U.S. patent application number 10/291238 was filed with the patent office on 2003-06-19 for milling system and method.
Invention is credited to Karkosch, Joe, Kochanski, John R., Mathee, Jurgen, Schelberg, Karl-Heinz.
Application Number | 20030113180 10/291238 |
Document ID | / |
Family ID | 26966659 |
Filed Date | 2003-06-19 |
United States Patent
Application |
20030113180 |
Kind Code |
A1 |
Schelberg, Karl-Heinz ; et
al. |
June 19, 2003 |
Milling system and method
Abstract
A milling system for milling patterns into a workpiece is
disclosed. The system comprises a baseplate having an aperture and
a template disposed within the aperture and positionable in a
plurality of registrated orientations relative to the baseplate.
The baseplate is formed of two separable baseplate parts. A system
for vertically supporting a rotary cutting tool is also disclosed.
The system comprises a base, a plurality of posts extending
upwardly from the base, and a tool support for supporting the
rotary tool. The tool support has a plurality of sleeves, one
associated with each of the posts. The sleeves slidably receive
respective ones of the posts. The tool support further includes
springs for biasing the tool support away from the base.
Inventors: |
Schelberg, Karl-Heinz;
(Frankenau, DE) ; Mathee, Jurgen; (Frankenau,
DE) ; Karkosch, Joe; (Palatine, IL) ;
Kochanski, John R.; (Palatine, IL) |
Correspondence
Address: |
Wallenstein & Wagner, Ltd.
311 S. Wacker Drive, 53rd Floor
Chicago
IL
60606-6630
US
|
Family ID: |
26966659 |
Appl. No.: |
10/291238 |
Filed: |
November 8, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60344570 |
Nov 9, 2001 |
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Current U.S.
Class: |
409/179 |
Current CPC
Class: |
Y10T 409/30644 20150115;
B23B 3/00 20130101 |
Class at
Publication: |
409/179 |
International
Class: |
B23C 001/20 |
Claims
What is claimed is:
1. A milling system, particularly for the milling of simple up to
complex complementary and expandable patterns from a workpiece (7)
with a router (11) guided therewith, characterized in that at least
one recess (1) is cut in a base plate (2) and at least one movable
template (3) lockable in preset positions can fit accurately into
said recess.
2. The milling system of claim 1, characterized in that the recess
for the movable template (3) can be in the form of a polygon,
circle, or arc of a circle.
3. The milling system according to claim 1, characterized in that
the movable template (3) can be divided into several sectors (8)
and can consist of transparent material.
4. The milling system according to claims 1 characterized in that
in the movable template (3), there is at least one recess into
which insertion parts (5) can be fitted and at least one pattern
recess in the insertion part (example) (6) is cut away from the
insertion parts (5).
5. The milling system according to claim 1 characterized in that
one or more movable templates can, in turn, be installed in the
movable template (3).
6. The milling system according to claim 1 characterized in that
the movable templates (3) have locking mechanisms (9) (14)
(15).
7. The milling system according to claim 1 characterized in that
the position of the movable templates (3) in the accurately fitting
recess of the base plate (2) or in the template (3) itself, can be
changed by shifting, turning, sliding, and rotating, as a function
of the required pattern to be milled after each milling step.
8. The milling system according to claim 1, characterized in that
at least one pattern cutout (example) (4) on the movable template
(3) is removed from a defined area.
9. The milling system according to claim 1, characterized in that
securing elements (10) for the employment of a guide bar (13),
which is adjustable in the X- and Y-directions, are located on the
base plate (2).
10. The milling system according to claim 1, characterized in that
by use of a guide bar (13) adjustable in the X- and Y-directions, a
pattern milling expansion is possible both in the X- and
Y-directions.
11. The milling system according to claim 1, characterized in that
the movable templates (3) for different templates may be compatible
and complementary in order to form new patterns.
12. The milling system according to claim 1, characterized in that
the pattern to be milled can be broken down into the form of sample
cutouts (example) (4) formed at precisely defined positions in the
movable template (3).
