Wt4603 lab book2010

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WT4603 Wood Processing Safety and Practice Laboratory Work Book.

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Wt4603 lab book2010

  1. 1. Department of Manufacturing & Operations Engineering (M&OE) WT4603: Wood Processing Safety and Practice Autumn Semester 2010 Lecturer: Mr. Joseph Lyster Teaching Assistant: Mr. Michael Crehan Technician: Mrs. Louise Madden Technician: Mr. Joseph Murray Document prepared by Mr. Des Kelly and Mr. Donal Canty
  2. 2. NAME: . Contents 1. GENERAL WORKSHOP SAFETY RULES: .................................................................................................................................. 5 2. HAZARD IDENTIFICATION & RISK ASSESSMENT .................................................................................................................. 6 2.1. IMPORTANT TERMS: ........................................................................................................................................................ 6 2.2. RISK MAGNITUDE ........................................................................................................................................................... 7 3. QUESTIONS ................................................................................................................................................................................. 8 4. PILLAR DRILL ............................................................................................................................................................................. 13 4.1. INTRODUCTION ............................................................................................................................................................ 15 4.2. PARTS OF THE PILLAR DRILL .......................................................................................................................................... 16 4.3. PILLAR DRILL HAZARD IDENTIFICATION & RISK ASSESSMENT .......................................................................................... 18 5. MORTISE MACHINE (HOLLOW CHISEL TYPE)..................................................................................................................... 19 5.1. INTRODUCTION ........................................................................................................................................................... 20 5.2. PARTS OF THE MORTISER: ........................................................................................................................................... 21 5.3. MORTISING MACHINE HAZARD IDENTIFICATION & RISK ASSESSMENT ............................................................................ 24 5.4. MORTISING MACHINE PRACTICE ................................................................................................................................. 25 6. BANDSAW................................................................................................................................................................................. 26 6.1. INTRODUCTION ............................................................................................................................................................ 27 6.2. PARTS OF THE BANDSAW.............................................................................................................................................. 28 6.3. BANDSAW HAZARD IDENTIFICATION & RISK ASSESSMENT ............................................................................................. 33 7. SURFACE PLANER (300MM) .................................................................................................................................................. 35 7.1. INTRODUCTION ............................................................................................................................................................ 36 7.2. PARTS OF THE SURFACE PLANER ................................................................................................................................... 37 7.3. SURFACE PLANER HAZARD IDENTIFICATION & RISK ASSESSMENT .................................................................................. 40 8. THICKNESSER (630MM) .......................................................................................................................................................... 41 8.1. INTRODUCTION ............................................................................................................................................................ 42 8.2. PARTS OF THE THICKNESSER ....................................................................................................................................... 43 8.3. THICKNESSER HAZARD IDENTIFICATION & RISK ASSESSMENT ......................................................................................... 46 9. RIP SAW (Ø450MM BLADE)................................................................................................................................................... 47 9.1. INTRODUCTION ............................................................................................................................................................ 