type-setting cutter is a set of cutting surfaces and washers, which allows you to assemble the cutter of the desired shape. In fact, there are a lot of cutters and this is only a small fraction of what is produced. All cutters differ in shank diameter, cutting surface diameter, cutting height, knife position, etc. As for manual milling equipment, it is enough to have a set of five most popular milling cutters. If necessary, they can be purchased at any time.
Rules for working with manual milling tools
Working with power tools requires special rules, especially when there are rapidly rotating elements. In addition, as a result of the work, chips are formed, which scatter in all directions. Despite the fact that most models are equipped with a protective shield, this does not fully protect against the flow of chips. Therefore, it is better to work with such a tool in protective glasses.
The photo shows a model where a vacuum cleaner is connected to remove chips. General requirements
If you fulfill the basic requirements for safe work with an electric hand mill, then the end result will please you with the quality of work and a safe outcome. Here are the conditions:
The requirements are not very difficult and quite feasible, and ignoring them means putting yourself in danger. And one more thing, no less important, is the ability to hold a milling tool in your hands and feel how it works. If serious vibrations are felt, then you need to stop and analyze the reasons. It is possible that the cutter is dull or a knot is caught. Sometimes it is necessary to correctly set the speed of rotation of the cutter. Here you can experiment: either add speed or reduce it.
Edge Processing: Using Templates
Processing the edge of a wooden board is best done on a thickness gauge. If this is not possible, then you can use a manual router, although this will take some time. These works are carried out both without a template and with a template. If there are no skills or there are very few of them, then it is better to use a template. For processing edges, straight edge cutters are used, both with one bearing at the end of the cutting part, and with a bearing at the beginning (see photo).
Edge cutters. For the template, you can take an already processed board or another, even object. Moreover, the length of the template must be greater than the length of the workpiece, both at the beginning and at the end of the workpiece being processed. This will avoid unevenness at the beginning of the edge and at its end. The most important thing here is that the template or object acting as a template has a smooth and even surface. In addition, its thickness should not be greater than the gap between the bearing and the cutting part.
The width of the part is less than the length of the cutting part
At the same time, the longer the cutting part, the more difficult it is to work with the tool, since more effort is required. In this regard, it is better to start work with cutters that have an average length of the cutting part. The working principle for edge processing is as follows:
- The template is attached so that it is at the desired height and has a flat horizontal surface.
- The template is firmly mounted to a table or other surface.
- The cutter with a roller is installed so that the roller moves along the template, and the cutter (cutting part) along the workpiece. To do this, perform all the necessary manipulations with the template, workpiece and tool.
- The cutter is set in working position and clamped.
- After that, the tool turns on and moves along the template. In this case, it is necessary to determine the speed of movement, which is determined by the depth of processing.
- The milling unit can be both pushed and pulled: as it is convenient for anyone.
After the first pass, you should stop and evaluate the quality of work. If necessary, another pass can be made by adjusting the position of the tool. If the quality is satisfactory, then the clamps are removed, freeing the workpiece.
With this approach, it is possible to remove a quarter along the edge or in some of its parts. This is done by setting the cutting edge so that it goes to the required depth into the part.
A quarter taken on a furniture facade. If you replace the cutter with a figured one and shift the guide, as well as use the stop, you can actually apply a longitudinal pattern to the part (in the photo below).
Drawing a longitudinal figured pattern on the workpiece. If you use a similar milling technique (with a template), then you can easily master the technique of working with wood in general. After some time, you can abandon the templates, as their installation takes a lot of useful time.
How to make a smooth edge without a template: experience is indispensable here. The width of the part is greater than the length of the cutting part
Quite often, the thickness of the workpiece is greater than the length of the cutting part of the cutter. In this case, proceed as follows:
- After the first pass, the template is removed and another pass is made. In this case, the already processed part will serve as a template. To do this, the bearing is guided over the machined surface. If the cutting part was again not enough, then you will have to make another pass.
- For final processing, you should take a cutter with a bearing at the end, and the workpiece must be turned upside down, after which it is fixed with clamps. As a result, the bearing will move over the machined surface. This approach allows processing thick parts.
The bearing is guided over the machined surface while the cutting edge machine the rest of the workpiece. In order to master the work of a manual milling tool, you will need a lot of rough workpieces, which you do not mind throwing away later. Nobody got it right the first time. For something to work out, you need to train hard.
Obtaining various curly edges
If a curly edge is required, which is most likely to be necessary, then first pay attention to the condition of this edge. If it is uneven, then it will have to be leveled and only then proceed to the formation of a curly edge, choosing the appropriate cutter.
