Technology and equipment for the production of decorative stone. Self-made machine for cold forging Machine for decorative

Hot stamping technology is used to obtain three-dimensional decorative images on flat and shaped surfaces of furniture boards made of solid wood, MDF, plywood or veneer. To implement this method on a baguette, molding or frame on furniture production used machine for embossing wood.

Technology features

Compared to milling, embossing makes it faster and easier to reproduce carved, braided, braided or voluminous textures of expensive woods on cheaper panels.

Hot pressing is more of a thermal molding of wood. Under the influence of temperature, the natural polymers contained in wood become soft and elastic.

How wood hot stamping machine works

Relief rolling is carried out on embossing machines. A heated roller with an engraved pattern is rolled over the surface of the workpiece and applies a relief image. The pattern can be applied to a flat surface and radius elements.

Design features

• The main element is the unit for embossing flat and radius blanks. The hot embossed roller is mounted on the machine support spindle.
• The shaft is heated by electrical resistance or by gas burners. The roller is placed in a closed casing and fixed on the bearing column. A thermostat and a temperature sensor are designed to maintain a constant temperature.
• The water-type cooling system ensures safe operation without bearing jamming due to overheating during long-term use.
• The efficiency of applying the pattern is emphasized by the finish. After applying coatings and patina, the drawing decorates profiles and baguettes very beautifully, giving them sophistication and originality.

Buy the full range of embossing equipment at KAMI

KAMI offers a wide range of baguette finishing machines – you can buy machines for hot stamping, paste and primer application at an affordable price.

Make machines for cold forging can be from improvised materials.

Since universal fixtures from manufacturers have a fairly high cost, a self-made machine for cold forging metal will become great solution for people involved in the manufacture of forged products.

Today metal constructions with a unique design and bold architectural forms used for the arrangement of houses in cottage settlements.

Figuratively curved forged elements of gates, fences and wickets bring an unusual image into landscape design estates.

On the proposed photos you can see what an unusual artistic look the metal structures create.

What parts can be made on a cold forging machine

Cold forging, unlike hot technology, is simple and safe. This process does not require the use of hot metal and the exact observance of the operating temperature.

You can make a do-it-yourself cold forging machine specifically for the manufacture of a certain type of part.

Also, a home-made machine will allow you to solve a wide variety of tasks, so it will be simply universal.

By using homemade machine it will be possible to achieve the ideal geometry of metal elements for individual design idea and make your own original details with a pattern.

In the process of cold decorative forging, as a rule, soft metal is used - it can be nickel and magnesium alloys, steel, copper or brass.

Otherwise, the range of products produced on the machine will be limited only by the imagination and the ability of the master.

Optionally, you can make openwork elements for stairs, gates and fences with your own hands.

The use of decorative details will allow you to decorate fireplaces and barbecues, beautifully decorate the outer walls of the house and the gazebo, make original tripods for flowers, as in the photo.

Types of equipment for cold forging

Existing types of machine tools can be operated with the participation of an electric motor or manual power.

The first version of the device makes it possible to perform work faster than manual ones, but at the same time it requires certain skills from the master.

Forging machines for forging are divided into types:

• snail - a machine with separate removable parts or a solid cast - it is used when making spiral-shaped separate parts;
• universal fixture - used for cutting, riveting and giving volume to the product;
• bending - with its help you can make arc bending of metal or bending parts at a certain angle;
• device for forming rings;
• twister - allows you to bend the product along the axis;
• press - for the formation of a matrix print on the product;
• wave - to obtain wave-like elements from metal rods.

Manufacturing of the machine "Snail"

Using the list of tools and metal parts below, you can assemble a one-piece snail machine.

For work you will need:

• metal rods;
• sheets and strips of steel;
• profile steel pipe;
• welding, pliers, grinder.