48 9.2. PARTS OF THE RIP SAW................................................................................................................................................. 49 9.3. RIP SAW HAZARD IDENTIFICATION & RISK ASSESSMENT ................................................................................................ 53 10. PORTABLE ROUTER .................................................................................................................................................................. 55 10.1. INTRODUCTION ............................................................................................................................................................ 56 10.2. PARTS OF THE PORTABLE ROUTER .............................................................................................................................. 57 10.3. ROUTER CUTTER ROTATION AND FEED DIRECTION .................................................................................................... 58 10.4. PORTABLE ROUTER HAZARD IDENTIFICATION & RISK ASSESSMENT ................................................................................ 65 _________________________________ 3 _________________________________
  3. 3. NOTES _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________ 4 _________________________________
  4. 4. 1. General Workshop Safety Procedures: a) Always wear a suitable lab coat. b) Use hearing protection when appropriate. c) Use eye protection when using machinery. d) Use the correct respiratory protection & make sure that the dust extraction to the specific machine you are using is switched on. e) Operate machinery only if you have been properly instructed on how to do so. f) Report any defects on the machine, safety device or guard to the T.A./Technician in charge. g) Properly position guards. h) Use relevant jigs, stops, guides and fences, etc. only as instructed. i) Use the most suitable machinery for the task. j) Ensure machinery cutting components are kept sharp, secure and correctly balanced. k) Remove jewellery and restrain long hair before using machinery. l) Set all adjustable guards to their lowest position after you have used the machine. m) Clean down all equipment after use n) Make sure you understand the inherent hazards and risks associated with a piece of machinery before attempting to use. o) Never switch on or operate machinery at low temperatures. p) Never adjust machinery or guards while the machine is running. q) Never remove off-cuts or chips from machine tables with your hands while the machine is running. r) Never start up a machine unless you are wearing all required personal protective equipment. s) Never switch on a machine if any safety device or guard is missing, damaged or incorrectly adjusted. _________________________________ 5 _________________________________
  5. 5. 2. Hazard Identification & Risk Assessment 2.1. Important Terms: A Hazard is any substance, article, material or practice that has the potential to cause harm to the safety, health and welfare of employees or others in the workplace. EXAMPLES OF HAZARDS  Slip/Trip/Fall  Lifting & Manual Handling  Falling Objects  Hand/Power tools  Electricity  Explosions  Fire  Hazardous Substances  Heat & Cold  Fall From Height  Chemicals  Flying Objects  Noise  Vibration  Compressed Air Risk is the likelihood or potential of a hazard to cause harm. Risk Assessment is the process of examining a particular hazard and evaluating any existing control measures in an attempt to determine the actual threat posed by the hazard. Its purpose is to determine if the risk control measures in place are sufficient (reasonably practicable) or if further control measures are required. Hierarchy of Risk Control A. Eliminate the Hazard Completely. MOST FAVOURABLE SOLUTION B. Substitute Hazard with a safer alternative. C. Isolate the Hazard. D. Use engineering controls to reduce risk at the source (Guarding). E. Provide training on how to avoid risks. & if all that fails… F. Use PPE. LEAST FAVOURABLE SOLUTION _________________________________ 6 _________________________________
  6. 6. 2.2. Risk Magnitude “An estimate of the likelihood of a certain risk of injury or loss actually occurring combined with an assessment of the injury or loss caused” Risk Magnitude = Likelihood x Severity LIKELIHOOD OF OCCURRENCE SEVERITY Highly Slightly Minor cuts, bruises, burns “Practically impossible” Unlikely Harmful etc. Quite Moderately Minor burns, sprains, “Conceivable but very unlikely” Unlikely Harmful fractures, etc Quite Serious burns, major Likely “Conceivable & likely” Harmful fractures, etc. Quite Very “Probably will happen” Breaks, deafness, etc Likely Harmful Highly Extremely Death, amputations, “Almost certain to happen” Likely Harmful cancer Risk Magnitude Matrix: SEVERITY Slightly Moderately Quite Very Extremely Harmful Harmful Harmful Harmful Harmful Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate LIKELIHOOD Quite Unlikely Tolerable Tolerable Moderate Moderate Substantial Likely Tolerable Moderate Moderate Substantial Substantial Quite Likely Moderate Moderate Substantial Substantial Intolerable Highly Likely Moderate Substantial Substantial Intolerable Intolerable _________________________________ 7 _________________________________
