Table for cutting chipboard with your own hands. Overview of models and characteristics of panel saws for chipboard sawing. Methods for cutting chipboard without chips

In the production of cabinet furniture, it will not be possible to do without a machine for cutting material. Furniture designs such as a kitchen wall, computer tables and even beds will require details with high dimensional accuracy. Make no mistake that you can start making furniture using only a circular saw for cutting. You will have to resort to making a panel saw with your own hands.

The fact is that a circular saw can cut at a low speed, while the quality of the finished part depends entirely on the master. Thus, the production of furniture will be not only slow, but also, possibly, unprofitable, because the possibility of manufacturing defective products is great.

Vertical sizing mechanism for board material, allows you to remove the responsibility from the master and make precise linear movements during cutting.

Furniture blanks are accurate, and the speed of their production reaches 15 parts per minute.

Sawing machine manufacturing

Such a machine has a lot of advantages, however, there is also a minus - the high cost of high-precision equipment. Not all novice manufacturers have the opportunity to purchase such a mechanism, so many decide to make a panel saw with their own hands.

FRS design

To manufacture a machine that will meet the requirements for quality and production speed, you need to be prepared for the cost of materials and be able to use drawings, because the unit consists of complex mechanisms and three-dimensional structures.

Required items:

Bed - must be made in accordance with the dimensions of the material being processed, for chipboard - it is 3.5x2.5 m. As practice shows, more is not required, of course, if production has not reached the factory scale. Also, this design, like the whole, must have a low level of vibration. To do this, the bed is made of welded joints and mounted on rubber heels that absorb vibration;
Tabletop - for a home-made panel saw, suitable from a laminated chipboard or metal sheet. The main thing is that the surface is perfectly smooth, otherwise defects may appear on the processed material, in the form of scratches and chips. Also, there should be no depressions or bulges on the surface of the tabletop, this will lead to inaccurate product dimensions;
Moving carriage - can be made in 3 versions, depending on the choice of machine functionality. However, its main quality is the smooth linear movement of the saw or sawn material;
Engine - best used without transmission devices (belts, gears). As a driving force for the saw, you can use high-speed electric motors and even motors from angle grinders;
Dust collector system - necessarily contains a sleeve for removing chips and dust, a waste container and a pump. This system turns out to be extremely important for long-term operation;
– do not allow sheets to move during cutting. Important characteristics of the clamps are the holding strength and the absence of marks after use. To do this, the clamps are equipped with rubber substrates and the necessary pressure on the part is selected.

How to make a table saw

How to prevent chipping on chipboard

A material such as laminated chipboard has a harmful property, leaving chips on the ends after cutting. To avoid such a nuisance, only an increase in the speed of rotation of the saw or a slow feed of the saw to the material allows. However, not all so simple. Chipboard sheets consist of pressed sawdust and a laminating layer. The laminating layer is a thin but very durable material, and the pressed sawdust is a thick and soft layer.

Using a powerful motor, the soft sawdust is cut like butter, causing the hard laminate to simply chip off. The solution is to use 2 saws at different speeds or to cut slowly.

Everything is clear with the speed of feeding the saw to the material, but with the use of two saws it is worth understanding. It is worth noting that here you will need drawings for panel saws. To achieve the desired result, the blade for sawing the laminate is placed so that it cuts no more than 2 mm, and the rotation speed is achieved by reducing the blade or a more powerful motor.

Detail for cutting

For sawing the main layer, a large disc with a cut depth of up to 40 mm is used. It is worth noting that this version of the sawing mechanism allows you to achieve a cut speed of 1 m in 10 seconds.

Options for using the mechanism for cutting

There are 3 options, thanks to which the vertical panel saw cuts materials:

feeding the saw to the material - the saws are located under the table;
feeding the saw to the material - the saws are located above the table;
feeding material to the saw - the saws are located under the table.

In the case of feeding the saw to the material, which is located above the table, the motor and cutting discs are fixed on the carriage. The carriage is mounted on skids placed at the desired height, which allow the entire structure to be held and moved for cutting along the plane of the table. Skids or guides can be made of or powerful pipes.