Drawings and step by step diagram, as well as watching a thematic video, will allow you to get a high-quality device with the necessary parameters:

• Using a sheet of paper, draw on it the image of a spiral with three turns. Next, check the dimensions so that as a result a reinforced rod with a diameter of 10 mm fits into the thread;
• Using a grinder, cut out two plates from a steel sheet. The first should have parameters 100x100 mm, the second - 130x130 mm;
• Take a 3 cm rod and three steel strips. The edges of the cuts of all used parts must be cleaned with emery to get rid of burrs;
• Using pliers, bend the steel strips according to the template, as a result you will have three spiral parts with different lengths;
• With the help of welding, all elements of the machine are welded according to the scheme, it is recommended to carry out welding work with high quality, since the life of the tool will depend on them;
• The steel pipe is welded last from the bottom in the center of the machine.

As a result of the work carried out, equipment for cold forging of metal should be obtained, as in the photo.

If during the design of any interior elements with cutting profile pipes no one experiences difficulties, then if necessary, bend them, on the contrary, everything becomes more complicated.

Qualitatively and quickly to carry out such work will allow a special bending machines for pipes that you can do in advance with your own hands.

Drawings for the manufacture of this type of equipment can be used differently, depending on what materials will be used in the work.

It is difficult at first glance to assemble a production-type machine for cold forging metal, as in the photo.

But if the master, working with metal, has already managed to gain experience, nothing is impossible for him. The main thing is to choose a solid stable foundation for the future design.

For example, it could be massive metal table made on the basis of pipes or profiles.

Since the bending of the metal will occur due to the shafts present in the structure, it is necessary to select three such elements.

Each of them is a metal cylinder with thick walls and an axis of rotation. Two cylinders are fixed slightly above the table, and the third, the central one, is placed above them.

The distance between the two extreme cylinders determines at what angle the pipe will be bent.

In order to be able to change the position of the cylinders if necessary, it is necessary to make additions to the design drawings in the form of stoppers and rollers that will make this part adjustable.

After the cylinders are fixed, it is necessary to organize a rotation transmission system for them.

For this purpose, they use a chain mechanism from an old car, which can be found on the spare parts market.

It is better if the mechanism is equipped with gears, if not, then they will have to be purchased separately.

Gears are mounted on two extreme cylinders and a tensioner placed below the shafts in the center. Then one of the extreme cylinders is equipped with a handle in order to create a rotating force.

The machine for cold forging of metal products is ready. The following video will help to supplement the above material with details.

How to make a torsion machine

A machine for cold forging of torsion-type products is used to twist metal spirals in the form of a snake.

It is difficult to work with such a device manually, therefore, most often for the manufacture of a torsion bar, drawings with electrical versions of machine tools are used.

In order to properly assemble the torsion bar, we suggest watching the video and reading the guide below.

Tools and materials for machine assembly:

• steel sheet;
• I-beam;
• vice and fasteners;
• gearbox, electric motor, chain;
• Bulgarian;
• welding.

Sequence diagram:

• An I-beam will serve as the basis, to one side of which it is necessary to weld a steel sheet;
• Then a vice is attached to the steel, welded and fixed with bolts and nuts;
• So that when tensioning a metal product does not jump out of the machine, plates are attached to the vice from below and from above;
• The other side of the I-beam is equipped with rollers, on which, subsequently, the platform is mounted;
• Other vices with movable main elements are attached to the surface of the resulting structure. In this case, both structures located along the edges of the I-beam should be located on the same level;
• Further, the structure is equipped with a steel handle made of a rod; due to its rotation, the product will bend;
• Using bolts, connect the reduction gear and the motor. The wheel rim is equipped with a chain;
• The structure is covered with a steel casing.

As a result of the actions taken, a machine with two blocks is obtained - a movable and a fixed one.

Plywood is one of the best decor materials. In addition to its operational qualities, it is easy to process. However, mechanical curly cutting does not always give the desired result. Therefore, plywood laser cutting machines have been developed. This is an innovative technology that allows you to make complex three-dimensional drawings and patterns.

Plywood laser cutting technology

Point thermal effect on the decorative natural material partially destroys it. This is due to the formation of plasma, similar to arc welding. However, the plywood does not melt, but burns out.