13. A method for the milling of patterns from a workpiece (7) by
means of the milling system (12) and a router (11) guided
therewith, with tracing collar (16) and router bit (17), according
to claim 1, characterized by the following steps: specification of
the pattern to be milled, or its selection from an included pattern
sheet; setting up and locking the milling system to the workpiece;
selection of the pattern recesses (example) (4) belonging to the
pattern of the movable template (3); adjustment of the cutting
depth of the router; turning on the router (11), bringing it into
position and plunging the router bit into the workpiece; guiding
the router (11) equipped with tracing collar (16) and router bit
(17) along the inner contours of the pattern cutouts (example) (4)
belonging to the pattern in the template (3); switching off and
removing the router (11); bringing the template into a new position
within the base plate (2), in accordance with the pattern, after
each milling process, by shifting, turning, sliding, and rotating,
as a function of pattern requirements; and repetition of steps e)
to f) until the desired pattern has been cut.
14. A milling system for milling patterns into a workpiece, the
system comprising: a baseplate having an aperture; and a template
disposed within the aperture and positionable in a plurality of
registrated orientations relative to the baseplate, wherein the
baseplate is formed of two separable baseplate parts.
15. The milling system of claim 14 wherein the two baseplate parts
are symmetrical.
16. The milling system of claim 14 wherein the two baseplate parts
include means for interconnecting them together.
17. The milling system of claim 16 wherein the interconnecting
means comprises a tongue on one of the parts and a cooperative slot
in the other of the parts to received the tongue.
18. The milling system of claim 17 wherein the tongue has a raised
detent and the slot includes an aperture to receive the detent.
19. The milling system of claim 16 wherein the interconnecting
means comprises a tongue on each of the parts and a cooperative
slot in each of the parts, wherein each of the slots receives a
respective one of the tongues.
20. The milling system of claim 19 wherein each of the tongues has
a raised detent and each of the slots includes an aperture to
receive the respective detent.
21. The milling system of claim 14 including means for locating the
baseplate relative to the template.
22. The milling system of claim 21 wherein the locating means
comprise indicia on one of the baseplate or the template.
23. The milling system of claim 14 wherein: the baseplate aperture
has a peripheral surface and the baseplate includes a plurality of
recesses disposed about the periphery of the aperture; and the
template has a protrusion for meshing engagement with one of the
recesses for positioning the template relative to the
baseplate.
24. The milling system of claim 23 wherein the template has a
plurality of protrusions for meshing engagement with respective
ones of the recesses for positioning the template relative to the
baseplate.
25. The milling system of claim 24 wherein the protrusions and the
recesses include indicia for rotationally positioning the template
relative to the baseplate.
26. The milling system of claim 25 wherein the indicia comprise a
number of repeating characters.
27. The milling system of claim 26 wherein the baseplate has a
number of protrusions and the number of repeating characters is
evenly dividable into the number of protrusions.
28. The milling system of claim 14 wherein the baseplate includes
opposing notches for aligning the workpiece with the milling
system.
29. The milling system of claim 14 wherein: the baseplate aperture
has a beveled aperture surface; and the template has a
cooperatively beveled outer surface.
30. The milling system of claim 14 wherein the template has a
center positioning aperture.
31. The milling system of claim 14 wherein the template has an
upper surface and a lower surface, and the upper surface is
flush.
32. The milling system of claim 31 wherein the baseplate lower
surface is ribbed.
33. A system for vertically supporting a rotary cutting tool, the
system comprising: a base; a plurality of posts extending upwardly
from the base; a tool support for supporting the rotary tool, the
tool support having a plurality of sleeves, one associated with
each of the posts, the sleeves slidably receiving respective ones
of the posts; means for biasing the tool support away from the
base.
34. The system of claim 33 including means for selectively limiting
the travel of the tool support towards the base.
35. The system of claim 34 wherein the limiting means comprises a
gauge having one end secured to the tool support and the other end
adapted to engage the base.
36. The system of claim 33 wherein the biasing means comprises a
spring.
37. The system of claim 36 wherein the tool support includes a
spring sleeve, and the spring has a first end disposed in the
spring sleeve and a second end engaging the base.
38. The system of claim 33 wherein the biasing means comprises a
plurality of springs.
39. The system of claim 38 wherein the tool support includes a
plurality of spring sleeves, and each of the springs has a first
end disposed in a respective one of the spring sleeves and a second
end engaging the base.
40. The system of claim 39 wherein the tool support includes a
threaded opening to receive a threaded nose of the rotary tool.
41. The system of claim 33 wherein the tool support includes a
handle for moving the tool support relative to the base.
