So, I collected a sufficient amount of material and decided to dash off another analytical note. This time the theme is sawing chipboard without chips.
There is a fairly fair opinion that it is possible to cleanly saw chipboard only on professional equipment(that is, a panel saw).
The whole highlight of this machine is that it has two saw blades located strictly on the same axis. The first cuts the chipboard, the second cuts it through.
The cost of this unit is about 700,000 - 1,000,000 rubles (of course, there are more expensive))). NOT VERY ACCEPTABLE FOR THE AMATEUR.
Not a bad way to trim incorrectly marked parts, but you can’t cut the whole cabinet in this way. Chips, of course, are present, but in an amount that is quite comparable with the formatter (it also, in secret, leaves a small number of small chips). A lot of hassle with markup. Only straight cuts can be made.
Method 5 - Fraser
Provides the cleanest edge of the workpiece; the quality is no different from the formatter, often even better.
With it, we first saw the workpiece with a jigsaw, departing from the marking line 2-3 mm, and then align the line according to the template (I usually use the second piece of chipboard, sawn on a formatter, of a suitable size). should be copy, that is, with a bearing.
Very clean cut. The possibility of carrying out curvilinear cuts, that is, the manufacture of many, including several completely identical ones. Cons - a lot of trouble: the need for accurate marking, preliminary sawing of blanks, setting a template or tire under the router, that is, not very suitable for mass use.
Many consumers today are faced with the question of what equipment is better to use for the manufacture of cabinet furniture. Based on the opinion of experts, we can conclude that a panel saw, which is also called a circular saw or a circular saw with a carriage, can act as an excellent acquisition. If you also decide that you need such a unit, then you can assemble it yourself.
Format-cutting machines are composed of the following elements:
- bed;
- movable additional table;
- working fixed table;
- carriage;
- support frame;
- separator;
- trolley;
- ruler;
- saw knot.
The latter consists of guides and two saw blades.
Purpose
The panel saw is used for longitudinal and transverse cutting at a certain angle. This equipment can be used to work with panel blanks, to remove overhangs after cladding, in order to cut full-size slabs into individual elements. Today, the panel saw has found its wide distribution in the production of cabinet furniture. It can be used to produce high quality products.
The function of these devices is the ability to give basic parameters to parts for subsequent processing. Such machines can be used for batch or piece cutting. Homemade or factory models are able to work with different materials:
- plywood;
- wood;
- composite sheet materials;
- laminated paper sheets;
- film materials;
- melamine;
- veneer.
The equipment is used for material that has precise geometric dimensions.
Machine manufacturing technology: tool preparation
You can easily make a panel saw yourself. The principle of its operation is quite simple, but factory models have an impressive cost. To carry out work, prepare:
- metal channels;
- pipes;
- metal corners;
- electric motors;
- shafts from agricultural machinery;
- scoring and saw blade;
- fasteners;
- welding machine;
- metal working tools.
Work on blanks
If you decide to make a panel saw, then at the first stage you should make a steel bed, for which you need to use metal channels. The dimensions of the blanks for the base will be as follows: width - 2500 mm, length - in the range from 6500 to 6700 mm, height - from 800 to 1100 mm. The next step is to design the floor and main rails. Their fastening should be carried out on the bed.
For guides, a pipe is used, the dimensions of which will be equal to 60x5x6500 mm. When making a panel saw with your own hands, you should make a movable desktop that will move along the guides. This will ensure that the sheet is fed during cutting. The master should provide for the length of the cutting line, which will be a limit from 3000 to 3200 mm. If necessary, this parameter can be reduced or increased, for this the length of the guides is changed.
Carrying out assembly
When running a vertical panel saw, two saws should be hung on it, one of them will be the main one, while the other will be the scoring one. These elements must be located on the saw block and rotate towards each other. Movement will be provided asynchronous motors. It is important to provide for the possibility of tilting the block at an angle of 45 °. The saw block is equipped with a rotary mechanism for this.
A good place where you can buy a panel saw quite inexpensively is Avito (ad site). However, if you want to save money on doing this equipment yourself, then you should choose the right engine. The efficiency of the saw movement will depend on this element. That is why the motor must have a power of 2.9 kW.