The main component of the machine is a laser machine. It forms a concentrated radiation that affects the material. CO2 lasers are used for this. Semiconductor models do not have sufficient power and can only be used for artistic burning.

The procedure for performing figured laser cutting of plywood.

1. Creating a drawing. Depending on the capabilities of the equipment, this can be done in in electronic format or independently apply a pattern to the surface.
2. Choice of cutting mode. The determining parameter is the laser power. It depends on the thickness and structure of the plywood. If the degree of heating is exceeded, the width of the cut will increase.
3. Drawing formation. Its speed is affected by the power of the laser. The higher it is, the faster the process runs. However, this increases the area of ​​darkening at the edges.

This general description technology, which can be changed depending on the parameters and functionality of the equipment. The average power of the laser machine is about 20 watts. It directly depends on the thickness of the plywood and the complexity of the pattern.

For work, it is best to use automated CNC processing centers for wood. This will increase accuracy and improve performance.

Features of cutting plywood with a laser

The main disadvantage of this type of equipment is its high price. A number of benefits that are not possible for machining, make wood laser centers very popular. They are used to complete production, are used to perform a small amount of work at home.

The defining advantage of laser cutting is the thin seam on the wood. It may be slightly larger than the beam diameter. Thus, maximum detail and exact correspondence of the result to the original layout is achieved.

This technology has the following features:

• a slight darkening is formed in the area affected by the beam. This is unavoidable but can be corrected by painting or varnishing;
• cutting requires no mechanical force. In the process, there is no surface deformation characteristic of classical processing methods;
• The quality of work is affected by the composition of the wood. It is not recommended to use sheets made of softwood. They contain a large amount of resins, which, when evaporated, affect the appearance.

For large volumes of production, it is necessary to provide a system for extracting fumes. This is done using local ventilation. The absence of chips significantly softens the requirements for working conditions when cutting plywood with a laser machine.

The surface of the processed material is preliminarily cleaned of dust and dirt. The presence of varnish, paint or similar decorative and protective compositions is not allowed.

List of cutting equipment

To complete a professional production line, it is recommended to purchase specialized equipment. But in addition to the laser installation, other components must be present in it.

To ensure maximum automation of work, the laser head must move freely along the length and width wooden surface. To do this, install a special carriage that moves along the guides.

In addition, the following components are required for normal operation:

• electronic control unit. He controls the operation of the laser, gives commands to move it relative to the sheet;
• exhaust system for combustion products. Despite their small number, forced ventilation the concentration of harmful substances will quickly increase;
• interface for entering information - drawing, machine operating modes, etc.

To perform a small amount of work, it will not be advisable to purchase expensive equipment. The best option- use the services of specialized manufacturing companies. In this case, you only need to draw up the drawing correctly and select the material on which it will be applied.

In the video you can see an example of the operation of a machine for forming a pattern on the surface of a plywood sheet:

Overview of finished machine models

If you want to purchase a laser cutting machine for plywood, then pay attention to their difference in power:

• desktop. Designed for work at home or a small workshop with small workpieces. Power up to 80 W, price from 50,000 rubles;
• professional. It is used in small business in the production of designer jewelry, engraving, cutting materials to size. Power up to 195 W, price from 150,000 rubles;
• industrial. Used on production lines high power and throughput with increased requirements for quality and accuracy. Power from 3000 W, price from 450,000 rubles.

Consider machines from different price categories.

Today, artificial stone is very popular. construction material. It is widely used both for cladding the facade of houses, and for laying out paths in areas, creating tiles and even fence elements.

Manifold colors, greater strength and lower price make this material more affordable and more popular among both professionals and people who simply planned repairs. Due to the fact that the price of equipment for production decorative stone quite affordable, technologies are not secret, manufacturing artificial stone can be an excellent way to develop your own business.

The stone of own production will turn out cheaper than the purchased one, and the owner can choose and improve the texture and quality on his own. All that is needed is to understand the details: what material and how much to buy, what molds are needed for the production of decorative stone, to purchase a convenient production room and the entire set of required equipment.

