Wt5912 lab manual_2012

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Wt5912 lab manual_2012

  1. 1. 2012 WT5912: Technology Education & Workshop Practice 2 Materials and ConstructionU L Mr. Joseph Lyster University of Limerick: Dept. of Design & Manufacturing Technology 1/1/2012
  2. 2. TABLE OF CONTENTS:TABLE OF CONTENTS: .............................................................................................................................. 21.1 INTRODUCTION: ........................................................................................................................ 31.2 MODULE DETAILS:......................................................................................................................... 31.3 AIM: ............................................................................................................................................... 31.4 OBJECTIVES: .................................................................................................................................. 31.5 RESOURCES: .................................................................................................................................. 31.6 LABS: ............................................................................................................................................. 31.7 LAB REQUIREMENTS: .................................................................................................................... 41.8 HEALTH & SAFETY: ........................................................................................................................ 41.9 MODULE ASSESSMENT: ................................................................................................................ 51.9.1 Table Project: ......................................................................................................................... 51.9.2 Lab Booklet: ............................................................................................................................... 51.9.3 Construction Teacher Resource: ............................................................................................... 51.9.4 Section Detail Drawings: ........................................................................................................... 51.9.5 Machines Exam: ........................................................................................................................ 61.9.6 Building Science & Experimentation: ........................................................................................ 61.9.7 Group Presentations: ................................................................................................................ 61.9.8 Day Practical Exam: ................................................................................................................... 61.9.9 Written Exam: ........................................................................................................................... 62.1 WOOD PROCESSING SAFETY & PRACTICE: IMPORTANT TERMS .................................................. 8 Risk Magnitude .................................................................................................................................. 102.2 QUESTIONS ...................................................................................................................................... 112.3 SURFACE PLANER (300MM) ............................................................................................................. 16 Introduction ....................................................................................................................................... 17 Parts of the Surface Planer ......................................................................................................... 182.4 THICKNESSER (630MM) ................................................................................................................... 23 Introduction ....................................................................................................................................... 24 Parts of the Thicknesser ..................................................................................................................... 252.5 RIP SAW (Ø450MM BLADE) ............................................................................................................. 31 Introduction .................................................................................................................................... 32 Parts of the Rip Saw...................................................................................................................... 332.5 PROCESS SHEETS: COMPONENT NOTES ....................................................................................... 22.6 Built Section Detail Drawings: ....................................................................................................... 5
  3. 3. 1.1 INTRODUCTION:Students will be introduced to the Construction related syllabi at senior cycle level and developstrategies to teach their concepts and content. Students will draw on their knowledge base fromtheir primary degree and content of this module to formulate a coherent approach to teachingconstruction based subjects at second level.In addition to the Construction syllabi students will be involved in extensive laboratory work toensure the competent and effective implementation of wood processing safety and practice insecond level technology education settings. This is a core issue regarding the management of theclassroom environment for health and safety of all and the nature of work being conducted.1.2 MODULE DETAILS: Lecturer: Joseph Lyster Teaching Assistant: Joseph Lyster Senior Technicians: Joseph Murray, Richard Hennessy & Louise Madden Lab Groups: 2A Courses Involved: Grad. Dip. In Technology Education Lecture Times: Thursday 4-5pm in SR2029...Be on time!!! Lab Times: Monday 9-12pm/Wednesday 3-5pm Lecture Notes: Available @ www.slideshare.net/WT46031.3 AIM: A. The overall aim of this module is to prepare you for the role of teaching, learning and assessment of second level leaving certificate Construction Studies.1.4 OBJECTIVES: i. Affective Domain: To motivate and foster your moral development as a teacher of Construction Studies with emphasis on critical pedagogy and practice, i.e. health & safety, through the integration of previous knowledge and methods of reflective inquiry ii. Cognitive Domain: To draw on the learning obtained from your pervious qualifications to support the development of your knowledge, comprehension and application of both theoretical and practical elements of Constructions Studies iii. Psychomotor Domain: To foster your ability to plan, develop and demonstrate practical processes and techniques through organised teaching and learning activities in the Construction Studies setting1.5 RESOURCES:Students will have access to the facilities in SR2-047, which is the main wood processing machine lab.Basic material will be provided to you as according to the activities schedule for this semester. Anyadditional materials to be incorporated into any element of your practical project work must besourced at your own expense. In addition to hand tools provided, you will be required to purchase asmall number of basic tools etc…1.6 LABS:o Permitted entry to timetabled labs only!o Labs will take place in SR2047.o Lab coat and safety glasses are a prerequisite to gaining entry to the lab.
