WT46  3Wood Processing Safety & PracticeAutumn 2011Lecture Unit 0<br /><ul><li> WT4603: Introduction & Lab 1 Activity
 Lecturer: Mr. Joe Lyster
joseph.lyster@ul.ie
 Department of Design & Manufacturing Technology
 Lecture notes prepared by Mr. Joseph Lyster</li></li></ul><li>Module Outline<br /><ul><li>Lecturer: 			Joseph Lyster
Teaching Assistant: 	Michael Crehan
Technicians:		Joseph Murray</li></ul>					Louise Madden<br />				Richie Hennessy <br /><ul><li>Lab Groups		2A-2B-2C-2D-2E
Courses Involved:
LM094 Materials & Architectural Technology
LM067 Wood Science & Technology
Lecture Times
Monday9-11am in FB-028 (Foundation Building)
Lecture Notes
Available @ www.slideshare.net/WT4603</li></ul>WT4603<br />Department of Design & Manufacturing Technology<br />
WT4603<br />Module Outline<br />The aim of WT4603 is wood processing safety and best practice. This is a core module and a...
Module Assessment<br />WT4603<br /><ul><li>Module Assessment:
35% Laboratory Work:
Table Manufacture 20%
A3 Process Booklet 15%
25% Term Assignments:
Risk Assessments 15%
Information posters 10%
35% Written Exam (Terminal)
5% Lecture Worksheets
Machines Practical Exam (Pass / Fail Basis)
Lab Booklet (Pass / Fail Basis)
Note:
Students must pass allassessment elements to obtain a pass in the module.
Students that fail the practical machines exam will automatically fail the entire module.</li></ul>Department of Design & ...
WT4603<br />Coursework Marking Scheme<br />Department of Design & Manufacturing Technology<br />
WT4603<br />Module Outline<br /><ul><li> Nature of Project work:
Laboratory Work:
Table project
Lab Booklet
Term Assignments:
Risk Assessments
Information Poster
Lecture Work:
Worksheets</li></ul>Department of Design & Manufacturing Technology<br />
WT4603<br />Module Outline – Coursework <br /><ul><li>Table project
Purpose of the table project is to reflect your use of woodworking machinery through wood processing safety and best pract...
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Wt4603 unit 0-week1-05-09-2011

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Wt4603 unit 0-week1-05-09-2011

  1. 1. WT46 3Wood Processing Safety & PracticeAutumn 2011Lecture Unit 0<br /><ul><li> WT4603: Introduction & Lab 1 Activity
  2. 2. Lecturer: Mr. Joe Lyster
  3. 3. joseph.lyster@ul.ie
  4. 4. Department of Design & Manufacturing Technology
  5. 5. Lecture notes prepared by Mr. Joseph Lyster</li></li></ul><li>Module Outline<br /><ul><li>Lecturer: Joseph Lyster
  6. 6. Teaching Assistant: Michael Crehan
  7. 7. Technicians: Joseph Murray</li></ul> Louise Madden<br /> Richie Hennessy <br /><ul><li>Lab Groups 2A-2B-2C-2D-2E
  8. 8. Courses Involved:
  9. 9. LM094 Materials & Architectural Technology
  10. 10. LM067 Wood Science & Technology
  11. 11. Lecture Times
  12. 12. Monday9-11am in FB-028 (Foundation Building)
  13. 13. Lecture Notes
  14. 14. Available @ www.slideshare.net/WT4603</li></ul>WT4603<br />Department of Design & Manufacturing Technology<br />
  15. 15. WT4603<br />Module Outline<br />The aim of WT4603 is wood processing safety and best practice. This is a core module and a requirement for second year teaching practice (TP). <br />Department of Design & Manufacturing Technology<br />
  16. 16. Module Assessment<br />WT4603<br /><ul><li>Module Assessment:
  17. 17. 35% Laboratory Work:
  18. 18. Table Manufacture 20%
  19. 19. A3 Process Booklet 15%
  20. 20. 25% Term Assignments:
  21. 21. Risk Assessments 15%
  22. 22. Information posters 10%
  23. 23. 35% Written Exam (Terminal)
  24. 24. 5% Lecture Worksheets
  25. 25. Machines Practical Exam (Pass / Fail Basis)
  26. 26. Lab Booklet (Pass / Fail Basis)
  27. 27. Note:
  28. 28. Students must pass allassessment elements to obtain a pass in the module.