  7. 7. 3. Questions What is the main piece of Irish health and safety legislation? _____________________________________________________________________________________ _____________________________________________________________________________________ What British Standard document is considered to be most relevant when attempting to manage health & safety in technologies education classrooms at second level? _____________________________________________________________________________________ _____________________________________________________________________________________ List the 6 steps of health and safety management using the diagram below: 1 ____________ __________ 2 ____________ __________ 6 ____________ __________ CONTINUOUS IMPROVEMENT 3 ____________ __________ 5 ____________ __________ 4 ____________ __________ List the 3 main reasons for managing health and safety: 1) __________________________________ 2) __________________________________ 3) __________________________________ Explain the following two terms: Pro-active monitoring Re-active monitoring ________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________ _________________________________ 8 _________________________________
  8. 8. “The purpose of a safety audit is……” _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Explain what CE markings are: ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ List the PPE used to protect the following body parts Eyes ______________________ Body __________________________ Hearing ______________________ Face __________________________ What can a teacher do to encourage pupils to wear PPE? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ What is a carcinogenic material? (Give an example) _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ What is tinnitus and how is it caused? _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ ____ Describe the term “reasonably practicable” in your own words: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ What is the purpose of preparing a safety statement? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ What is an “ancillary” safety statement as applied to technologies education at second level? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________ 9 _________________________________
  9. 9. List at least 7 things to be included in a typical safety statement: 1) ________________________________________________________________________________ 2) ________________________________________________________________________________ 3) ________________________________________________________________________________ 4) ________________________________________________________________________________ 5) ________________________________________________________________________________ 6) ________________________________________________________________________________ 7) ________________________________________________________________________________ What is the purpose of a safety representative? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ What is a “doubly insulated” power tool? ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ What is the piece of equipment shown? _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ ___ What is its function and importance in terms of health and safety? _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _____ List 5 situations when power to machinery and equipment should be locked/isolated? 1_____________________________________________________________ 2_____________________________________________________________ 3_____________________________________________________________ 4_____________________________________________________________ 5_____________________________________________________________ _________________________________ 10 _________________________________
  10. 10. What is an exclusion zone? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________________________________________ Describe & differentiate between the following types of guarding: (i) Fixed _________________________________________________ _________________________________________________ (ii) Self-adjusting _________________________________________________ _________________________________________________ (iii) Interlocked _________________________________________________ _________________________________________________ (iv) Distance _________________________________________________ _________________________________________________ (v) Adjustable What type of guarding is shown _________________________________________________ on the machine above? _________________________________ _________________________________________________ Why is it important to include machinery in a system of preventative maintenance? _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ ____________________________________________________________ What are the reasons for keeping records of machinery and equipment maintenance? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Describe the difference between the following 2 terms: Emergency stop _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________ Power Isolation _________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________ 11 _________________________________
  11. 11. NOTES _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________ 12 _________________________________
  12. 12. ___________________ A closer look at some common classroom machinery ____________________ 4. Pillar Drill _________________________________ 13 _________________________________
  13. 13. _________________________________ 14 _________________________________