  4. 4. o You must have your lab booklet during all labs.o Groups are divided and timetabledo Labs will begin on Week 1o Labs are mandatory – 100% attendanceo Absence in the case of illness must be explained with a doctor’s note.o Other reasons must be explained to the lecture/TA.o Labs begin on the hour and finish at 10 minutes before the hour.o Late arrivals will not be permitted to join the lab session.1.7 LAB REQUIREMENTS:o Report for lab on timeo White lab coato Safety glasseso Students must sign the attendance sheeto Students will be assigned a work bencho I.D. cards to be submitted to T.A. for locker keyso Students must follow instructions of T.A.o Students under the influence of alcohol will not be permitted.o House Keepingo Students have a responsibility for the care of the tools in their lockero At the beginning and end of the lab students must:o Check tools list and conditiono Report to T.A. if any tools are missingo Report to T.A. if tools are damagedo At the end of each lab session:o Benches must be brushed downo Bench hooks returned to the underneath of each bench.o Vices must be in the closed position.o The floor area is swept and/or all waste material is removed from the ground area.o Wood waste and paper waste to be segregated.o If stools are used during a lab session, they must be removed from the floor and placed on top of the bench.o I.D. cards will only be returned to students when they have complied with these regulations.1.8 HEALTH & SAFETY:o Lab coats must be worn at all times in the workshop.o Safety glasses must be worn at the appropriate times as laid out by the T.A. in charge.o Students must report damage to tools and equipment to the T.A. in charge.o Students must immediately report any personal injury (nicks, cuts etc.) to the T.A. in charge.Failure to comply with safety regulations will result in removal from the lab session.Any malicious damage to University property or equipment will result in removal from the lab andUniversity disciplinary procedures will be enforced.
  5. 5. 1.9 MODULE ASSESSMENT:  80% Laboratory Work  20% Written Exam  Machines Exam/Day Practical Exam/Lab Booklet (Pass / Fail Basis)  Note:  Students must pass all assessment elements to obtain a pass in the module.  Students that fail the practical machines exam and repeat exam will automatically fail the entire module.Nature of Project work: As follows.1.9.1 Table Project: Weighting: (15%) LW  Purpose of the project is to reflect your use of woodworking machinery through wood processing safety and best practice  Project enables you to purposely process material to construct an artefact from a raw plank state in the most efficient and safe manner possible  Use of the surface planer, thicknesser, rip saw, mortiser, bandsaw, panel saw and dowel jig as part of this project  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  Develop hand skills in preparation for teaching practice by producing a series of hand-crafted joints to construct the table  Develop your awareness of machine safety through risk assessment procedures including aspects such as hazard identification and risk magnitude  Table project requirements: o Produce fully constructed Table with cutting list/plans/procedures1.9.2 Lab Booklet: Weighting: Pass/Fail  The purpose of the lab book is to record in-lab exposure to wood processing safety and best practice.  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 machinery1.9.3 Construction Teacher Resource: Weighting: (35%) LW  Create a resource that can be used interactively by second level students of Constructions Studies to foster their understanding of built environment detail, services and heritage.  This project will operate from week 6 and will involve working in groups.  Tasks will be assigned to pre-selected groups in week 6.1.9.4 Section Detail Drawings: Weighting: (15%) – 1.5% per drawing  You will be required to complete a small package of building section detail drawings as relevant to the Construction Studies Syllabi/leaving certificate exam  All drawings are to be done by hand on A3  There are a total of 10 drawings that will be assigned on a weekly basis beginning in week 4.
  6. 6. 1.9.5 Machines Exam: Weighting: (Pass/Fail)  The machines exam will take place in week 3 or 4.  It is assessed on a pass/fail basis.  The machines involved are the surface planer, Thicknesser and ripsaw o Risk assessment 1 – Surface planer o Risk assessment 2 – Thicknesser o Risk assessment 3 – Rip saw1.9.6 Building Science & Experimentation: Weighting: (5%)  Experiments will take place during lab time in designated location o Slump test, batching etc…  Structured lab report to be completed1.9.7 Group Presentations: Weighting: (10%)  Takes place in Lectures (Week 9,10,11,12)  Groups of 4  30 minute presentation assigned Construction Studies syllabus topic  1 group scheme of work  4 Individual lesson plans1.9.8 Day Practical Exam: Weighting: (Pass/Fail)  To be confirmed.1.9.9 Written Exam: Weighting: (20%) WE  Exam: 1.5 hours  Two sections: A and B – Answer one question from eachImportant Submission Dates:  Refer to Module Matrix
  7. 7. LAB BOOK
  8. 8. 2.1 WOOD PROCESSING SAFETY & PRACTICE: IMPORTANT TERMSA Hazard is any substance, article, material or practice that has the potential to cause harm to thesafety, 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 AirRisk 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 controlmeasures in an attempt to determine the actual threat posed by the hazard. Its purpose is todetermine if the risk control measures in place are sufficient (reasonably practicable) or if furthercontrol measures are required.Hierarchy of Risk Control MOST FAVOURABLE SOLUTION A. Eliminate the Hazard Completely. 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… LEAST FAVOURABLE SOLUTION F. Use PPE.