42. The system of claim 33 wherein the tool support includes two
spaced handles for moving the tool support relative to the
base.
43. The system of claim 33 wherein each of the sleeves includes a
bushing.
44. The system of claim 33 wherein each of the sleeves includes
first and second bushings.
45. The system of claim 33 including three of the posts and a
respective three of the sleeves.
46. The system of claim 33 wherein the base is transparent.
47. The system of claim 46 wherein the base has a lower surface and
the lower surface includes a raised rib.
48. The system of claim 47 wherein the rib is generally
circular
49. The system of claim 33 wherein the base includes a guide
bushing.
50. The system of claim 49 includes means for releasably securing
the guide bushing to the base.
51. The system of claim 50 wherein the releasably securing means
comprises a lip on the base to receive a respective lip on the
guide bushing.
52. The system of claim 33 including means for locking the tool
support in a position a selected distance relative to the base.
53. The system of claim 52 wherein the locking means includes a
spring loaded release.
54. A milling system for milling patterns into a workpiece, the
system comprising: a baseplate having an aperture; a template
disposed within the aperture and positionable in a plurality of
registrated orientations relative to the baseplate, wherein the
baseplate is formed of two separable baseplate parts; a rotary
cutting tool plunger, the plunger comprising a base, a plurality of
posts extending upwardly from the base, a tool support for
supporting the rotary tool, the tool support having a plurality of
sleeves, one associated with each of the posts, the sleeves
slidably receiving respective ones of the posts; and means for
biasing the tool support away from the base.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. provisional patent
application, serial No. 60/344,570, filed Nov. 9, 2001.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The invention pertains to a device in the form of a milling
system 12 associated with a method for the milling of simple up to
complex, complementary and expandable patterns from a workpiece 7
by means of a router 11 with tracing collar 16 and router bit 17.
The milling system 12 has a base plate 2 and a movable template 3
that contains sectors 8 with pattern cutouts (examples) 4 in
defined positions.
[0004] By shifting, turning, and rotating the parts of the milling
system 12 after each milling process, particularly the movable
template 3, several of the pattern cutouts (example) 4 in the
template 3 can be used to mill out a great number of pattern
combinations and pattern variations.
[0005] The milling of complementary patterns is also possible,
since the pattern to be milled can be broken down in accordance
with a defined system and cut out with the pattern cutouts
(example) 4 of the movable template 3.
[0006] Different templates are compatible and can complement each
other to form new patterns. Due to the use of a guide bar 13,
several patterns to be milled can be expanded in the X-direction
and in the Y-direction.
[0007] The invention pertains to a device in the form of a milling
system, associated with a method for milling simple to complex,
complementary and expandable patterns from a workpiece by means of
a router 11 with tracing collar 16 and router bit 17 according to
the preamble of claim 1. A pattern can be understood as the
following: shapes, images, symbols, letters, numbers, ornaments in
the manner of chip carvings, decorations, etc.
[0008] Using milling systems when routing or inlay-milling a wide
variety of patterns with the aid of hand router is known. These
templates are used as interior and exterior templates. A template
must be made for each pattern to be milled. The milling process
then runs as follows. The template is affixed to the workpiece.
Then by means of a stop collar attached to the hand router, the
contours of the template are traced (for exterior templates:
tracing of the template's exterior contour; for interior templates:
tracing of the template's interior contour). More complex milling
work is possible with the aid of a CNC milling machine
(computer-controlled NC machine).
[0009] Known milling systems (interior templates, exterior
templates) have the disadvantage that a separate milling system
must be created for each pattern to be milled. With these
templates, only the one designated pattern can be milled. This
applies to the exterior templates as well as to the interior
templates. The production of such templates is very time-consuming
and expensive. Moreover, it requires, in addition to the
appropriate manufacturing methods, a certain creativity and special
skills in the field of ornamentation of workpieces.
[0010] The quality of the milling depends directly on the execution
of the template. Thus, uneven areas on the cutouts (for interior
templates) and on the template periphery (for the exterior
templates) are transferred directly to the milling.