  29. 29. Students that fail the practical machines exam will automatically fail the entire module.</li></ul>Department of Design & Manufacturing Technology<br />
  30. 30. WT4603<br />Coursework Marking Scheme<br />Department of Design & Manufacturing Technology<br />
  31. 31. WT4603<br />Module Outline<br /><ul><li> Nature of Project work:
  32. 32. Laboratory Work:
  33. 33. Table project
  34. 34. Lab Booklet
  35. 35. Term Assignments:
  36. 36. Risk Assessments
  37. 37. Information Poster
  38. 38. Lecture Work:
  39. 39. Worksheets</li></ul>Department of Design & Manufacturing Technology<br />
  40. 40. WT4603<br />Module Outline – Coursework <br /><ul><li>Table project
  41. 41. Purpose of the table project is to reflect your use of woodworking machinery through wood processing safety and best practice
  42. 42. Project enables you to purposely process material to construct an artefact (table) from a raw plank state in the most efficient and safe manner possible
  43. 43. Use of the surface planer, thicknesser, rip saw, mortiser, bandsaw, panel saw as part of this project
  44. 44. Produce appropriate cutting lists, plans and procedures with the awareness of material processing waste, which is an important element for the sustainable use of material and procurement of bulk raw plank material for class projects
  45. 45. Develop hand skills in preparation for teaching practice by producing a series of hand-crafted joints to construct the table
  46. 46. Develop your awareness of machine safety through risk assessment procedures including aspects such as hazard identification and risk magnitude. This is a critical aspect regarding the safe operation of any second level technology classroom.</li></ul>Department of Design & Manufacturing Technology<br />
  47. 47. WT4603<br />Module Outline – Coursework <br /><ul><li>Table project requirements:</li></ul>Produce fully constructed and finished table<br />Produce an orthographic plan, elevation and end view of table showing component detail. Can be done using hand or CAD/Solidworks<br />Produce a cutting list for components<br />Produce a graphical procedure handbook of project material processing safety & best practice. Templates will be provided for this aspect.<br />Department of Design & Manufacturing Technology<br />
  48. 48. WT4603<br />Module Outline – Coursework <br /><ul><li>Lab book:
  49. 49. The purpose of the lab book is to record your in lab exposure to wood processing safety and best practice.
  50. 50. It is advised that you complete the lab book during your lab time as it intends to capture your initial exposure to using wood processing machinery
  51. 51. You will not be permitted to the lab without your lab book
  52. 52. Lab book can be purchased from snap printing at a cost of €6.</li></ul>Department of Design & Manufacturing Technology<br />
  53. 53. WT4603<br />Module Outline – Coursework <br /><ul><li>Term Assignments:
  54. 54. Risk Assessments
  55. 55. Create an A3 booklet to include the following:
  56. 56. Lab Machines:</li></ul>Risk assessment 1 – Surface planer<br />Risk assessment 2 – Thicknesser<br />Risk assessment 3 – Rip saw<br />Risk assessment 4 – Bandsaw<br />Risk assessment 5 – Mortiser <br />Risk assessment 6 – Pillar Drill<br />Risk assessment 7 – Router <br /><ul><li>You will each be assigned and required to perform 3 risk assessments of staged (hazard induced) machines. This will account for 3 of your 7 individual risk assessments outlined above. In case of staged machines you will be provide with an image and scenario and you will be required to perform your risk assessment based on this information.