Production room

Like any other, the stone manufacturing process requires compliance with certain technical and thermal conditions.

So the area of ​​the main production premises can be from fifty to one hundred square meters.

There must be a warehouse for storing raw materials separately from the workshop.

The temperature in the room should not exceed 25 degrees. Heating can only be carried out in the production workshop. Lighting should be both general and local in those places where machines for the production of decorative stone are located. It is necessary to carry out plumbing in the room and equip the sewer drain. Be sure to install a quality ventilation system to ventilate the workshop.

Necessary equipment

When the premises are ready and equipped in compliance with all safety standards, the next step is to choose what equipment will be needed for the production of decorative stone. The following devices are often used:

• Vibrating table (cost from 50,000 to 70,000 rubles).
• Concrete mixer (5,000 - 13,000 rubles).
• Electronic scales (15,000 - 25,000 rubles).
• Multiple desktops.
• Tanks for bulk materials.
• Construction mixer (2,500 - 5,000 rubles).
• Stone molds that you can buy or make yourself.
• Pallets for molds.
• Various small tools such as shovels, shovels, wheelbarrows, trowels, etc.

The vibrating table is needed in order to remove air bubbles from the solution using vibration. You can buy such a table or make it yourself according to the drawings and separately purchase a vibration motor to move the table.

Polyurethane molds can also be made by yourself, which saves money at the beginning of production. But the quality of the form itself directly affects the properties of the product, its durability and aesthetics. Therefore, it is better not to save on the quality of polyurethane. Experts advise using the product of German and American manufacturers.

Raw material

It is important to decide on the material from which the stone will be made: gypsum or concrete, and then purchase all the necessary mixtures. You may need:

• The cement is white and grey.
• Sand (river or quartz).
• Pigment and dye.
• Plasticizers for gypsum and concrete.
• Gypsum, gypsum polymer.
• Chemical mixtures.
• Fiberglass.

Artificial stone can be painted in various colors. To do this, use a compressor with spray nozzles and an airbrush. You can also use brushes of various shapes to achieve the desired texture and color. The pigment can be added both to the finished stone surface and to the mixture itself.

Finished products

Purchased equipment for the production of decorative stone can be used for personal needs or for the manufacture of products for sale. It is advisable to pack the finished stone in order to protect it from damage during transportation and storage in warehouses. It is better to pack in cardboard boxes, laying the stone in layers. Each layer must be separated with a layer of cardboard or packaging film.

Production technology

Decorative stone can be made in several ways. The most common are vibrocasting and vibrocompression. Both methods are good in their own way and have a number of special advantages.

It is cheaper to manufacture equipment for the production of decorative stone by vibrocasting than to purchase a vibropress. This technique is easier to work with and set up. Manufacturing in this way will retain more moisture in the product, since there is no need to steam the stone; eventually finished products more saturated coloring is obtained. The vibrocasting process takes place in several stages:

• Preparation of a mixture of cement, pigments, modifiers and mineral fillers. The solution can be kneaded by hand construction mixer, and a special concrete mixer.
• Pouring the solution into ready-made molds mounted on a vibrating table. The product must be in shape for at least 48 hours.
• Separation of the product from the mold, removal of chips, packaging of the finished material.

The vibropress, in turn, makes it possible to produce material that is less expensive at cost. This process can be almost completely mechanized, which will increase productivity. Thanks to this choice, the future owner of the production can decide for himself which technology will be used depending on the expected performance.

Due to their beauty and sophistication, metal products made by forging have long become very popular. Such decorative elements quite expensive and it is not always possible to order all the desired decorations for the interior or Vacation home. But, in addition to the hot type of forging, which is needed in order to create metal decorative structures, there is a cold version of it. The latter option can be implemented independently, for this you need to build a cold forging machine with your own hands, after which you can begin to implement all your ideas and ideas.