  14. 14. 4.1. Introduction A pillar drill is a sturdy drilling machine which is usually securely fixed to the floor or worktop. It consists of a sturdy base, a rising column, and a head which houses the motor and drive mechanisms. A pillar drill is usually fitted with an adjustable table for holding work securely in place during processing. This allows for much greater precision and accuracy than when drilling with most hand held drills. During the lab demonstration particular attention should be paid to: 1. Setting-up 2. Appropriate use of personal protective equipment 3. Inspect machine before use 4. Degree of concentration and responsible behavior required. 5. Power isolation & Emergency Stop 6. Clamping workpieces 7. Fitting of drill bits 8. Drive speed selection 9. Setting chuck guard 10. Depth stop settings 11. Safe drilling procedures 12. Adjusting worktable height 13. Machine location Personal Protective Equipment EYE PROTECTION HEARING PROTECTION LAB COAT Mandatory Mandatory Mandatory _________________________________ 15 _________________________________
  15. 15. 4.2. Parts of the Pillar Drill Identify the parts of the Mortising Machine as indicated below: 1 9 8 2 3 4 7 6 5 1____________________ 2____________________ 3____________________ 4 ____________________ 5 ____________________ 6 ____________________ 7 ____________________ 8 ____________________ 9 ____________________ _________________________________ 16 _________________________________
  16. 16. What is the function of the Pillar Drill? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Why is it important to fix the pillar drill securely to the floor or worktop? _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ What precautions must be taken when drilling into a narrow or slender piece? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ List the steps taken when changing a bit in the pillar drill: 1. ___________________________________ 2. ___________________________________ 3. ___________________________________ 4. ___________________________________ 5. ___________________________________ 6. ___________________________________ 7. ___________________________________ What steps can be taken to prevent hair and clothes becoming entangled in the rotating parts of the pillar drill? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________ 17 _________________________________
  17. 17. 4.3. Pillar Drill Hazard Identification & Risk Assessment LOCATION: ___________________ ASSESSMENT CARRIED OUT BY: ______________________ DATE: ________________ PAGE ____ OF ____ ASSESSMENT REVIEW DATE: _______________ RISK PERSONS EXISTING REQUIRED PERSON TARGET HAZARD MAGNITUDE AT RISK CONTROLS CONTROLS RESPONSIBLE DATE
  18. 18. 5. Mortise Machine (Hollow Chisel Type)
  19. 19. 5.1. Introduction The mortising machine is made up of a hollow square chisel with a rotating auger fitted inside it. Both are fixed to the head of the machine which houses the motor and which can be raised and lowered into the workpiece as required. The workpiece is held on a special table which allows it to be moved in line with the mortising machine head and attachments as they are lowered. During the lab demonstration particular attention should be paid to: 1. Setting-up 2. Appropriate use of personal protective equipment. 3. Holding workpiece 4. Inspect machine before use 5. Power Isolation & Emergency Stop 6. Degree of concentration and responsible behavior required. 7. Setting auger and chisel 8. Chisel escape window direction 9. Relationship between auger & chisel 10. Setting depth stop 11. Adjusting the table 12. Correct Mortising Procedures 13. Processing long stock 14. Mortising at an angle Personal Protective Equipment EYE PROTECTION HEARING PROTECTION LAB COAT Mandatory Mandatory Mandatory _________________________________ 20 _________________________________
  20. 20. 5.2. Parts of the mortiser: Identify the parts of the Mortising Machine as indicated below: 1 10 2 3 9 4 8 5 6 7 1____________________ 2____________________ 2 3____________________ 4 ____________________ 5 ____________________ 6 ____________________ 7 ____________________ 8 ____________________ 9 ____________________ 3 10____________________ _________________________________ 21 _________________________________
  21. 21. What is the function of the hollow chisel mortise machine? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ What is the function of (i) the auger & (ii) the chisel (i) _______________________________________________________ _______________________________________________________ _______________________________________________________ (ii) _______________________________________________________ _______________________________________________________ _______________________________________________________ Why is there a need for clearance between the chisel and the auger? How is this clearance created? ____________________________________________ CHISEL ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ AUGER ____________________________________________ ____________________________________________ CLEARANCE Why should long stock be supported using support rollers if it extends beyond the length of the table? _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________ 22 _________________________________