Rounded edge. It is necessary to prepare the surface so that the cutter does not copy the curvature along which the roller will move. In this case, a sequence of actions is needed, otherwise a positive result will not work.
Machining manufactured parts with a milling cutter presents many possibilities. Details with the necessary grooves, grooves of various shapes are necessary for a quality finish. Operations for working with manual equipment on wood are performed with a special tool - milling cutters. Each type of action provides a separate type of equipment used.
Classification and types of cutters for woodworking
Power tool for working with lumber - manual type milling cutter. The surfaces of parts made of wood are subject to work with the help of special devices. The manufacture of products that require the necessary grooves, recesses and recesses implies the use of. Before starting, you need to purchase equipment designed for specific purposes according to the configuration of the product.
The choice of a tool that processes wood occurs according to the specification of handicrafts. Professionals have enough experience and skills to use the right equipment. A wood cutter has many purposes:
- When edging, it is used to connect workpieces by splicing grooves.
- Making recesses for use, installation of hinged loops, other devices.
- Making decor - in this case, a cutter is used to make a pattern or in woodworking processes with a complex configuration.
The tool differs greatly in the type of configurations, purpose. Before starting the actions performed with the tree, it is necessary to determine the type and types used for blanks. The unit of measurement of the tail is calculated in millimeters or inches, depending on the type of router used. Common options are types of cutters with a diameter of 6 to 12 mm. It is worth concentrating on the fact that the use of an inch collet and a millimeter tail is unacceptable, as this can cause equipment damage or injury.
Kit manufacturers provide various modifications. On the construction market, there is a large selection of types of milling cutters for manual milling, depending on the purpose and material used in the manufacture. The equipment of a handheld device can be used for processing plastic and metal, but it is most widely used in wood processing. The main varieties for working with wood.
- The production of grooves, the formation of recesses is carried out by end types of cutters.
- Groove, the used cylindrical cutter for wood processes the required groove of a rectangular shape.
- Shaped tooling for wood is used in curly recesses, edges, and allows you to give the product a unique look.
- Edge bands are made in a design with a bearing, which allows you to make a product according to a template.
It is important to remember that the presence of a bearing in a hand mill implies its maintenance. It is necessary to lubricate the rotating element with a thin layer, this action is carried out in order to achieve a long tool life.
End mills
End devices in design and appearance are similar to a conventional drill. A distinctive feature is the absence of a conical part at the end of the cutter. On the end part, located to the sides at an angle of 90 degrees, cutting teeth are made. The design feature allows you to perform various operations. The main types of work performed include:
- Production of products with grooves of a certain depth, through holes.
- Open products.
- Drilling, or processing the edges of the part.
The main functions of a manual milling cutter of the end type of cutters are to obtain grooves for locks and hinges installed in doors. The kit is multifunctional, with the help of prepared equipment and a competent approach, you can perform many interesting elements.
Edge cutters for wood
Edging devices are used for the manufacture of a variety of types of edges and recesses. Wood products can be processed with a manual milling cutter with edge cutters for complete processing. The edge view is the most common in use and has many modifications:
- Profile sets process parts in such a way as to give the necessary shape to the edges.
- Molders have the ability to round the edge of the part by a quarter of a circle.
- Tapered chamfer, the angle of which is often 45 degrees.
- Disk are used to make chamfers in parts, making subsequent connections possible.
- Folded ones process the part from the edge, leaving a quarter of the height.
- Fillets are needed to make a groove, which is drawn into a quarter of a circle.
Edge cutters for wood used for a hand router are often equipped with a bearing, the function of which is to limit the depth of required processing. Departure adjustment of the processing area is made by adjustment on the tool itself. Performing processing of massive parts requires many attempts. A manual milling cutter works on wood in several stages until the thrust bearing begins to operate.
Groove cutters for wood
The main purpose of the type of grooving for wood is the manufacture of grooves using a hand-held power tool. There are enough varieties of devices, a groove cutter, allows you to perform actions on wood with a manual milling cutter. The main types of groove cutters:
- Spiral, resembling a drill, formed with a helical edge of the outer type. They make it possible to produce parts with recesses and grooves with a right angle.
- Fillet - made with a rounded tip.
- Conical are often used for operations with planes.
- Shaped allow you to make recesses of the required structure.
- "T" figurative, cutters "Dovetail".
- Combined are used when joining large wooden parts.
Most of the types are made in a monolithic format, tooling made of carbide metal is less common.
Copy cutters
The least common type of attachment for hand-held woodworking tasks are copy cutters. Distinctive features are numerous types of cutting elements, different arrangement of thrust bearings and small dimensions. The milling head, for wood crafts, is arranged in the shape of an arc. The recess in the workpiece depends on the machining angle.