Types of machines

Basically, all fixtures that are designed for the manufacture of metal parts using cold forging are characterized by manual drive. Few of them work on the principle of an electric drive, although it is possible to build such a structure with each of the devices. The only question regarding the drive is expediency, because the cost of the energy resource that feeds the unit and the complexity of the installation process of the mechanism may not justify itself if we correlate them with the amount of work performed and its regularity.

The table lists all the fixtures that are operated by a manual drive type related to the cold forging process.

Reference: very often in some sources you can find the name of machines designed for torsion as well as for machines that make winding - twisters. However, this is not entirely true, machines that twist metal are torsion-type machines.

Video on the manufacture of a machine for cold forging with your own hands.

Differences of cold forging

There is such a thing as "stamping", which is sometimes confused with cold forging. Cold forging itself has 2 principles by which this process can occur. The table shows the process differences.

Cold-type forging, which is carried out according to the principle of bending, is quite simple to do, especially if there is special equipment of a stationary type, which greatly facilitates the process. The advantage of this variety is that you can assemble almost any cold forging machine with your own hands without high costs on this.

Video review of a manual metal forging machine

Cold forging machines

Each device in order to be able to engage in cold forging has its own characteristics and parameters. In order to easily make a cold forging machine with your own hands, you need to figure out what each of them is.

Machine		Device
Bending machines		The design of this device is such that by changing the rollers and wedges, the size of the waves and bends changes. They can bend rods up to 16 mm. The only caveat of this device is that it cannot be made independently, because it requires processing and turning a lot of details. exact size. The cost of such a device is low.
twister		The unit works thanks to equipping it with a special template, to which the processed piece of metal is pressed. The pressure must be very high, so those who work on the twister must have sufficient strength for this. In addition, the safety of the template itself is ensured by the presence of a persistent horn (terminal). As for the middle horn, which is otherwise called circumferential, it should be done in such a way that it can change its position and be fixed in it. The efficiency of work depends on this, especially for those who start the process for the first time.
Base with spacers		Such a unit will allow you to make patterns of absolutely any variations. The design itself is very simple and is a plate of durable and reliable material, into which spacers are screwed at a certain distance. For such purposes, bolts with sizes from m8 to m24 can be used. The thickness of the metal in this case depends only on the skill of the one who works on the machine. Basically, such a device is well suited for metal with a thickness of 6 mm.
Snails Loom-twister	with collar	Such an installation is a base plate on which there is a special coil. Such a coil is used as a template for a future product. The peculiarity of the machine is that the “snail” template is divided into several parts, which are fixed to each other with the help of special connecting elements, which allows the template to vary in shape during operation, which creates various kinds of waves and bends. There are also disadvantages in this design, because in order to make such a cold forging machine with your own hands, you need to select a very durable material that will not bend over time. Also think over the connecting loops, which are quite vulnerable, given the amount of force with which the entire process of bending the metal takes place.
	lever type	In this type of machine "snail" the template is attached very firmly to the base. Due to this fact, his performance is less, however, the reliability is greater. using a special lever, the metal plate is pressed against the template; at the same time, it is necessary to move the mobile roller in the process. To make such a cold forging machine with your own hands, you can use steel material, which is distinguished by its strength, and the roller can be made from a conventional roller bearing. In general, the design is similar to a pipe bender.
Torsion machine		Such a device will help well in the helical twisting of the rods. Such a machine is made from a cylindrical metal base and two fastening and simultaneously twisting elements. It is advisable to equip such a design with a special pair of paws that will not allow the metal being processed to bend inappropriately. The principle of operation on the machine is such that the rod is placed in the elements holding it, clamped from one end, and twisted from the other end using a rotating spindle to right size helical wave.

Electrically driven torsion machine for cold forging

In order to improve not only the efficiency of the cold forging machine by twisting the rods into a helical wave, but also to increase the speed, as well as ensure stability and not be subject to overwork, an electric type drive can be installed.