  57. 57. Information Poster</li></ul>Create an appropriately designed A2 laminated poster on an assigned machine.<br />Must be accompanied by a user information sheet<br />You must also develop a work activity sheet that addresses machine safety and best practice to reinforce operant knowledge, understanding and safety culture<br />All assigned machine lists, as discussed in both cases above, can be viewed in the lab.<br />Department of Design & Manufacturing Technology<br />
  58. 58. WT4603<br />Module Outline – Coursework <br /><ul><li>Lecture Worksheets:
  59. 59. Each week you will be given an activity sheet to be completed during the lecture.
  60. 60. The aim of the lecture worksheets is to reinforce wood processing safety and best practice.
  61. 61. The worksheet will prepare you in advance of activities taking place in forthcoming labs.
  62. 62. It will provide you with a theoretical understanding of wood processing safety and best practice that will strengthen your knowledge and understanding in preparation for labs.
  63. 63. The worksheets will also involve reflection on the use of machinery in previous labs</li></ul>Department of Design & Manufacturing Technology<br />
  64. 64. Module Outline<br />WT4603<br />Timetable:<br />Department of Design & Manufacturing Technology<br />
  65. 65. Lecture Content – 24hrs<br />WT4603<br />Introduction + Labs W2<br />Machine Provision + Labs W3 <br />Risk Assessment + Labs W4 <br />PPE + Labs 4 W5<br />Planing Machines + Labs W6<br />Circular saws + Labs W7<br />Material Management & Sustainable Use + W8 Labs + (Machines Exam Prep.)<br />Bandsaw + Labs W9 + (Machines Exam Prep.)<br />Morticer +Labs W10<br />Routers + Labs W11<br />Other Machines and Equipment + Labs W12<br />Dust, Noise, Manual Handling<br />Department of Design & Manufacturing Technology<br />
  66. 66. Laboratory Sessions<br />WT4603<br /><ul><li>Permitted entry to timetabled labs only!
  67. 67. Labs will take place in SR2058 & SR2047.
  68. 68. Lab coat and safety glasses are a prerequisite to gaining entry to the lab.
  69. 69. You must have your lab booklet during all labs.
  70. 70. Groups are divided and timetabled
  71. 71. Labs will begin on Week 2
  72. 72. Labs are mandatory – 100% attendance
  73. 73. Absence in the case of illness must be explained with a doctors note.
  74. 74. Other reasons must be explained to the lecture/TA.</li></ul>Department of Design & Manufacturing Technology<br />
  75. 75. WT4603<br />Laboratory Sessions<br /><ul><li>2 X 2 Hours per Week (Week 2 --- Week 13 incl.)
  76. 76. Labs begin on the hour and finish at 10 minutes before the hour, e.g. 9:00am to 10:50am
  77. 77. Late arrivals will not be permitted to join the lab session.
  78. 78. Lab Rules and Requirements:
  79. 79. Report for lab on time
  80. 80. White lab coat
  81. 81. Safety glasses
  82. 82. Students must sign the attendance sheet
  83. 83. Students will be assigned a work bench
  84. 84. I.D. cards to be submitted to T.A. for locker keys
  85. 85. Students must follow instructions of T.A.
  86. 86. Students under the influence of alcohol will not be permitted.</li></ul>Department of Design & Manufacturing Technology<br />
  87. 87. Laboratory Sessions<br />WT4603<br /><ul><li>House Keeping
  88. 88. Students have a responsibility for the care of the tools in their locker
  89. 89. At thee beginning and end of the lab students must:
  90. 90. Check tools list and condition
  91. 91. Report to T.A. if any tools are missing
  92. 92. Report to T.A. if tools are damaged
  93. 93. At the end of each lab session:
  94. 94. Benches must be brushed down
  95. 95. Bench hooks returned to the underneath of each bench.
  96. 96. Vices must be in the closed position.