  22. 22. The diagram below shows the outline of a mortise to be removed. Number each section in the order which they will be removed. MORTISE ESCAPE CHISEL WINDOW Explain the reason for this order: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Some mortises are removed at an angle to the face-side or face-edge (as shown below). What extra device is required to process this mortise? _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________ 23 _________________________________
  23. 23. 5.3. Mortising machine Hazard Identification & Risk Assessment LOCATION: ___________________ ASSESSMENT CARRIED OUT BY: ______________________ DATE: ________________ PAGE ____ OF ____ ASSESSMENT REVIEW DATE: _______________ RISK PERSONS EXISTING REQUIRED PERSON TARGET HAZARD MAGNITUDE AT RISK CONTROLS CONTROLS RESPONSIBLE DATE
  24. 24. 5.4. Mortising Machine practice PROCEDURE 1. _________________________________________ 2. _________________________________________ 3. _________________________________________ 4. _________________________________________ 5. _________________________________________ 6. _________________________________________ 7. _________________________________________ 8. _________________________________________ _________________________________ 25 _________________________________
  25. 25. 6. Bandsaw _________________________________ 26 _________________________________
  26. 26. 6.1. Introduction The bandsaw uses a flexible metal blade fixed in a loop which is driven between 2 wheels. This blade is guarded at all points but the cutting zone. At this point there is a level table to support workpieces as they are being cut. During the lab demonstration particular attention should be paid to: 1. Setting up procedures 2. Appropriate use of personal protective equipment 3. Dust Extraction 4. Inspect machine before use 5. Degree of concentration and responsible behavior required 6. Power Isolation & Emergency Stop 7. Thrust guide assembly settings 8. Tension and tracking settings 9. Lighting levels 10.Correct setting of telescopic guard 11.Changing the blade 12.Processing material 13.Relief cuts 14.Push sticks 15.Table slot insert 16.Removing waste from work table Personal Protective Equipment EYE PROTECTION HEARING PROTECTION LAB COAT Mandatory Mandatory Mandatory _________________________________ 27 _________________________________
  27. 27. 6.2. Parts of the Bandsaw Identify the parts of the bandsaw as indicated below: 5 1 6 2 7 3 8 4 9 1. ____________________ 2. ____________________ 3. ____________________ 4. ____________________ 5. ____________________ 11 6. ____________________ 12 7. ____________________ 13 8. ____________________ 9. ____________________ 10. ____________________ 14 11. ____________________ 12. ____________________ 13. ____________________ 9 14. ____________________ 10 _________________________________ 28 _________________________________
  28. 28. 15 19 16 17 18 _________________________________ 29 _________________________________
  29. 29. 15. ______________________ 16. ______________________ 17 17. ______________________ 18. ______________________ 19. ______________________ What is the function of the bandsaw? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Explain the following terms: (i) Blade tension _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ (ii) Blade tracking _____________________________________________________________________________________- _____________________________________________________________________________________ _____________________________________________________________________________________ (iii) Relief cut _____________________________________________________________________________________- _____________________________________________________________________________________ Why should care be taken when withdrawing the workpiece while the machine is still in operation? _________________________________ 30 _________________________________
  30. 30. _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Why should the tension on the blade be released when not in use over a long period of time? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _________________________________ 31 _________________________________
  31. 31. What is the function of the thrust/guide assembly? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Examine the two photographs shown below and identify the main problem created when cutting material as shown in Figure 1 below.: Figure 1. Figure 2. Problems: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ List the steps required to remove the blade from a bandsaw. 1______________________________________ 2______________________________________ 3______________________________________ 4______________________________________ 5______________________________________ _________________________________ 32 _________________________________
  32. 32. 6.3. Bandsaw Hazard Identification & Risk Assessment LOCATION: ________________________ ASSESSMENT CARRIED OUT BY: __________________________ DATE: _________________ PAGE ____ OF ____ ASSESSMENT REVIEW DATE: _______________ RISK PERSONS EXISTING REQUIRED PERSON TARGET HAZARD MAGNITUDE AT RISK CONTROLS CONTROLS RESPONSIBLE DATE
  33. 33. NOTES ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ _________________________________ 34 _________________________________
  34. 34. 7. Surface Planer (300mm) _________________________________ 35 _________________________________