Using a template tool allows you to achieve the desired result when working with wooden blanks. The hand router must be used with precision and care, failure to comply may result in damage to the part or electrical equipment.
Milling cutter designs and their influence on the production technology of milling operations
The tools under consideration are divided into several main categories, classified by type and purpose. They perform their functions not only under axial load, they have the ability to move during operation, due to the presence of side edges. Cutting edges, or rather their number, directly depends on the quality of the actions performed by a manual router.
The tool used for processing is considered to be a manual milling cutter. There are means of execution of the crown type, they allow you to perform work with an ordinary drill. In this case, the milling head used on wood performs the role of edge processing, making simple holes.
The design and manufacture of products with grooves of the required depth and dimensions is carried out using end mills. Knives used for wood cutters are subjected to considerable stress. Prevention of over-machining has an effect, due to the use of bearings. End mills for a hand router allow you to create joints in wooden structures using a tenon / groove system.
To make the necessary hole on the tree, you will need a burr. In most cases, such a tool is used in intermediate processing. Cones allow you to "open" the hole to the required depth, after which further actions are performed.
Types of cutter construction
There are many designs and varieties of tooling for a manual woodworking machine. When choosing a tool, you should pay attention to the purpose, the device of the equipment. The shape of sharpening cutters can be of two types - helical and straight. The use of a straight form of sharpening can lead to rapid damage to the equipment, and the final product may turn out to have gouges and burrs.
For woodworking with a manual milling cutter, the best option is to use a tool with a helical line of teeth arrangement. The only drawback is the impossibility of sharpening with improvised means, in order to return to its former sharpness, it is necessary to use special equipment. Using milling cutters, for work with a manual wood router, you should pay attention to the sharpening angle. The wooden surface is best processed with a tool whose sharpening angle is not more than 90 degrees. The design provides for efficient chip removal, thereby achieving maximum tool action.
prefabricated
The most common type on the market is prefabricated. It consists of a blank, welded on top of the edges. Ease of manufacture makes them the most attractive to the manufacturer. The relatively low price allows you not to waste time on sharpening, but simply replace it with a new one when the sharpness is lost.
With interchangeable cutting edges
Milling cutters with replaceable edges. They have replaceable cutting edges, when there is a loss of sharpness of the knife on one side, it is possible to turn the tool over, then continue working.
Monolithic
Monolithic cutters have cutting edges at the base. They are distinguished by increased strength, however, after short work and subsequent sharpening, the part quickly loses its cutting properties.
Types of cutter blades
The materials used in the manufacture of wood cutters differ in some characteristics. The first type of material is high speed steel. Products made from this material are marked with HSS symbols. With a hand tool, using this type of rig will easily process soft wood. Due to the pointed properties, the working speed is increased in relation to the solid cutter.
The cutting part can be made of carbide metals. Such products are designated HM, mainly used in the processing of hardwood. A distinctive feature is strength and resistance to elevated temperatures. It will be difficult to qualitatively process soft wood species with such a cutter, since the frequency of the performed actions differs markedly from high-speed materials.
Functional cutter sets
Often you can find on sale functional sets that consist of two or more elements. This set includes accessories and nozzles for a wood router. The main purpose of such kits is the processing of two or more parts to obtain the same type of connection. For example, there is a set of 2 cutters, one of which forms an edge inside the product, and the second allows you to make a groove part.
There are universal options that, due to the design, can be used for various purposes. The collapsible part involves the replacement of knives for the cutter, after which work with wood is performed.
It is worth noting that the presence of a table for storing all types of equipment equipment will reduce the time for the actions performed, and it is also possible to build a kind of milling machine. By installing movable stops on the table, the master expands the range of possibilities of the tool for woodworking.
Applications
The use of any type of equipment involves dangerous work with rotating parts. When working with wood, you need to remember safety precautions. The implementation of complex elements is not done in one go, the edges of the cutter must be sharpened for the best result.
Wood carving with a milling cutter
Getting started, you should understand what type of cutter you need to use. The edging category tool has received a high prevalence. This category makes it possible to produce almost all types of woodwork with your own hands. Groove or cylindrical cutters are mainly used for making recesses in the ends of the material.
How to choose a wood cutter for a manual router
The choice of milling cutters on the building materials market is very rich. The price range is varied, it is not always possible to determine whether the purchase is made correctly. It is necessary to adhere to several basic conditions for the correct choice of a wood cutter.
- Quality. It is worth paying attention to the appearance of the part. The product must be burr-free, have high-quality threads, seats.
- Thermal strength is indicated in the passport, the higher, the better and more reliable for further use.
