1. UNIVERSITY of LIMERICK
OLLSCOIL LUIMNIGH
DEPARTMENT OF MANUFACTURING AND
OPERATIONS ENGINEERING (M&OE)
FACULTY OF SCIENCE AND ENGINEERING
END OF SEMESTER ASSESSMENT PAPER
MODULE CODE: WT4603
MODULE TITLE: Wood Processing Safety and Practice
SEMESTER: Autumn Semester 2010-2011
LECTURER: Mr. Joseph Lyster
EXTERNAL EXAMINER: Professor Eddie Norman
DURATION OF EXAM: 2 Hours 30 Minutes
GRADING SCHEME: 35% Examination / 65% Coursework
INSTRUCTIONS TO CANDIDATES:
Students MUST answer TWO questions from SECTION A (2 x 25 Marks)
AND
Students MUST answer ANY 10 questions from SECTION B (10 x 5 Marks)
NOTE FOR SECTION A:
LM094 – (Materials & Architectural Technology) must answer question 1 in Section A and may not answer question 2
LM067 – (Wood Science & Technology) must answer question 2 in Section A and may not answer question 1
2. SECTION A
1) LM094 - (Materials & Architectural Technology) ONLY.
a) Outline your approach to demonstrating the safe and efficient use of wood
processing machines appropriate for use by Junior Certificate Materials
Technology Wood students.
(5 Marks)
b) In a Junior Certificate Materials Technology Wood class, students are required to
use the Chisel Morticer, Pillar Drill and Scroll saw as part of their design project
activity. Outline 4 possible hazards which may arise and discuss the risk
magnitude and possible risk control measures of each.
(20 Marks)
2) LM067 - (Wood Processing & Technology) ONLY.
a) Outline the duties of employers and employees in relation to health and safety
management in a wood machining workshop environment.
(5 Marks)
b) Identify at least 5 potential hazards that may arise while using the following
machines and outline suitable risk control measures for each. In your answer,
make reference to “risk magnitude” and “the hierarchy of risk control”.
i. Bandsaw with blade guard.
ii. Surface Planing Machine with bridge guard.
(20 Marks)
3) Surface Planing Machine.
a) Using notes and sketches explain the terms “clearance angle”, “peripheral
cutting speed” and “cutter pitch”. A 4 knife cutter block is revolving at 4400 rpm
with a feed speed of 24m/min. Calculate the pitch distance and outline an
appropriate use for the processed material.
(15 Marks)
b) The knife clamping mechanism is an important feature of modern cutter block
design. Explain using a neat annotated sketch how modern cutter block designs
utilise forces that are created when in use and also outline the safety aspects of
such cutter block designs.
(10 Marks)
4) Rip Saw.
a) Using notes and sketches explain the terms, namely “hook angle” and
“clearance”.
(10 Marks)
b) Name the circular saw blade tooth configuration parts outlined in figure 1.
Fig1. (4 Marks)
c) A saw blade of Ø750mm is driven at 1300 rpm. Calculate the rim speed of the
saw blade. Also discuss the implications of setting an incorrect peripheral cutting
speed for a saw blade.
(11 Marks)
3. SECTION B
1. Explain, using a neatly annotated sketch, the purpose of a chip breaker in relation to
circular cutting blocks. (5 Marks)
2. Outline the names of two key legislative health and safety policy documents
pertaining to second level technology education and the work environment.
(5 Marks)
3. Using notes and sketches outline the appropriate method of setting the rip fence for
both ripping and cross cutting of material. (5 Marks)
4. Explain what the CE marking represents. (5 Marks)
5. Given a plank of rough sawn material, outline the procedure for planing the material
all-round. (5 Marks)
6. Indicate using arrows, the internal and external feed direction of the router relating to
the work piece in fig.2. Also describe the consequences of incorrect feed direction
when processing material with a hand router. (5 Marks)
Fig.2 (Re-draw in Answer booklet)
7. Identify and explain one reason why kick back can occur when ripping material.
(5 Marks)
8. Compare and contrast the tungsten carbide (TC) and high speed steel (HSS) cutter
knifes used in circular cutting blocks for surface planing machines. (5 Marks)
9. Discuss the use of PPE as a means of risk control. (5 Marks)
10. Using notes and sketches demonstrate the necessary hand positions and movement of
material when surface planing. (5 Marks)
11. Using notes and sketches outline the purpose of a riving knife when ripping material.
Also outline the position of the riving knife in relation to the saw blade. (5 Marks)
12. Discuss how the collet design contributes to the stability of the cutting bit during the
routing process. (5 Marks)
13. Using notes and sketches discuss two types of start/stop mechanisms related to wood
processing machinery. (5 Marks)
14. Identify and explain any 3 mechanical hazards that may arise from using a circular
sawing machine. (5 Marks)
15. Outline 3 safety considerations that must be taken into account when using the
thicknessing machine.
(5 Marks)