[0011] The disadvantage of exterior milling systems is that only
the exterior perimeter of a pattern can be cut out. And the
disadvantage of interior milling systems is that the complete
milling of a complex pattern is not possible since not all details
can be cut away from the milling system. This is due to the
dropping out of certain partial zones of the template due to a
possibly unavoidable overcutting in the milling pass (for example,
in a template for milling out the uppercase letter B). When using a
router 11 with tracing collar 16 and router bit 17 and the
corresponding template, the undesirable overcutting problems appear
in the middle milled region of the "B." Another example of this
problem is a template for milling several circles of different
diameter about a common center. Here, only the largest diameter
could appear on the template, since the smaller template sections
would merely drop out.
[0012] More extensive pattern structures (for instance, a rose with
petals) can only be milled out with the aid of computerized NC
machines (CNCs). For medium-scale woodworking shops, use of these
computerized NC machines is usually cost-prohibitive. In addition,
such machines can only be used in workshops. Due to their
significant weight, they cannot be used on-site. Moreover, as a
rule, for reasons of cost, the use of such NC machines is not
possible by the nonprofessional hobbyist.
[0013] Therefore, the object of the present invention is a milling
system, associated with a method for the milling of simple up to
complex complementary and expandable patterns from a workpiece 7 by
means of a router 11 with tracing collar 16 and router bit 17,
wherein a few basic patterns in the form of pattern cutouts
(examples) 4 are used to create a very large number of different
pattern combinations and variants.
[0014] Additionally, when milling, it has been difficult to
accurately and comfortably hold and control the milling tool.
SUMMARY OF THE INVENTION
[0015] According to the present invention, an object is realized by
a device associated with a method having the characteristics of
claim 1.
[0016] The user of the router 11 with tracing collar 16 and router
bit 17 will be able, by means of the milling system 12 according to
the present invention and the selection of only a few pattern
cutouts (example) 4 at specified positions on the movable template
3, to create several different, complex, complete, complementary
patterns whose shape and size can be expanded indefinitely, merely
by sliding, turning and rotating the movable template 3 after each
milling process. Thus, it will be possible to mill from one to a
significant number of pattern combinations, and also to mill
pattern variations. The milling of carved ornamentation (notch
cutting) is also possible. Due to an appropriate placement of the
pattern cutouts (example) 4 on the movable template 3, it is
possible to expand the size of the pattern being cut (e.g., a rose
with petals, where additional outer, supplemental petals can be
added on). Partial milling of a pattern is also possible (e.g., 1/4
or 1/2-pattern) (FIG. 12).
[0017] Due to the use of additional, compatible templates and also
of a guide bar 13 adjustable in the X-direction and in the
Y-direction, the size or shape of a pattern can also be varied.
[0018] This provides the user of this milling system with the
opportunity to form milled patterns like those that are only
possible with a CNC machine. The time-consuming, and thus
expensive, production of individual milling systems is now
unnecessary for the user. If the hobbyist and recreational user is
lacking in the required creativity and milling experience,
particularly in regard to ornamentation of workpieces, then by
using this milling system, he can quickly and easily form elegant
patterns in workpieces.
[0019] An additional advantage over conventional milling systems is
that the user now has the possibility of independently varying the
pattern to be cut. Furthermore, by breaking down the pattern to be
milled into a corresponding number of basic patterns on the milling
system in the form of pattern cutouts 4 in the movable template 3,
the milling of complex and complete patterns is possible. In
addition, due to this breaking down of the subsequent milling
process, any potentially undesirable overcutting during the course
of the milling can be prevented (for example, the letter `B`).
[0020] By means of an appropriate selection of the router bit 17
and of the tracing collar 16, the appearance of the milled pattern
can be varied once again. Insert and recess milling of patterns is
possible simultaneously with this milling system 12. The milling
systems are designed so that an expansion or complementation of
patterns is possible through the use of additional, compatible
movable templates 3 equipped with different pattern cutouts
(example) 4, or through the use of a guide bar 13 which is
adjustable both in the X-direction and the Y-direction.
[0021] Therefore, the task of the invention concerns a versatile,
easy-to-handle, low-cost, and expandable milling system which
avoids the disadvantages of known milling systems.
[0022] A preferred embodiment of the milling system of the
invention and also additional advantageous embodiment examples of
the invention are illustrated in principle in the drawings and will
be described below in greater detail.
[0023] It is a further object of the invention to provide a milling
system for milling patterns into a workpiece. The system comprises
a baseplate having an aperture and a template disposed within the
aperture. The template is positionable in a plurality of
registrated orientations relative to the baseplate, wherein the
baseplate is formed of two separable baseplate parts.