- Solder material, as well as the connection of the tail with the part responsible for cutting.
The quality of product soldering plays an important role in operations with lumber. When working with hardwoods, a certain margin of safety of the tool is necessary. Solder is divided into types and brands, when buying, you need to pay attention to its quality in the cutter. It is advisable to pay attention to the tool, the solder grade of which is not lower than PSr 37.5. The higher the number, the better the indicators of reliability and quality of the part. The brand is indicated in the composition by the amount of copper and silver. When connected by welding, the use of a router becomes unsafe and pointless.
Solid cutters must be checked before use. The quality of the metal is determined by the file. If there are noticeable scratches or cracks, then you should postpone this tool. Optimum metal hardness from 58 units. The quality of work performed by a manual router directly depends on the availability of fixtures and kits.
Choosing the right tool is the right way to a good result when working with wood. A cutter made for a wood router must meet all standards and be of high quality. There are many kits that are designed for woodworking. A high-quality set guarantees not only the completed tasks, but also safe work.
The main tool designed for processing a variety of metal surfaces is considered to be a milling cutter. In fact, it is a constantly rotating body, consisting of wear-resistant and very strong cutting teeth. Such a tool for processing metal surfaces is very diverse.
This makes it possible to carry out work in very difficult, hard-to-reach places. In the first place comes the exact definition of the pitch, which happens:
- Screw;
- Progressively - rotational.
Materials and types of cutters
Tool cutting edges can be made using various materials:
But, basic materials used in the manufacture of such equipment remain;
- diamonds;
- High speed steel;
- hard alloys;
- Metals, high hardness.
In addition, metal-ceramic was also used in the production of such tools. A huge variety of tools differ in appearance. Most often milling machine uses in its work tools:
- round;
- Cylindrical;
- end;
- Worm.
I must say that the price of each tool is very different. To perform simple surface treatment, tools are used at a lower cost. Special-purpose tools with increased hardness are rated an order of magnitude higher.
The many faces and great variety of this instrument led to the creation of a classifier, which takes into account the design of the tool and its price. So, they are divided into subspecies;
Depending on the position of the teeth. They can be screw, inclined and so on. Differ;
- Sharpening.
- The complexity of the design. The tool can be prefabricated or have a monolithic look.
- Manufacturing material.
Each subspecies has its own price set at the factory.
Milling cutters for metal are also divided into groups, depending on the type of teeth, which greatly affects their price. They are:
- One-piece, made from one material;
- Prefabricated, several different materials are used in the manufacture;
- Welded. The bearing part is welded to the main part.
This tool is used to process a wide variety of workpieces. Each of them requires a special approach and an automated machine. Purpose of milling, processing method, divided cutters for metal into different groups:
- End;
- Cut-off;
- Keyed;
- Disk;
- End.
Other varieties of this tool are much less commonly used:
- grooved;
- corner;
- pointed;
- Shaped;
- Backed.
Let's get acquainted with the main groups of cutters for metal in more detail.
End mills
With this tool, steel billets and their components are processed on a milling machine. Such milling cutters for metal are widely used on furniture manufacturing machines and manufacturing building parts.
End mills with a tapered shank are used for technological operations:
- Groove milling;
- processing ledges;
- Milling the ends of parts made of non-ferrous metals.
This group of cutters is used for processing a wide variety of metals, whose strength does not exceed 1000 N/mm2. These steels include:
- Structural;
- carbonaceous;
- Low-alloyed.
End mills have several varieties:
- With a shank in the form of a cone;
- With large teeth to complete pre-treatment;
- With small teeth, for finishing; Whole;
- whole
- With crowns:
- Peeling cutters process casting or materials after forging.
Key cutters
With such a tool, keyways are processed on the machine. If an end shank is used, it is carried out processing of brass parts and annealed cast iron. The price of the key cutter is in the affordable segment.
Cut-off cutters
They have been specially designed to work with high strength metals. This tool has another name - universal cutters.
They are easy handles cast iron and medium hard metals. For work, special milling machines, both automatic and CNC, are used. I must say that the price of milling machines is available only to large industrial enterprises.
In production, several types of cutting cutters are used:
All cut-off cutters, depending on the dimensions of the teeth, are divided into subspecies:
- small;
- Medium;
- Large.
Milling cutters with large teeth process non-ferrous metals, while others work with steel and cast iron.
Triangular disc cutters
Have plug-in knives, with hard-alloy plates. Tool used in the processing of grooves of metal parts. In most cases, cast iron parts are machined with these tools on automatic milling machines.
End mills
Used almost constantly. With their help, processing of any flat surfaces. More recently, the design of end tools did not differ in complex geometry.