  35. 35. 7.1. Introduction The surface planer has a sturdy base with a level table fitted on top along which wood can be passed. In line with this table is a cutter block which rotates at high speed, surfacing the face of the wood as it passes. The surface planer is considered to be a high risk piece of machinery. During the lab demonstration particular attention should be paid to: 1. Setting-up 2. Appropriate use of personal protective equipment 3. Degree of concentration and responsible behavior required 4. Inspect machine before use 5. Power Isolation & Emergency Stop 6. Bridge guard and fence setting 7. Push sticks 8. Dust extraction 9. Minimum length of material to be planed 10. Planing long stock 11. Arms and body position when planning 12. In-feed and out-feed table settings Personal Protective Equipment EYE PROTECTION HEARING PROTECTION LAB COAT Mandatory Mandatory Mandatory _________________________________ 36 _________________________________
  36. 36. 7.2. Parts of the Surface Planer Identify the parts of the bandsaw as indicated below: 1____________________ 2____________________ 3____________________ 4 ____________________ 10 5 ____________________ 6 ____________________ 7 ____________________ 11 8 ____________________ 9 ____________________ 10 ___________________ 11 ___________________ _________________________________ 37 _________________________________
  37. 37. What is the primary function of the surface planing machine? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ State which photograph shows the initial position of the guard for planing: (a) face-side & (b) face-edge a) ______________________________ b) __________________________________ Which side (Face side or face edge) should you plane first and why? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ What precautions must be taken when surfacing long lengths of material? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ _________________________________ 38 _________________________________
  38. 38. State which of the following push blocks are used for planing (a) “face-edge and (b) face-side. _____________________________________ ______________________________________ Indicate using arrows where the hand pressure is applied when surfacing the piece of material shown: (Guarding not shown for clarity only) S Stage 1 Stage 2 Stage 3 _________________________________ 39 _________________________________
  39. 39. 7.3. Surface Planer Hazard Identification & Risk Assessment LOCATION: _______________________ ASSESSMENT CARRIED OUT BY: __________________________ DATE: ________________ PAGE ____ OF ____ ASSESSMENT REVIEW DATE: _______________ RISK PERSONS EXISTING REQUIRED PERSON TARGET HAZARD MAGNITUDE AT RISK CONTROLS CONTROLS RESPONSIBLE DATE
  40. 40. 8. Thicknesser (630mm) _________________________________ 41 _________________________________
  41. 41. 8.1. Introduction The thicknesser is similar to the surface planer in that it uses a rotating cutter block fitted with extremely sharp knives to surface faces of wood passing through the machine. The thicknesser uses a flat face created on the surface planer as a reference and reduces a piece of wood to required thicknesses parallel to this face. During the lab demonstration particular attention should be paid to: 1. Setting-up 2. Appropriate use of personal protective equipment 3. Inspect machine before use 4. Degree of concentration and responsible behavior required 5. Power isolation & Emergency Stop 6. Dust Extraction 7. Infeed, outfeed & antifriction rollers 8. Grain direction & positioning of material fed through machine 9. Processing long and short material 10. Push sticks 11. Setting/changing of knives Personal Protective Equipment EYE PROTECTION HEARING PROTECTION LAB COAT Mandatory Mandatory Mandatory _________________________________ 42 _________________________________
  42. 42. 8.2. Parts of the Thicknesser Name the parts of the Planing Machine (Thicknesser) as indicated above: 1 2 3 4 1. ____________________ 5. ____________________ 9. ____________________ 2. ____________________ 6. ____________________ 10. ___________________ 3. ____________________ 7. ____________________ 11. ___________________ 4. ____________________ 8. ____________________ 11 10 9 9 8 5 6 7 _________________________________ 43 _________________________________
  43. 43. 4 1 3 2 5 6 7 10 9 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Sketch the location of the anti kickback teeth on the above drawing What is the function of the thicknesser? __________________________________________________________________________________ __________________________________________________________________________________ What processing should be carried out to the workpiece before using the thicknesser? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ _________________________________ 44 _________________________________
  44. 44. Which face of the workpiece should rest on the table of the machine? Explain. __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ Why is it inadvisable to thickness thin material to depth on this machine (as shown in diagram below)? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ What is the purpose of the chip breaker? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ What is the function of the pressure bar? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ _________________________________ 45 _________________________________