  9. 9. 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 Risk Magnitude Matrix:
  10. 10. 2.2 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 step, as outlined in the H.S.A Act 2005, for continuous improvement in terms of health and safety? List the 3 main reasons for managing health and safety: 1) __________________________________ 2) __________________________________ 3) __________________________________ Explain the following two terms:Pro-active monitoring Re-active monitoring________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________ “The purpose of a safety audit is……” __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ _________ Explain what CE markings are: ________________________________________________________________ ________________________________________________________________ ________________________________________________________________
  11. 11. 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?_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  12. 12. What is an “ancillary” safety statement as applied to technologies education at second level?____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________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? _____________________________________________________________ _____________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________
  13. 13. List 5 situations when power to machinery and equipment should be locked/isolated?1_____________________________________________________________2_____________________________________________________________3_____________________________________________________________ 4______________________________________________ 5______________________________________________ What is an exclusion zone? ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Describe & differentiate between the following types of guarding:(i) Fixed__________________________________________________________________________________________________(ii) Self-adjusting__________________________________________________________________________________________________(iii) Interlocked_________________________________________________ What type of guarding is shown on the machine above?_________________________________________________ _________________________________(iv) Distance__________________________________________________________________________________________________ (v) Adjustable _________________________________________________ _________________________________________________
  14. 14. 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___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  15. 15. 2.3 SURFACE PLANER (300MM)
  16. 16. IntroductionThe 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 asit 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
  17. 17. Parts of the Surface Planer Identify the parts of the bandsaw as indicated below:1____________________2____________________3____________________4 ____________________5 ____________________ 16 ____________________ 07 ____________________8 ____________________9 ____________________10 ___________________ 111 ___________________ 1
  18. 18. 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?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  19. 19. State which of the 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 materialshown: (Guarding not shown for clarity only) S Stage 1 Stage 2 Stage 3
  20. 20. NOTES____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  21. 21. 2.4 THICKNESSER (630MM)
  22. 22. IntroductionThe thicknesser is similar to the surface planer in that it uses a rotating cutter blockfitted with extremely sharp knives to surface faces of wood passing through themachine. The thicknesser uses a flat face created on the surface planer as a referenceand 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 behaviour 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
  23. 23. Parts of the Thicknesser Name the parts of the Planing Machine (Thicknesser) as indicated above: 12 3 4 1. ____________________ 5. ____________________ 9. ____________________ 2. ____________________ 6. ____________________ 10. ___________________ 3. ____________________ 7. ____________________ 11. ___________________ 4. ____________________ 8. ____________________ 11 10 9 8 5 6 7
  24. 24. 4 1 3 2 5 6 7 10 9 81. 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?____________________________________________________________________________________________________________________________________________________________________
  25. 25. What processing should be carried out to the workpiece before using the thicknesser?______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________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 diagrambelow)?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  26. 26. What is the purpose of the chip breaker?______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________What is the function of the pressure bar?________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  27. 27. NOTES____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  28. 28. 2.5 RIP SAW (Ø450MM BLADE)
  29. 29. IntroductionThe rip saw uses a motor driven saw blade projecting above a sturdy table with specially designedteeth 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
  30. 30. Parts of the Rip Saw 8 7 1 2 6 5 3Name the parts of the Rip Saw as indicated:1____________________ 42____________________3____________________4 ____________________ 4 65 ____________________ 56 ____________________7 ____________________8 ____________________ 89 ____________________ 910 ___________________ 10
  31. 31. 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 SLILDING TABLE TABLESliding Table:______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  32. 32. Out feed Table:______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Which of the following photographs show the correct positioning of the rip fence for (A) crosscutting, (B) ripping and (C) trenching material? (Tick the correct box) guarding removed for clarityonlyFig. 1 Cross Cut Rip GrooveFig. 2 Cross Cut Rip Groove Fig. 3 Cross Cut Rip Groove
  33. 33. 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 longmaterialWhat is the minimum length of timber to be processed while…(i) Ripping material to width __________ mm(ii) Cross cutting material to length __________ mmWhat 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 nutand remove the blade?
  34. 34. NOTES________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
  35. 35. 2.5 PROCESS SHEETS: COMPONENT NOTES
  36. 36. 2.6 Built Section Detail Drawings:C.C. = Concrete CavityT.F. = Timberframe             –    

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