Today, metalworking technology has reached a new level. New tools have been developed - long edge cutters. They make it possible to process very complex workpieces on modern automatic milling machines.
The workpiece is very durable and high-precision. Such a novelty is distinguished by a high price.
Worm
This tool is used only in special cases. The machining of the part is carried out by the rolling method.
Disk
Very good for cutting grooves. Disc cutter cuts workpieces, chamfering, and other operations. The tool is divided into groups:
The location of the cutting edges can be very different. Sometimes they are located only on one side, sometimes they are made bilateral. Depending on the size of the teeth, the cutters perform several technological operations:
- Rough processing;
- Clean processing.
You can work with a disc cutter in the most difficult conditions, for example, with high vibration, when it is difficult to remove metal chips.
Cylindrical
Such cutters can be with helical or straight teeth. For simple operations where processing area is small, use a spur cutter.
Screw cutters are considered more versatile. Due to the fact that in some cases axial loads reach large values, the use of helical loads is limited by the angle of the cutting edge, it should not exceed 450.
To carry out processing in such situations, double cylindrical tools are used.
The cutter is a cutting tool with which a manual milling machine or a stationary unit performs surface treatment of various materials (wood, plastic, metal). Since the equipment is designed for rotational movement, then its basic shape will be disk-shaped or cylindrical. At the same time, the cutting edges of the tool can have a rather intricate shape. Milling cutters for a manual milling cutter are divided into several types. The most common among them is for wood processing. At the same time, wood cutters also have their own classification. Consider what types of cutters are designed for processing wooden surfaces, and how to choose them correctly.
If needed choose a groove any depth and width, then a groove cutter is the best suited for this purpose. Its design allows this operation to be performed both on the face (face) of the part and on its edge. The groove cutter is mainly used when joining parts with a tenon. Also, using nozzles for a wood router that follow a ruler, you can cut even grooves of any width.
Shaped
Allows you to give the groove certain shapes, similar to braces. The tool selects not only the grooves inside the workpiece, but also change the shape of the edge ribs. When making a complex pattern on the face of the workpiece, first a straight cutter (groove) cuts through it. In the future, this simplifies the centering of the shaped equipment.
The following figures show the main types of groove cutters.
Structural
After processing the workpiece with this tooling, a groove is obtained that looks like a trapezoid (dovetail) or an inverted letter “T”.
This method of connecting parts is considered one of the most reliable, since the spikes slide into the grooves of the same shape, and they cannot be separated by another method.
Fillet V-shaped
Although the word “fillet” refers to a semi-circular notch or groove, V-cutters also fall into this category. The tool allows you to select not only vertical grooves, but also grooves at a certain angle. Also, a fillet cutter is often used for decorative carving and changing the geometry of edges in furniture production.
Fillet
They have a rounded cutting edge. If you look at the groove after it has passed in section, it will resemble the letter "U".
The cutter is used for decorative finishing of the edges and ends of wood products, creating complex patterns on the face of the workpiece or various fillet recesses (grooves) on the face of the product and on its ribs.
Direct
This is the simplest tool that has the shape of a cylinder. The groove obtained in the workpiece has a rectangular cross section.
Tooling is most often used with plunge cutters.
Straight groove (finger) cutters are used if you want to choose a rectangular groove with a clean bottom, for example, for cutting door locks and hinges.
Edge cutters
In most cases, edge cutters have thrust bearing. Thanks to him, it becomes possible to guide the tool according to the template, processing the edges and edges of the workpieces.
Half rod
The tool creates semi-circular ridges on the edges of the workpieces.
If you use a half-rod cutter paired with a moulder or fillet cutter, then you can make hinged joints. Also, rods of round section are made with a semi-rod tool. In this case, the workpiece is processed on both sides.
curly
These curly cutters are also called multi-profile. Depending on the tasks, the wizard can use part of the snap-in profile or use it completely. In the second case, you will need to install the tool in a unit that has a power of at least 1600 watts.
Fillet
Designed to give the ribs of the workpiece an inner radius or a selection of grooves with a circular cross section.
Fillet cutters are equipped with one or two bearings, which exclude tool distortion.
Cone
With cone cutters you can:
- chamfer on the edge of the workpiece;
- decorate the edge of the tabletop;
- create an angular cut on the edges of the workpiece before gluing them (it is possible to obtain products with a polygonal shape).
Folded
Apply to quarter samples and grooves of rectangular section. Thanks to the thrust bearing, the rebate cutter can be used on both flat and curved workpieces.
To adjust the depth of the groove, thrust bearings of different diameters are used.