  97. 97. The floor area is swept and/or all waste material is removed from the ground area.
  98. 98. Wood waste and paper waste to be segregated.
  99. 99. If stools are used during a lab session, they must be removed from the floor and placed on top of the bench.
  100. 100. I.D. cards will only be returned to students when they have complied with these regulations.</li></ul>Department of Design & Manufacturing Technology<br />
  101. 101. Health & Safety<br /><ul><li>Lab coats must be worn at all times in the workshop.
  102. 102. Safety glasses must be worn at the appropriate times as laid out by the T.A. in charge.
  103. 103. Students must report damage to tools and equipment to the T.A. in charge.
  104. 104. Students must immediately report any personal injury (nicks, cuts etc.) to the T.A. in charge.
  105. 105. Failure to comply with safety regulations will result in removal from the lab session.
  106. 106. Any malicious damage to University property or equipment will result in removal from the lab and University disciplinary procedures will be put in place.</li></ul>WT4603<br />Department of Design & Manufacturing Technology<br />
  107. 107. Lab Requirements – Week 2 <br /><ul><li>Students must present at labs on Week 2 with the items requested on the 2nd Year Tools List, namely:
  108. 108. 2B Pencil
  109. 109. Max 3M Measuring Tape
  110. 110. 150mm Steel Rule
  111. 111. Masking Tape
  112. 112. Lab Book (Available from Snap Printing on 07/09/2011 (Wednesday))
  113. 113. Failure to present this equipment at the beginning of the lab will result in you not being able to participate in the lab
  114. 114. You must bring all equipment & PPE to all labs</li></ul>WT4603<br />Department of Design & Manufacturing Technology<br />
  115. 115. WT4603<br />Department of Design & Manufacturing Technology<br />
  116. 116. WT4603<br />WT4603<br />Department of Design & Manufacturing Technology<br />
  117. 117. WT4603<br />Week2: Lab 1 & 2<br />Table<br />Department of Design & Manufacturing Technology<br />
  118. 118. WT4603<br />Week 2: Lab 1 & 2<br /> Machine Exposure:<br />Surface Planer<br />Planer Thicknesser<br />Bandsaw<br />Material Process – Component A:<br />Each student will receive an unprocessed plank of red deal measuring 750 x 245 x 50 (mm)<br />Aim of week 2 labs is to square the material to a clean workable condition of required dimension. <br />242<br />740<br />Department of Design & Manufacturing Technology<br />
  119. 119. WT4603<br />Surface Planer<br />Department of Design & Manufacturing Technology<br />
  120. 120. WT4603<br />1<br />9<br />8<br />2<br />7<br />3<br />4<br />6<br />5<br />Surface Planer<br />10<br />11<br />12<br />Department of Design & Manufacturing Technology<br />
  121. 121. WT4603<br />Step 1:<br />Isolate machine<br />Out feed Table<br />Step 2: Squaring guide fence<br /><ul><li>Set up surface planer guide fence @ 90⁰ to table surface
  122. 122. Note infeed and outfeed table.
  123. 123. Square to infeed using right angle square.
  124. 124. Use red lock handles to open and adjust fence.
  125. 125. Lock gently when fence is perpendicular to infeed table.</li></ul>Infeed Table<br />Department of Design & Manufacturing Technology<br />
  126. 126. WT4603<br />Infeed<br />Infeed<br />Step 3: Setting infeed dept<br /><ul><li>This machine is calibrated in metric.
  127. 127. Maximum recommended material removal is 1-2mm/pass
  128. 128. Dept stop to be set at 2mm
  129. 129. Open infeed lock handle
  130. 130. Turn wheel to left to drop table to 2mm
  131. 131. Lower you drop, the more the planer cutting block is exposed
  132. 132. Close infeed lock handle when required dept is achieved.