  45. 45. 8.3. Thicknesser Hazard Identification & Risk Assessment LOCATION: ___________________________ ASSESSMENT CARRIED OUT BY: _________________________ DATE: ________________ PAGE ____ OF ____ ASSESSMENT REVIEW DATE: _______________ RISK PERSONS EXISTING REQUIRED PERSON TARGET HAZARD MAGNITUDE AT RISK CONTROLS CONTROLS RESPONSIBLE DATE
  46. 46. 9. Rip Saw (Ø450mm blade) _________________________________ 47 _________________________________
  47. 47. 9.1. Introduction The rip saw uses a motor driven saw blade projecting above a sturdy table with specially designed teeth to rip planks of wood along and across the grain. During the lab demonstration particular attention should be paid to: 1. Setting-up 2. Appropriate use of protective equipment 3. Inspecting machine before starting 4. Degree of concentration and responsible behavior required 5. Power isolation & Emergency Stops 6. Push sticks 7. Saw blade selection 8. Processing long & short material 9. Crown guard setting and use 10. Setting Fence 11. Sliding Table 12. Adjusting blade height and angle 13. Position of operator when starting the machine 14. Changing blades Personal Protective Equipment EYE PROTECTION HEARING PROTECTION LAB COAT Mandatory Mandatory Mandatory _________________________________ 48 _________________________________
  48. 48. 9.2. Parts of the Rip Saw 8 7 1 2 6 5 3 4 Name the parts of the Rip Saw as indicated: 1____________________ 4 6 2____________________ 3____________________ 5 4 ____________________ 5 ____________________ 6 ____________________ 7 ____________________ 8 8 ____________________ 9 ____________________ 9 10 ___________________ 10 _________________________________ 49 _________________________________
  49. 49. What is the function of the rip saw? __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ What is the function of the following? (i) Riving Knife __________________________________________________________________________________ __________________________________________________________________________________ (ii) Crown Guard/Overhead Guard __________________________________________________________________________________ __________________________________________________________________________________ What is the function of the tables as shown in the photograph below? OUTFEED TABLE SLILDING TABLE Sliding Table: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ Out feed Table: __________________________________________________________________________________ _________________________________ 50 _________________________________
  50. 50. __________________________________________________________________________________ __________________________________________________________________________________ Which of the following photographs show the correct positioning of the rip fence for (A) cross cutting, (B) ripping and (C) trenching material? (Tick the correct box) guarding removed for clarity only Fig. 1 Cross Cut Rip Groove Fig. 2 Cross Cut Rip Groove Fig. 3 Cross Cut Rip Groove _________________________________ 51 _________________________________
  51. 51. What may happen if the rip fence is set incorrectly: __________________________________________________________________________________ ______________________________________________________________________________ A push stick must be used on material less then _____mm long and on the last _____mm of long material What is the minimum length of timber to be processed while (i) Ripping material to width __________ mm (ii) Cross cutting material to length __________ mm What precautions must be taken before removing the saw blade? 1. ____________________________________________________________________________ 2. ____________________________________________________________________________ List the stages when removing a blade from the bench saw: 1. ____________________________________________________________________________ 2. ____________________________________________________________________________ 3. ____________________________________________________________________________ 4. ____________________________________________________________________________ 5. ____________________________________________________________________________ 6. ____________________________________________________________________________ Indicate (with an arrow) the direction that the spanner needs to be rotated in order to loosen the nut and remove the blade? _________________________________ 52 _________________________________
  52. 52. 9.3. Rip Saw Hazard Identification & Risk Assessment LOCATION: _________________________ ASSESSMENT CARRIED OUT BY: __________________________ DATE: ________________ PAGE ____ OF ____ ASSESSMENT REVIEW DATE: _______________ RISK PERSONS EXISTING REQUIRED PERSON TARGET HAZARD MAGNITUDE AT RISK CONTROLS CONTROLS RESPONSIBLE DATE
  53. 53. NOTES ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ _________________________________ 54 _________________________________
  54. 54. 10. Portable Router _________________________________ 55 _________________________________