Moulder
Moulder cutters allow you to get an arcuate, straight, as well as a figured edge on the workpiece. Working with any part of the same equipment, you can:
- round the edge of the part;
- get an edge with a fold;
- make a half-rod protrusion;
- get EDGE WITH SPONGE;
- make decorative processing of ribs, for example, by making window frames.
Also, with molding cutters, you can create complex-shaped ornaments on the edges and ends of a wooden part.
The tooling of this series can also be doubled, as shown in the following figure.
On the double cutter the distance between the elements can be changed in accordance with the thickness of the workpiece. Thanks to two elements, the workpiece is processed in one pass, simultaneously on both sides.
Direct
A straight edge (overrunning or face) cutter is used when finishing the ends of a workpiece or creating an ideal angle of 90 between the face of the part and its edge (end). The bearing can be installed at the top or bottom of the tool.
With the lower position of the bearing, the template is fixed under the workpiece, and with the upper position - above the workpiece.
In addition to the facing function, the tooling with the upper bearing can be used as a grooving tool and cut a rectangular slot on the workpiece face, of course, using a template of a certain height. The bearing diameter is usually the same as the tool diameter, i.e. it is flush with the cutting edge. But in some cases, it is changed to a smaller or larger diameter in order to expand the possibilities of equipment.
The corn cutter is also an edge cutter. Its main purpose is to grind and align the edges of the workpiece according to the template. Thanks to the special arrangement of the knives (in a spiral), easy chip removal and smooth running of the tool.
Combined cutters
Splicing of workpieces is considered the most effective if you use a combined tool. These types of cutters consist simultaneously of tenon and groove elements: thanks to this design of the equipment, both profiles are obtained in one pass by the apparatus. As a result, the area of the edge intended for gluing increases, which has a positive effect on the strength of the connection.
Framework
Frame cutters are compound tools. All cutting elements are installed on the base, and the master can place them in the desired order. Type-setting cutters have the following components:
- base;
- cutting elements;
- bearing;
- washer;
- fixing nut.
When changing the location of the cutting elements, it is not required to remove the shank from the collet of the unit. It is enough just to unscrew the fasteners located at the bottom of the equipment, and all its elements are removed. Thanks to collapsible design tooling, the tool overhang remains the same, and its re-adjustment is not required.
Groove-thorn
The kit contains 2 cutters, one for grooving and the other for the tenon.
Groove and tenon cutters have a mirror-identical profile of the cutting elements, due to which the machined parts are spliced as accurately as possible.
The only disadvantage of this equipment is that the grooves and spikes are made by different cutters, which have to be changed and again adjusted for their overhang relative to the sole of the unit.
For the manufacture of lining
Milling cutters for the manufacture of lining, according to their principle of operation, are similar to a tongue-and-groove tool, but with the only difference that when connecting parts, a V-groove between them to simulate a beam. A set of 2 pieces is also required to make the connection.
Universal
After the passage of the tool, 2 planes are obtained that are fully compatible with each other, having a groove and a spike. Both of the latter are located at an angle to each other.
A micro-thorn cutter is also used for splicing parts.
The equipment can be used both for longitudinal splicing of blanks (in the manufacture of shields) and for end splicing of parts.
For corner splicing of wood, equipment from the combined series is also used, which allows you to prepare the joints at an angle of 45 degrees.
It should be noted that the same combined cutter is used to process workpieces that need to be spliced. The original design of the tooling allows to achieve the highest quality of joining parts, and also saves time, since it is not necessary to change the tool.
Apply tool in the manufacture of panels, namely for decorative processing of the edges of parts. All equipment has a thrust bearing fixed from below. A milling cutter with a bearing can process not only rectangular workpieces, but also curly ones. You should be aware that infill tools have a diameter of 50 to 70 m, therefore, in order to use them effectively, you must have a device with a power of at least 1500 watts. For a domestic router, processing a panel with this type of equipment will become an impossible task.
To make doors with a manual router (meaning kitchen facades), you will need to purchase a special set consisting of three elements.
The set contains the following facade cutters: one paneled and two accessories for furniture strapping (profile-counter-profile).
Horizontal
Apply for pre-treatment panels. To form a spike for insertion into the groove of the frame, you will need to additionally process the edge.
vertical
Most often, vertical figure cutters are used for the manufacture of plinth.
Horizontal double-sided
This type of equipment significantly simplifies the production process, since in one pass of the tool a connecting spike and a part of a panel of a certain configuration appear on the edge.
In addition to the above types of equipment, many masters also use homemade cutters. Usually they are standard locksmith drills, reground in a special way. How to do this at home, you can learn from the video.