The location of the saw under the table, which is fed to the material, also implies the presence of guides and a carriage moving along them. The difference of this arrangement lies in the fact that the dust collector system is hidden under the table and does not interfere with the movement of large objects.

When sawing is carried out while feeding material to the saw, a powerful mechanism is required to move the sheets. In this case, the carriage for moving is a table with legs on rollers. It should be noted that the design of such a sawing mechanism requires more space and has a lower throughput.

Clamps

The simplest clamping mechanisms can be taken as the basis, however, in this case, the time to complete the work increases. Ideally, for a sawing machine, make a clamping device in the area of the saw passage. A fairly simple device will be a pipe laid above the table, along the cut line, on which the clamps will be placed.

Video: Panel saw

I have a small workshop, but I like to make big things, like wardrobes. To make the most of tight spaces. 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, place it on stop blocks to position it at a convenient height, and fix it with clamps to the posts.

To accurately set the guide bar for a circular saw, fasten a 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 align it completely.

Chipboard (chipboard), and nowadays, mostly laminated (chipboard) is one of the main materials for making affordable furniture in a home workshop. This board is made from coniferous and hardwood materials, so it has such qualities as strength and ease of processing. But with improper cutting, chipping of this material is possible. Therefore, before making furniture, you should find out how to properly cut chipboard.

For this purpose, you can even assemble industrial equipment yourself - a cutting machine.

Sawing rules

First you need to choose a sawing method.

Be sure to carry out the following preparation (cutting):

to protect the laminated coating of the plate from damage during operation, it is necessary to prepare masking tape or adhesive tape;
for marking blanks - a ruler and a pencil;
from the ends of the plate, mark the future cutting points with a pencil;
in order to prevent chips from appearing, you need to stick a masking tape or adhesive tape in place of the cut;
after gluing the tape, connect the preliminary marking points with a pencil;
prepare sandpaper for finishing cut lines.

The following rule no longer applies to preparation, but to actions after cutting, but is common with any method: e If irregularities are found on the edges, then they must be processed with a file or rasp. Cover the ends resulting from the cut with veneer with a pattern similar to that of a laminated coating.

What can not be cut

Chipboard cannot be sawn with an angle grinder, also called a grinder. When working with this tool, the likelihood of injury is high, especially when using large diameter discs. It is also possible to be injured when the protective cover is removed from the tool.

Methods for cutting chipboard without chips

You can cut on a panel saw. But its cost starts from 50,000 and reaches 1,000,000 rubles. If you need to cut chipboard to make several pieces of furniture for yourself, other methods are more suitable.

Scratch

It is necessary to scratch a marking line along the ruler with an awl or nail to the thickness of the laminated coating. Sawing along this line, making sure that the edges of the saw teeth fall exactly into the scratch. You can cut with a jigsaw or hand saw.

Electric jigsaw

Suitable for cutting a small area. The file should be with the smallest tooth size. You need to move the jigsaw smoothly, without pressure, set the speed slightly above the average level.

On the side where the teeth enter the plate, there will be practically no chips, and on the opposite side, with insufficient experience, they will appear, but in a small amount.

A circular saw

You will need a saw blade with fine teeth. With this method, long straight cuts will be more successful than when cutting with a jigsaw. On the side where the teeth cut into the slab, there will be no chipping. If they appear, then from the opposite side, as in the case of a jigsaw.

The use of guides increases the accuracy of the cut. In this case, it is better to fix the saw on the table.

Undercut Sawing

You will need a large ruler (tire), which is fixed on the workpiece with clamps. The first cut is carried out to cut the laminate along the marking line. The tire must be installed on the line, and the cut should be made to a depth of 6-10 mm - there will be no chips.

The second cut is through. There will be no chips at the entry line of the teeth into the slab, and at the exit point the laminate has already been cut off, so they simply cannot be.

Frazier

In this case, you should first cut the workpiece with a jigsaw, departing from the marking line by 2-3 mm, and then align the line with the template. The cutter must be with a bearing. With this method, you can also cut curvilinearly.