[0024] It is a still further object of the invention to provide a
system for vertically supporting a rotary cutting tool. The system
comprises a base, a plurality of posts extending upwardly from the
base, and a tool support for supporting the rotary tool. The tool
support has a plurality of sleeves, one associated with each of the
posts. The sleeves slidably receiving respective ones of the posts.
The system further includes means for biasing the tool support away
from the base.
[0025] These and other aspects and attributes of the present
invention will be discussed with reference to the following
drawings and accompanying specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1, a perspective view of a preferred embodiment of the
milling system according to the present invention, with fitted,
movable template and guide bar adjustable in the X-direction and
Y-direction;
[0027] FIG. 2, a top view of a preferred embodiment of the milling
system according to the present invention, with examples of pattern
cutouts in the movable template;
[0028] FIGS. 3 to 8, a selection of combination milling patterns
and variants for the use of the sample pattern cutouts according to
FIG. 2 of the milling system according to the present invention,
while still using the guide bar adjustable in the X-direction and
Y-direction according to FIG. 1;
[0029] FIG. 9, a top view of an additional, preferred embodiment of
the milling system according to the present invention, with
additional examples of sample cutouts in the movable template;
[0030] FIGS. 10 to 15, a selection of milling pattern combinations
and variants for the use of the pattern cutout examples according
to FIG. 9 of the milling system according to the present
invention;
[0031] FIG. 16, a top view of an additional embodiment of a milling
system with movable template in a base plate and also an
alternative locking means;
[0032] FIG. 17, a top view of a milling system with movable
template, in which, in turn, one or more movable templates are
installed;
[0033] FIG. 18, a top view of a milling system with movable
template, in which, in turn, one or more rectangular movable
templates are installed, in which, again in turn, a movable
template has been installed;
[0034] FIG. 19, a top view of a rectangular milling system with
movable, rectangular template, in which, in turn, a movable
template has been installed;
[0035] FIG. 20, a top view of a milling system with movable,
rectangular template;
[0036] FIG. 21, a top view of an additional embodiment of a milling
system with movable template in a base plate, and also an
additional, alternative locking means;
[0037] FIG. 22 is a perspective view of a particular embodiment of
a milling system according to the invention;
[0038] FIG. 23 is a perspective view of a baseplate of the milling
system of FIG. 22;
[0039] FIG. 24 is a perspective view of an upper side of a template
of the milling system of FIG. 22;
[0040] FIG. 25 is a perspective view of a lower side of the
template of the milling system of FIG. 22;
[0041] FIG. 25a is a perspective view of a pencil guide in
accordance with the invention;
[0042] FIG. 26 is a perspective view of a system for vertically
supporting a rotary tool in accordance with the invention;
[0043] FIG. 27 is a perspective view of a baseplate of the system
of FIG. 26;
[0044] FIG. 28 is a perspective view of a tool support of the
system of FIG. 26
[0045] FIG. 29 is a perspective view of the tool support of FIG.
28, from its underside;
[0046] FIG. 30 is a perspective view of a guide bushing of the tool
support of FIG. 29; and
[0047] FIG. 31 is a perspective view of a portion of a base of the
tool support of FIG. 29.
DETAILED DESCRIPTION OF THE INVENTION
[0048] While this invention is susceptible of embodiment in many
different forms, there is shown in the drawing, and will be
described herein in detail, specific embodiments thereof with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the invention to the specific embodiments
illustrated.
[0049] The preferred embodiment of the milling system according to
the present invention (FIG. 1) consists of a base plate 2 and also
at least one movable template 3. The base plate can be made from,
e.g., wood, aluminum, hard plastic, hard paper or another
nondeformable material. The thickness of the base plate 2 and also
the given template 3 should be ideally about 2-20 mm, depending on
application. In this regard, both parts should have the same
material thickness. In the preferred embodiment of the milling
system according to the present invention, a cutout 1 has been
formed in the base plate 2 in order to hold the movable template 3.
The movable template 3 in the preferred embodiment of the milling
system according to the present invention is circular, and fits
exactly into the circular cutout of the base plate 2 when inserted.