The engine will rotate the main saw at a speed of 5000 rpm, but as for the scoring saw, it will rotate at a speed of 8000 rpm. saw blades should also be present in the design, their diameter will be 250 mm, which will provide the possibility of cutting sheets and cutting laminated particle boards.
Safety of use
In order for the use of the machine to be safe for health, it is necessary to provide exhaust ventilation so that wood dust particles are not ignited by a small spark that occurs when the engine is running.
As soon as the manufacture of the machine is completed, you can begin to process the material. For the reason that sheets usually have large sizes, before installing the canvas in the mechanism, it is necessary to mark up in those places where the cuts will be made. The size of the workpiece should be larger by about 8 mm on each side. As soon as a small stack is ready, you can start cutting.
The Filato panel saw will cost the consumer 230,000 rubles. If you do not have such an amount, then you can make the equipment yourself. To do this, make the main support frame on which the canvas is laid. Metal corners will go to it, which are sometimes replaced by a profile. A canvas with a cut for discs is laid on the frame. The surface of the blade must be smooth to ensure the sliding of the workpieces. At the next stage, you can start making a carriage from chipboard or any other similar material. With its help, it will be possible to fix the saws and move them along the guides. The sheets are interconnected at four corners by a conical shaft, the distance must be such that the shaft can move along the guides.
Quite often, craftsmen look at panel saws before manufacturing the described devices, 3200 is a value that indicates the length of the roller carriage. Such parameters are possessed by WoodTec equipment, which costs $4500. The device weighs 900 kg, and also has a large protective cap on the bracket. The main stop is complemented by a construction mechanism that ensures sawing accuracy and speed when setting up. If this price does not suit you, then you can start manufacturing such a unit yourself.
At the next stage, an automatic sawmill starter is installed in the upper part of the carriage. The first and second saw must be fixed under the carriage. In this case, the disks will be located frontally. They are covered with a screen, for which you can use any transparent material.
Guides require two pipes large diameter. They are connected with a metal strip, while the surface should be smooth and free from defects. There will be a stop at the edge of the rack. In height, it must withstand a sheet or part. Nearby is a metal ruler, the zero level of which should be at the point of cutting the blade. This will determine the size on the sheet.
Perpendicular to the stop, you need to place the clamping mechanism. It is made of a metal profile and fixed with bolts. A corrugation is attached to the upper part of the screen of the carriage, the other end can be brought to the ventilation hatch. As soon as the automatic starter is installed under the hood, the machine can be put into action and cutting work can be carried out. Before turning on the equipment, it is necessary to connect the hood, which will keep the room clean.
Conclusion
You will need saws for panel saws if you plan to make the equipment yourself. For example, a circular saw with parameters 300x3.2 / 2.2x30 will cost the consumer 4800 rubles. But for cut-off saw 120x2.8 / 3.6x20 will need to pay 2800 rubles. A circular saw from the manufacturer FREUD with parameters 300x3 / 2x30 will cost 3400 rubles.
I have a small workshop, but I like to make big things, like wardrobes. To with maximum efficiency use tight space. it is worth making an inexpensive one for rough cutting of sheet materials.
To make a formatting machine with your own hands, you need:
First of all, bolt the 600 mm long hinged stops on the lower ends of the posts with a section of 40x90 mm. At the bottom of the racks, make 12 mm holes in 200 mm increments for dowels that fix the adjustable stop blocks. At the top ends of the uprights and in the three wall brackets, drill 38mm holes for 1" steel pipe. Make holes for cotter pins at the ends of the pipe. The pipe is threaded into the holes of the brackets and racks, and then fixed with cotter pins.To work, arrange the stands so as to provide support for the outer edges of the workpiece. If you need to cut a whole sheet across, place it end-to-end on the floor and press it with clamps to the posts above the cutting line so that the clamps do not interfere with the saw. For cutting a smaller piece, and also when you need to cut a whole sheet lengthwise, put it on stop blocks to place it on comfortable height, and fix with clamps to the uprights.
To precisely set the guide bar for circular saw, fasten the clamp at one end below the marking line and place one end of the guide on it, fixing the second end, go to the first and finally align it.