  55. 55. 10.1. Introduction The router is a hand held tool used for a variety of moulding and trenching processes. The body of the router houses a motor which rotates specially designed cutters at high speeds. The motor is fixed to a flat base and is fixed with a mechanism to allow the cutter to be plunged down vertically into the workpiece. The router is a high risk power tool. During the lab demonstration particular attention should be paid to: 1. Setting-up 2. Appropriate use of personal protective equipment 3. Inspect tool before use 4. Degree of concentration and responsible behavior required 5. Safe operating procedure 6. Rotational direction of cutter & direction of material feed 7. Powering down correctly 8. Dust extraction 9. Changing cutters 10. Holding workpiece 11. Using fence, collar and jigs Personal Protective Equipment EYE PROTECTION HEARING PROTECTION LAB COAT Mandatory Mandatory Mandatory _________________________________ 56 _________________________________
  56. 56. 10.2. Parts of the Portable Router Name the parts of the Router as indicated: 9 8 1 7 2 6 3 5 4 12 1. _____________________ 2. _____________________ 10 3. _____________________ 4. _____________________ 5. _____________________ 6. _____________________ 7. _____________________ 8. _____________________ 11 9. _____________________ 10. _____________________ 11. _____________________ 12. _____________________ _________________________________ 57 _________________________________
  57. 57. 10.3. Router Cutter Rotation and Feed Direction When using the router freehand, the rotation of the cutter tends to pull the router to one side, depending on the direction in which it is fed. If the operator feeds the router away from the body, it will pull to the left hand side as it moves forward. If is fed towards the body, it will pull to the right hand side as shown. This natural tendency must be considered and can even be used to help achieve OPERATOR STANDING more stability and accuracy while routing. HERE When routing out a slot using a router fitted with either a fence or a template guide, consider the direction the router will want to go resulting from the rotating action of the cutter. Use it to your advantage! _________________________________ 58 _________________________________
  58. 58. In the diagram shown, the direction of feed is away from the operator, therefore the rotation of the cutter will pull the router to the left. Below, this has been considered. The fence has been attached to the right-hand side of the router. The resulting forces pull the router fence tighter against the edge of the material as it is being processed, helping ensure a straight and accurate trench is processed. ROUTER PULLS TO THE LEFT FENCE PULLED TOWARDS WORKPIECE FEED DIRECTION _________________________________ 59 _________________________________
  59. 59. The same principle is used when routing using a straight edge. In the diagram shown, the router is being fed away from the operator. This causes it to pull to his/her left. With the clamped material positioned the side shown, the router will be pushed against the straight edge rather than away from it making it easier to run the tool in a straight line. ROUTER PUSHES TOWARDS STRAIGHT EDGE FEED DIRECTION _________________________________ 60 _________________________________
  60. 60. When trying to determine the correct feed direction, use the “RIGHT HAND RULE”: Using the right hand with palm facing downwards, point the thumb towards the edge to be routed. The direction of the index finger will point in the correct feed direction for the router. This is the case for not only external edges (LEFT) but also internal ones (BELOW). _________________________________ 61 _________________________________
  61. 61. What is the function of the router? _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ What is the function of the following: (i) Variable speed __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ (ii) Depth Stop __________________________________________________________________________________ __________________________________________________________________________________ (iii) Spindle Lock __________________________________________________________________________________ __________________________________________________________________________________ (iv) Depth Turret __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ (v) Plunge Mechanism __________________________________________________________________________________ __________________________________________________________________________________ _________________________________ 62 _________________________________
  62. 62. Why is there a bearing attached to some router bits? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ What is the function of a template guide? _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ Use arrows on the diagram to show the direction the router is to be fed in to process a chamfer around its perimeter. _________________________________ 63 _________________________________
  63. 63. Tick the appropriate box below to show which router attachment each of the following router cutters are used in conjunction with: A B C D E F A B C D E F Fence Guide Template Guide Guided by Template _________________________________ 64 _________________________________
  64. 64. 10.4. Portable Router Hazard Identification & Risk Assessment LOCATION: _______________________ ASSESSMENT CARRIED OUT BY: _________________________ DATE: ________________ PAGE ____ OF ____ ASSESSMENT REVIEW DATE: _______________ RISK PERSONS EXISTING REQUIRED PERSON TARGET HAZARD MAGNITUDE AT RISK CONTROLS CONTROLS RESPONSIBLE DATE
  65. 65. NOTES ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ _________________________________ 66 _________________________________

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