Alternatively, in an additional embodiment of the milling system
according to the present invention, the movable template 3 can be
formed as a polygon (FIG. 20). Accordingly, the base plate 2 will
then also contain polygonal cutouts. A means for locking the plate
in place (base plate/movable template) 9 is provided. This makes it
possible to lock the movable template 3 for one milling pattern in
a defined position to the base plate 2. Depending on the pattern to
be cut, the movable template 3 is divided into several same sectors
8 of the same size. At least one pattern cutout (example) 4 is
incorporated as a cutout at one precisely defined area of the
movable template 3. The position of the movable template 3 can be
changed after each milling process, by sliding, turning, or
rotating within the base plate 2. The number of the pattern cutouts
(example) 4 depends on the size of the movable template 3 and also
on the complexity of the pattern to be milled. In order to attain
additional versatility in the pattern, an insert 5 can be installed
into a pattern cutout provided therefor.
[0050] The templates, in particular the movable template 3, are
designed so that they are mutually compatible and will complement
each other for the cutting of new patterns. However, this only
applies to templates with the same-size template. In one particular
refinement of the milling systems according to the present
invention, through the use of a guide bar 13 adjustable in the X-
and Y-directions, an expansion of the patterns is possible. On the
base plate 2 of the milling system according to the present
invention, there is a means 10 provided for securing of this guide
bar. The guide bar 13 can be locked in place, for example, by use
of a locking bolt 15. When this locking feature is used, the
locking bolts 15 are inserted into the holes drilled for the
locking unit 14. The distance between the drilled holes for the
locking unit 14 is a defined value, in order to ensure the precise
movement of the milling system in the X- or Y-directions. FIGS.
16-21 show additional, particularly useful possibilities for
embodiments of the milling system according to the present
invention.
[0051] Selection of the pattern to be milled is made by using a
pattern selection sheet included for each milling system. Thus, the
user can obtain information concerning which pattern cutouts
(examples) 4 are needed for forming the desired pattern.
[0052] In the simplest case, the actual milling process proceeds as
follows: in the preferred embodiment of the milling system
according to the present invention, the base plate 2 is placed upon
the workpiece, suitably aligned, and then locked in place by using
threaded clamps, for example. The rotatable template 3 must remain
movable mobile in this case. The size of the tracing collar 16 and
also the router bit 17 to be used are suggested on the router 11
for each pattern. Then, the cutting depth of the router 11 is set.
Next, the router 11 equipped with tracing collar 16 and router bit
17 is guided along the inside edges of the pattern cutouts
(example) 4 belonging to the pattern in the template 3.
[0053] According to the specified cutting pattern, the movable
template 3 is moved into a new position after each milling process
by shifting, turning, sliding or rotating. These steps are then
repeated until the desired pattern has been completely formed. For
cutting particular patterns, often only partial segments of the
pattern cutouts (example) 4 are needed. Based on the pattern
selection sheet, the user will be able to obtain information
indicating which partial segments of the pattern ring of the router
are to be followed. FIG. 2 and FIG. 9 show top views of the
preferred embodiment of the milling system according to the present
invention, with examples of pattern cutouts (examples) 4 in the
movable template 3 and also a small selection (FIGS. 3-8 and FIGS.
10-15) of patterns that can be cut with these templates. In the
milling patterns according to FIGS. 3-8, a guide bar 13 is used in
order to expand the milling pattern in the X- or Y-directions.
[0054] A preferred embodiment of the invention is described
below.
[0055] A milling system 20 for milling patterns into the workpiece
7 is illustrated in FIGS. 22-25. The system 20 comprises a
baseplate 22 having an aperture 24. The system 20 further includes
a template 26 disposed within the aperture 24 and positionable in a
plurality of registrated orientations relative to the baseplate
22.
[0056] Referring to FIG. 23, the baseplate 22 is formed of two
separable, symmetrical baseplate parts 22a. The two baseplate parts
22a each include a tongue 28 on one of the parts 22a and a
cooperative slot 30 in the other of the parts 22a to received the
respective tongue 28, for interconnecting the parts 22a together.
The tongue 28 has a raised detent 28a and the slot includes an
aperture 30a to receive the detent 28a.
[0057] The baseplate 22 includes twenty-four recesses 34, which are
sequentially labeled A, B, C, D. The template 26 includes six
protrusions 36, which locate the template 26 relative to the
baseplate 22.