  133. 133. * Do not adjust outfeed table level, this is for maintenance purposes only*</li></ul>Department of Design & Manufacturing Technology<br />
  134. 134. WT4603<br />242 + 10<br />Step 4: Setting the guide fence width<br /><ul><li>Minimum blade exposure
  135. 135. Width of material + 10mm is recommended
  136. 136. This results in 10mm blade exposure - Safety
  137. 137. Adjust lock handle to wind in or out guide fence
  138. 138. Lock in appropriate position</li></ul>242 + 10<br />Department of Design & Manufacturing Technology<br />
  139. 139. WT4603<br />Step 5: Guard adjustment<br /><ul><li>Guard set for face side = handle up – 10mm blade exposure
  140. 140. Guard set for face edge = handle flat – no blade exposure</li></ul>Department of Design & Manufacturing Technology<br />
  141. 141. WT4603<br />Step 6: Material Inspection<br /><ul><li>Inspect material for the following defects
  142. 142. Cupping
  143. 143. Bowing
  144. 144. Twist
  145. 145. Knots
  146. 146. Loose grain
  147. 147. Example - if material is bowed, set the bowed face to the surface planer table surface and process. Material should never be run through hump side down.</li></ul>Department of Design & Manufacturing Technology<br />
  148. 148. WT4603<br />Step 7: Determining face side and face edge<br /><ul><li>Use machine surface to check square
  149. 149. Select appropriate face side and face edge based on inspection
  150. 150. Preliminary surface marking using an ‘X’ with no less than a HB pencil
  151. 151. Ensure extraction gate valve is open and extraction is on
  152. 152. Proceed to plane material – face side and face edge only!</li></ul>Gate Valve locate on extractor pipe just above surface planer<br />X<br />X<br />Department of Design & Manufacturing Technology<br />
  153. 153. WT4603<br />Step 8: Planing face side<br /><ul><li>Material position
  154. 154. Hand positions</li></ul>Dept of Hand<br />Dept of Hand<br />Ensure Guard Guide is in a vertical position to plane face side<br />Department of Design & Manufacturing Technology<br />
  155. 155. WT4603<br />Department of Design & Manufacturing Technology<br />
  156. 156. WT4603<br />Note Hand Positions in relation to material<br />Department of Design & Manufacturing Technology<br />
  157. 157. WT4603<br />Step 9: Planing face edge<br /><ul><li>Material position
  158. 158. Hand position</li></ul>Dept of Hand<br />Dept of Hand<br />Ensure Guard Guide is in a horizontal position to plane face edge<br />Department of Design & Manufacturing Technology<br />
  159. 159. WT4603<br />Note Hand Positions in relation to material<br />Split second blade Exposure<br />Blade guard flat onto table<br />Department of Design & Manufacturing Technology<br />
  160. 160. WT4603<br />Thicknesser<br />Department of Design & Manufacturing Technology<br />
  161. 161. WT4603<br />1<br />2<br />3<br />4<br />Thicknesser<br />Department of Design & Manufacturing Technology<br />
  162. 162. WT4603<br />Lab sequence – Thicknesser<br />Step 1:<br />Unlock twist release stop mechanism<br />Press green button to start<br />Allow machine to build up, this can be determined by noise consistency<br />When noise is consistent flip delta switch to on position<br />Feed rate, i.e. Speed at which material is passed, is set.<br />Adjust table height as required<br />Feed material as directed<br />Delta Switch<br />Stop/Start<br />Twist Release Stop<br />Display Panel<br />Thicknesser Bed Adjustment Control<br />Feed Rate Control<br />Department of Design & Manufacturing Technology<br />
  163. 163. WT4603<br />Bandsaw<br />Department of Design & Manufacturing Technology<br />
  164. 164. WT4603<br />The bandsaw<br />Department of Design & Manufacturing Technology<br />
  165. 165. See you all next week!<br />Next week:<br />Machine Provision<br />Risk assessment<br />Week 3 ripsaw labs<br />WT4603<br />Department of Design & Manufacturing Technology<br />
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