Sawing with a panel saw

For sawing by the machine, the workpiece is placed on the left fixed table up to the adjustable stop. The required length is measured. The saw unit starts up. When the disk reaches the required speed, the table moves forward.

The workpiece together with the table is fed onto the disc for sawing off the desired piece.

Basic machine settings:

workpiece position;
cut depth;
cutting angle.

There are three types of machines:

light (designed for a workload of five hours);
medium (8-10 hours);
heavy (16-20 hours).

Design

The most popular models are Mj 45kb-2, JTS-315SP SM, Woodtec ps 45, Altendorf F 45. Despite their different features, they have a common design.

Mandatory components of the cutting machine:

The bed is the basis on which all mechanisms are attached. Heavy beds exclude vibrations and vibrations, which is extremely important for accurate cutting.
The saw knot consisting of two disks. The first disc is located in front of the assembly and serves to pre-cut the workpiece. The second is for the complete sawing of the slab.
Three desktops. The first is motionless, a node is located on it. The second, formatted, is movable, on which the plate is fed to the disk. The third supports the sawn off parts.
Carriage - a part that allows the format table to move.
Stops and rulers that fix the workpiece in the desired position.

Depending on the model, price and cutting features, the machines may have different design nuances.

Additional components of the machine:

a branch pipe that removes chips and sawdust, and connects a dust removal system;
clamps for securely fixing the workpiece on the table;
rotary ruler and corner stops, with the help of which the cut is made at the desired angle and without marking;
frame with a stubborn leg for sawing long workpieces;
ball and roller carriages.

The first sliding table saw was assembled in 1906 by the German carpenter Wilhelm Altendorf.

How to make a machine with your own hands

When using a panel saw, you can get high quality furniture parts. This is due to the high precision of the production process, including cutting. Therefore, if it is difficult to purchase ready-made equipment, but you really want to start a chipboard processing business, you can assemble the machine yourself.

Necessary tools and materials

The saw unit of the machine is most often a welded structure, as it most effectively resists vibration.

Instruments:

welding machine;
"Bulgarian" with a disk for metal;
electric drill;
measuring tool.

In order for the equipment to work for several years, it is better to choose those materials for its manufacture that have been subjected to heat treatment.

Materials:

pipes of square or round section;
a beam or two round pipes connected to each other;
videos;
steel sheet with a thickness of at least three millimeters;
chipboard sheet;
lever mechanism of any configuration.

Manufacturing

Production begins with the main components and ends with smaller ones.

Stages of manufacturing a machine for cutting chipboard with your own hands:

The manufacture of the bed. You will need square or round pipes. They are cut and fastened to each other with clamps. After checking the dimensions and the correct location of the components - welding.
Production of a movable carriage. Install guides, preferably a beam or two round pipes connected to each other. The carriage must be equipped with rollers for smooth sliding.
Desktop production. The base is made of a steel sheet with a thickness of at least three millimeters, the working surface is made of a chipboard sheet, measuring rulers are attached to it.
Production of clamps for sheets, for example, from a lever mechanism of any configuration.
Upon completion, the cutting block is connected to the chip ejector.

The quality of finished products produced on home-made machines is higher than that of products created entirely by hand tools, but still lower than on industrial-made machines.

Video about cutting chipboard without chips

In the video you can clearly see the process of sawing chipboard without chips.

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 facing, 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 frame.

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. The movement will be provided by 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 make it possible to trim sheets and cut laminated particle boards.

Safety of use

In order for the use of the machine to be safe for health, exhaust ventilation should be provided so that the dust particles from the wood do not ignite from 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. Due to the fact that the sheets are usually large, before installing the web 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.

The guides will require two large diameter pipes. They are connected with a metal strip, while the surface should be smooth and free of 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 a cutting saw 120x2.8 / 3.6x20 you will need to pay 2800 rubles. A circular saw from the manufacturer FREUD with parameters 300x3 / 2x30 will cost 3400 rubles.

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 cut 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 we 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.

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