[0058] The baseplate 22 includes opposing notches 38, and the
template 26 has a center positioning aperture 24b for aligning the
workpiece 7 with the milling system 20. Additionally, the baseplate
aperture 24 has a beveled aperture surface 24a, and the template 26
has a cooperatively beveled outer surface 27.
[0059] The template has a plurality of pattern cut-outs 27. The
template 26 further has an upper surface 26a and a lower surface
26b. The upper surface 26a is flush. The lower surface 26b has
cored out segments 26c to reduce material cost. The baseplate lower
surface 26b is textured.
[0060] In order to view a resulting pattern before milling the
workpiece 7, a pencil guide 40, illustrated in FIG. 25a, is
provided. The pencil guide 40 holds a pencil 41, or other like
writing instrument. With the pencil guide 40 and the pencil 41, one
can trace the pattern on the workpiece 7. The pencil guide 40 has
two diameters, to vary the distance the pencil 41 is spaced from
the walls of the pattern cutout 27, and hence varies the resulting
pattern.
[0061] A preferred embodiment of a system 44 for vertically
supporting a rotary cutting tool 46 is illustrated in FIGS.
26-29.
[0062] The tool support system 44 comprises a transparent base 48
and a three posts 50 extending upwardly from the base 48. The base
has a lower surface 48a having two, generally circular ribs 48a
(FIG. 29), raised approximately 1/20,000 of an inch. The ribs 48a
raise the base away from the template 26, so as to prevent
scratching of the base 48 and maintain its transparency. The
periphery of the base 48 is also beveled, to permit it to smoothly
slide over surface bumps.
[0063] The system 44 further includes a tool support 52 for
supporting the rotary tool 46. The tool support 52 has a plurality
of sleeves 54, one associated with each of the posts 50. Each of
the sleeves 54 includes first and second bushings 55a, 55b. The
sleeves 54 slidably receive respective ones of the posts 50. The
system still further includes two springs 56 disposed in respective
spring sleeves 57 for biasing the tool support 52 away from the
base 48. The springs 56 each have a first end 56a disposed in the
spring sleeve 57 and a second end 56b engaging the base 48.
[0064] The system 44 also includes a gauge 60 having one end 60a
secured to the tool support 52 by a set screw 61 and the other end
60b adapted to engage the base 48 for selectively limiting the
travel of the tool support 52 towards the base 48, which sets the
depth of cut into the workpiece 7. The gauge is graduated, to
display the selected depth of cut.
[0065] The tool support 52 includes a threaded opening 64 to
receive a threaded nose 66 of the rotary tool 46. The tool support
52 also includes a pair of handles 68 for permitting a user to move
the tool support 52 relative to the base 48.
[0066] Referring to FIGS. 30 and 31, the base 48 includes a guide
bushing 70 having a cylindrical nose 70b. The diameter of the
cylindrical nose 70b determines the distance the tool bit is spaced
from the walls of the pattern cutout 27, and hence affects the
pattern milled in the workpiece 7. The diameter of the cylindrical
nose 70b is identified by a molded indicia I (raised or depressed)
on the surface of the guide bushing 70. The guide bushing 70 is
easily removable and includes three tapered lips 72 to receive a
respective one of three lips 74 on the base 48. Each of the bushing
lips 72 includes a recesss 72a to lockingly engage with a
cooperating protrusion 74a on the base lip 74. A wall 75 prevents
over-rotation of the guide bushing 70. Accordingly, the guide
bushing 70 can readily be changed to one having a different nose
70b diameter without the need for special tools. The guide bushing
70 includes large openings 70a for visibility and to permit
grasping to rotate the bushing 70. The guide bushing 70a further
includes indicia 70c indicating the circumferential dimension of
the nose 70b.
[0067] The system 44 also includes a spring loaded release 76 for
locking the tool support 52 in a position a selected distance
relative to the base 48.
[0068] The base 48 further includes a vacuum attachment 78 to
attach a vacuum device (not shown) to remove cuttings through the
large openings 70a in the guide bushing 70.
[0069] From the foregoing, it will be observed that numerous
variations and modifications may be effected without departing from
the spirit and scope of the invention. It is to be understood that
no limitation with respect to the specific apparatus illustrated
herein is intended or should be inferred. It is, of course,
intended to cover by the appended claims all such modifications as
fall within the scope of the claims.
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