Criteria for choosing a cutting tool for wood
When choosing wood cutters for a manual unit, attention should be paid to the following equipment parameters.
Shank diameter and size
Please note that some foreign manufacturers of cutters may indicate the diameter of the shank in inches. In most cases, if a collet is installed on the machine, then there will be no problems with installing the tooling, of course, provided that the collet diameter matches the diameter of the shank.
It is important to know that the collet of a manual unit is not a drill chuck into which you can clamp a tool of different diameters. The inner diameter of the collet must strictly correspond to the diameter of the tool shank. Difficulties can arise if you buy a tool with a 1/2ʺ (12.7 mm) shank and try to insert it into a collet with a diameter of 12 mm. At the same time, a shank with a diameter of 6 mm will fit 1.4” (6.35 mm) into the collet without any problems.
Before buying a cutter, especially an expensive one, read the instructions for the unit and find out which collet is installed on it.
Shank length snap is also of great importance. Not all of them have extended shanks, and sometimes their sizes are not enough to use the tool, for example, when expanding deep grooves. Also, long tooling shanks may be needed when fixing the unit under the table. In this case, it is customary to use cutter extension, which is clamped in the collet of the unit.
blade material
This is an important criterion when choosing equipment. The product can be made of high speed steel (HSS) or hard metal (HM). Blades from high speed steel easily cope with soft woods of low density. But for processing hard wood, these cutters are not suitable. In this case, they can be replaced with a snap-in with carbide blades.
Location of cutting elements
The blades on the tool can be located vertically, that is, parallel to the axis of the shank, or at a certain angle to it. Vertically arranged blades work like a planer and cut wood more than they cut it. Therefore, if the blades are a little dull, they will leave marks on the surface they have processed, which will have to be sanded.
Blades located at an angle to the axis of the tool, they work much cleaner and do not form chips.
Stone cutters
To process an artificial stone with a router (manual), you can use traditional types of cutters designed for wood, but only with carbide blades. There is one nuance here: an artificial stone is a composite material that contains the smallest abrasive particles. Therefore, no matter what carbide material the cutter is made of, it will only be enough to process no more than 10 linear meters of a stone blank. Further, dull blades will not give the required cleanliness, for example, of the surfaces to be bonded, which will affect the quality of the connection.
Therefore, professionals advise using the best cutters from well-known manufacturers such as Festool, Leuco, Titman, Leitz, Dimar. The resource of cutting tools manufactured by these enterprises is 5-10 times higher than that of conventional carbide tools. “Branded” equipment can already be processed from 60 to 100 meters of the composite.
Cutters for wood and stone are similar in appearance and even have the same name. Some of them are very often used for stone operations. But there are cutters specially designed for the processing of composite products.
With this stone cutter, you can create sills on kitchen (toilet) sinks and composite countertops. Typically, the complete formation of the collar occurs in 2 passes of the tool.
There is also a modification of the cutter “anti-overflow”, which has a thrust bearing.
This tool is for surface preparation before splicing. The cutting part of the equipment has a wavy profile.
The tooling selects a groove, which is further intended for inlay with composite materials.
This kit is used to eliminate damage on the surface of artificial stone products. The set contains 2 elements. One is a cork, and the second is a hole for it.
CERATIZIT milling cutters can also be used for processing composites.
it diamond cutters which are known for their durability. They are made by sintering several layers of diamond chips. The multi-layer coating allows you to extend the service life of the tool, since during its operation new layers of abrasive appear to replace the worn layers.
Milling cutters for metal
There is no specially designed tooling for metal for a manual router. Usually, craftsmen use tooling designed for machine tools with a suitable shank diameter. Most often, on manual units, end mills are used to create grooves. But you should know that the router is a machine that develops high speeds, which is not very suitable for end cutters. Therefore, the metal must be removed in minimal layers, a few tenths of a mm thick, and in several passes. The following photo shows a spiral cutter for metal.
Also on milling machines you can install burrs of various configurations that can easily cut steel, cast iron, stainless steel, brass and even titanium. But since they most often have a small shank diameter (6 mm), an adapter is required to install in an 8 mm collet.
Burrs for metal are of the following types.
- Disk. You can make all kinds of cuts and grooves.
- Conical (60°). Used for countersinking holes.
- Tapered with reverse taper. The equipment is used for grinding grooves, processing sharp corners of the workpiece, removing welds in the corners of the product, processing hard-to-reach holes.
- Conical rounded. They are used for processing interfaces, cleaning welds, processing planes.
- Tapered pointed. The tool can handle sharp corners, parts mating, as well as milling in hard-to-reach places.
- oval. They process and expand the holes, as well as align the welds in the corners of the parts.