Working by hand, it is quite difficult to make all the decoration elements from metal rods the same, since the uniformity of the torque in this situation will vary greatly. In order to avoid errors in the manufacture of products, you can use:

• axle shaft from the car, which is installed on the drive axle;
• you will also need a differential gear pair;
• Use a cover for protection.

From the above devices, you can build electric drive to the torsion machine. Such an engine is better not to exceed power ratings of 900 rpm and 3 kW.

Building a curl for the machine with your own hands

Before you start creating a machine for cold forging with your own hands, you need to be able to calculate the parameters of the template spiral, because there are practically no special programs for such purposes. Such a template should not only be technically literate, but also have an attractive appearance.

The calculation of such a template is based on a logarithmic spiral. Some of the nuances in the construction can be distinguished in the following list:

• the beginning of the construction is taken at the point R0;
• the turning radius will be equal to the fixed angle;
• the indicator of the length of such an angle must be multiplied by the divergence of the coil;
• the discrepancy in the standard version is basically taken equal to 1.2;
• for ease of calculation, as well as maintaining accuracy, the bending angle is best taken at an angle of 45 degrees;
• if there is a need to build a template that will have a denser spiral, then the 8th part (s) of a unit distance from the spiral should be added to the radius value;
• as for r0, it must be equal in magnitude cross section the size of the diameter that the workpiece for the spiral has.

Important: r0 can take any value, it all depends on what characteristics the metal is used for the workpiece, namely, on its density.

Considering all the nuances, you can start making a “snail” template, for this it is best to be able to solve equations that have a cubic degree and higher. There is no exact formula for calculating such a device, but there is one that allows you to achieve the best result. The sequence when building a spiral pattern can be as follows:

• the initial point r0 is determined first;
• the turns that the template will have are taken arbitrarily, their number can be any;
• using tabular data, you should calculate the diameter (b), while making sure that it is smaller in width in the opening for the template;
• using the formula, the radius R is calculated;
• the last step is to transfer all the obtained points in accordance with the scale, after which you can proceed directly to the construction. In the process, let's adjust using a similar formula to the radius R in the final version.

Reference: if it becomes necessary to calculate intermediate values, then this is done in accordance with the geometric proportion.

Construction of a cold forging machine

When drawing up a drawing for further creating a template for the machine, it is best to make sure that it has the maximum number of different variations regarding bends and waves. Having such blanks, it is possible to create a cold forging machine with a variety of interchangeable nozzles, which will make it possible to produce various patterns and monograms.

The sequence of actions when creating a device:

• Initially, you need a metal sheet, the size of which will depend on the number of patterns placed on it. The templates themselves should be placed in such a way that there is room for the manufacture of products, because during the process the material from the nozzles may move due to lack of space. Also, if the templates are not sufficiently removed from each other, complications may arise in the work.
• As for the variations of the templates themselves, they can be either simple or contain more than one turn of the monogram. You can make a similar snail of the share type and think over the design of the bends in the disassembled and assembled state. At the same time, you should be careful when choosing the material for fixing the sliding parts - it should be as strong as possible.
• The change of nozzles can be ensured by making a slot rectangular shape, it will be possible to insert interchangeable forging templates into it. They should all be attached to metal plates having the shape of a rectangle. The fastening of such nozzles will be provided with the help of bolts.

Video instruction

Device assembly

This version of the machine is used as an example because of its simplicity. Knowing the basic principles and sequence of equipment design, it can be upgraded as desired. To assemble all parts of the equipment into a single whole, you will need to use:

• drill with carbide type drills;
• apparatus for welding;
• a saw that cuts metal, or a hacksaw;
• metal sheet of the selected size;
• round metal pipe;
• metal rod;
• bearings of different sizes;
• M8 bolts.

To assemble a cold forging machine with your own hands, you need to use a proven sequence of actions:

Conclusion

Those who decide to seriously engage in forging and make a cold forging machine with their own hands should be very scrupulous at the stage of creating drawings and calculations. Otherwise, the creation process is quite simple, and having understood the principle of equipment design, you can come up with various kinds of variations that will help improve products.