In the process of manufacturing modern cabinet furniture, a large number of a variety of equipment, including panel saws. These machines are designed to process wood, full-length chipboard with or without coating, plywood, fiberboard, MDF board, veneer and different types facing plastic. With the help of a panel saw, longitudinal, transverse and angular cutting of the material is performed in order to give it a certain shape and size. A simplified version of such equipment will not be left without work in a home workshop and may well be made from improvised means with your own hands.
Design
The main parts of the panel saw are:
- Bed - this element takes on the main load during the operation of the machine. All other hinged elements are attached to the bed;
- Fixed desktop - a sheet of the material being processed is laid on it, and a frame with clamps, an emphasis and a ruler are also attached;
- Guides for the movable carriage;
- Additional movable table (it has a saw unit carriage, electric motors and a saw unit drive);
- Saw assembly, which consists of two circular saws that rotate towards each other;
- Protective covers.
How to make a panel saw
- The manufacture of the machine begins with the bed. Good for her as a material. steel pipes square or rectangular section, from which a spatial truss is welded. dimensions frames are selected based on how large sheets you plan to process, in addition to this, it is necessary to take into account the overhang of the guides for the carriage of the saw unit. First, we fix the elements of the future frame with the help of clamps and roughly grab them together. After checking the frame geometry for parallelism and perpendicularity of its main bearing parts, they are finally welded together.
- As guides for the movable carriage of the saw unit, you can use a profile in the form of an I-beam or channel. This shape of the profile provides it with sufficient rigidity, and is also well suited as a support surface for the rolling of carriage rollers. The profile is fastened to the frame of the machine using bolted connections. To do this, in the upper tubes of the frame on the side where the carriage will move (usually to the left of the operator), a series of holes is made with a drill at an equal distance from each other. It is necessary to carefully mark the holes, since the accuracy of the installation of the guides largely depends on this. In addition, it is desirable to check the curvature of the profile in vertical plane, since this will determine how even the cut will be in the material being processed.
- The fixed table serves as a support for the sheet workpiece, which is processed on this machine. It can be made from any material that has a thickness of 10 ... 15 mm and has a smooth smooth surface(For example, laminated chipboard or thick plywood). Brackets for clamping the workpiece, a measuring ruler, as well as a movable stop will be fixed on the edge of the table with screws.
- The movable carriage is one of the most critical components of the panel saw. It is she who, with the help of support rollers, moves on guides and serves as the basis for fixing the electric motors of the drive of circular saws. The movement of the carriage is carried out either manually or with the help of a cable drive and an additional motor. In our case, the carriage is made by welding from square pipes And sheet metal 5…10 mm thick, which provides it with good rigidity. Support rollers are machined from steel or durable nylon. By appearance the carriage resembles a rectangular box, to the bottom of which two electric motors with a power of 3-3.5 kW are fixed with bolts, and a saw unit is located on top.
- The rotation of circular saws is carried out using a belt drive, one pulley of which is fixed to the motor shaft, and the second is rigidly connected to the shaft on which the mounting flange for the saw sits. As a blank for this assembly, you can take a saw block with any factory circular saw that is suitable in size. There, all the details are already adjusted in size and calculated for strength. Similarly, rotation in the opposite direction of the second circular saw located in front of the main instrument at a short distance. We need this saw in order to ensure a smooth cut without chips on the material being processed. The gear ratio of the pulleys is selected in such a way as to ensure the rotational speed of the saws in the range of 4-6 thousand revolutions per minute.
- The mechanism for adjusting the position of the saw unit in height consists of four bolts with wide washers that move along the longitudinal cuts in the side posts of the carriage. Changing the height of the saw unit is done by loosening the bolts and moving it the required distance up or down the grooves.
- The clamp and stop for sheets of the material being processed are made from pieces of a corner measuring 50x50 mm. The lower part of the corner is pasted over with dense rubber or felt so that the clamp does not spoil the surface of the material being processed. The sheet is pressed by a special foot by turning an eccentric driven by a lever, which is manually moved by the operator.
- As a measuring scale for the stop, we use a ready-made ruler from a decommissioned metal-cutting machine or tape from a tape measure. The stop is fixed either with an eccentric (similar to a sheet clamp), or with a screw with a large thread pitch, similar to that used in manual meat grinders.
- According to safety requirements, all moving parts of the machine are necessarily closed with removable screens made of sheet steel, and the saw unit is located at a distance from where the operator stands.