- Flame-shaped. Due to the universal form, the tool is used to create fillets, as well as for their processing.
- Spherical. The tooling can be used for making holes, creating semi-circular mates, and making slots.
- Spheroconic pointed. It is possible to process honey with planes connected at an acute angle.
- Spheroconical rounded. Mates with internal radii are processed.
- Spherocylindrical. You can process edges, profiles, welds, radius grooves. Also, this equipment removes chamfers and burrs and prepares the surface for welding.
- Cylindrical with a smooth end. Used for processing contours, seams after welding, edges, for chamfering and deburring.
- Cylindrical with teeth. Tooling with teeth on the end is used for the same purposes as tooling with a smooth end. Only this type of tool can work simultaneously in two planes at a right angle.
Devices for a manual router
The main task performed by various devices for this unit is to expand the functionality of the device. Some of the accessories come with the machine, but the rest of the attachments to the router must be purchased separately or made by hand.
This device is available in standard equipment any cutter.
The stop allows you to make straight cuts on workpieces. The edge of the workpiece or the guide rail is used as the basic guide.
The tire acts as a guide along which the stop of the apparatus moves. By using this device, straight line milling.
This device is attached to the sole of the unit and allows you to produce radial milling and cutting circles.
Grooving
For grooving a certain width, use the router attachment shown in the following figure.
The width of the groove is regulated by one platform. In this case, a straight groove cutter with an upper bearing is used.
copier
To transfer any complex ornament or pattern special devices are used on the workpiece - copiers (pantographs).
The copier works like this:
- the workpiece is placed under the unit installed in the pantograph;
- at the right distance from the copier, an ornament or pattern is placed that needs to be copied;
- the pantograph pointer is set to the initial position, after which the engine of the unit is turned on;
- all movements of the pointer along the pattern are transmitted with accuracy to the milling cutter, and it cuts out a copy of the required pattern on the workpiece.
The copy sleeve is needed, first of all, to protect the template from the impact of the tool blades. In addition, the copy ring, moving along the edge of the template, transfers all its forms to the cutter, which processes the part under the fixture.
If the hole in the template exceeds the dimensions of the sole of the device, then it can be installed on a platform of suitable sizes.
This simple device allows you to cut transverse and longitudinal grooves in cylindrical workpieces (turned table legs, poles, balusters).
To make spikes for box connection, straight or dovetail, use a tenon cutter.
Using this attachment allows you to make spikes with equal distances between them, so that the connection of parts is perfect.
Tenon-groove device
The tenon-groove connection is the most common in carpentry.
To make this connection, there are special devices called pantorouters.
Despite the apparent complexity of the design, this machine is easily made by hand according to the drawings, which are enough on the Internet.
By installing a manual unit in the table, you get stationary mini machine. With it, it is convenient to process small and long parts that cannot be clamped with clamps. Ready-made milling tables are on sale, specially designed for fixing manual milling machines. Below is a table manufactured by Corvette.
But as practice shows, most craftsmen prefer to make milling tables do it yourself because their design is not complicated. A table for a milling cutter can be made of thick plywood or chipboard with a thickness of 16 mm or more.
If you cut an isosceles triangle, for example, from plywood, and fix it on the sole of the router, as shown in the following figure, you get a simple fixture for processing door panels.
This overlay allows for additional decoration of ready-made doors without disassembling them, without using templates.
How to sharpen a cutter at home
Sharpening of the cutter should be carried out only after the complete removal of soot and dirt from its body and cutting elements. For these purposes, it is better to use a special cleaning fluid (shown in the figure below).
Apply the product to the cutting parts of the equipment and wait a few minutes for it to dissolve the carbon deposits. Then you should take a regular toothbrush and carefully clean the blades of the remaining dirt. After cleaning, you can proceed to the sharpening process itself. To carry out this operation at home, you will first need to purchase set of diamond stones, differing in granularity.
For coarse sharpening, bars with a larger grain are used. But the process of dressing blades should always be completed by polishing with the finest abrasive.
To sharpen a cutter, follow these steps:
- place the bar on the edge of the table and moisten it with water. If necessary, fix the device;
- lay the snap on the bar so that its cutting edge is in contact with the bar along the entire length;
- drive the cutter along the emery with smooth movements with the same pressure force, periodically wetting it with water;
- make the same number of strokes for each blade of the tooling so that the edges are ground evenly.
If the equipment prepared for sharpening has a thrust bearing, then it must be removed before the start of the process.
Of course, if there is such an opportunity, it is better to hand over the cutter for sharpening to a specialized workshop, where it will be restored on precision equipment. This procedure is inexpensive when compared with the cost of diamond bars.
