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.

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.