Wt4603 unit 0-week1-05-09-2011

WT46 3 Wood Processing Safety & PracticeAutumn 2011Lecture Unit 0

WT4603: Introduction & Lab 1 Activity Lecturer: Mr. Joe Lyster [email protected] Department of Design & Manufacturing Technology Lecture notes prepared by Mr. Joseph Lyster

mailto:[email protected]

Module Outline Lecturer: Joseph Lyster Teaching Assistant: Michael Crehan Technicians: Joseph Murray

Louise MaddenRichie Hennessy

Lab Groups 2A-2B-2C-2D-2E Courses Involved:

LM094 Materials & Architectural Technology LM067 Wood Science & Technology

Lecture Times Monday 9-11am in FB-028 (Foundation Building)

Lecture Notes Available @ www.slideshare.net/WT4603

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Department of Design & Manufacturing Technology

http://www.slideshare.net/WT4603

Module Outline

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Lectures Labs

Aim

1. To underline and explain the legislative and technical material associated with wood processing safety and practice.

1. To underline and develop best practice approaches and use in wood processing safety and practice.

Objectives

a. Standardized documentation, legislation and accountability

a. Safe wood processing procedures and practice

b. Machine anatomy, performance and terminology

b. Develop safety culture

c. Develop safety culture and supervising for safety

c. Supervising for safety

d. Safe wood processing procedures and practice

d. Confident and competent machinists

The aim of WT4603 is wood processing safety and best practice. This is a core module and a requirement for second year teaching practice (TP).


Module Assessment Module Assessment:

35% Laboratory Work: Table Manufacture 20% A3 Process Booklet 15%

25% Term Assignments: Risk Assessments 15% Information posters 10%

35% Written Exam (Terminal)

5% Lecture Worksheets

Machines Practical Exam (Pass / Fail Basis) Lab Booklet (Pass / Fail Basis)

Note: Students must pass all assessment elements to obtain a pass in the module. Students that fail the practical machines exam will automatically fail the entire module.

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Coursework Marking Scheme

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Module Outline Nature of Project work:

Laboratory Work: Table project Lab Booklet

Term Assignments: Risk Assessments Information Poster

Lecture Work: Worksheets

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Module Outline – Coursework Table project

Purpose of the table 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 (table) 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 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. This is a critical aspect regarding the safe operation of any second level technology classroom.

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Module Outline – Coursework

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Table project requirements:1. Produce fully constructed and finished table2. Produce an orthographic plan, elevation and end

view of table showing component detail. Can be done using hand or CAD/Solidworks

3. Produce a cutting list for components4. Produce a graphical procedure handbook of project

material processing safety & best practice. Templates will be provided for this aspect.


Module Outline – Coursework

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Lab book: The purpose of the lab book is to record your 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 machinery

You will not be permitted to the lab without your lab book

Lab book can be purchased from snap printing at a cost of €6.


Module Outline – Coursework Term Assignments:

Risk Assessments Create an A3 booklet to include the following:

Lab Machines:1. Risk assessment 1 – Surface planer2. Risk assessment 2 – Thicknesser3. Risk assessment 3 – Rip saw4. Risk assessment 4 – Bandsaw5. Risk assessment 5 – Mortiser 6. Risk assessment 6 – Pillar Drill7. Risk assessment 7 – Router You will each be assigned and required to perform 3 risk assessments of staged (hazard induced)

machines. This will account for 3 of your 7 individual risk assessments outlined above. In case of staged machines you will be provide with an image and scenario and you will be required to perform your risk assessment based on this information.

Information Poster1. Create an appropriately designed A2 laminated poster on an assigned machine.2. Must be accompanied by a user information sheet3. You must also develop a work activity sheet that addresses machine safety and best practice

to reinforce operant knowledge, understanding and safety culture• All assigned machine lists, as discussed in both cases above, can be viewed in the lab.

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Module Outline – Coursework Lecture Worksheets:

Each week you will be given an activity sheet to be completed during the lecture.

The aim of the lecture worksheets is to reinforce wood processing safety and best practice.

The worksheet will prepare you in advance of activities taking place in forthcoming labs.

It will provide you with a theoretical understanding of wood processing safety and best practice that will strengthen your knowledge and understanding in preparation for labs.

The worksheets will also involve reflection on the use of machinery in previous labs

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Module Outline

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Timetable:


Lecture Content – 24hrs1. Introduction + Labs W22. Machine Provision + Labs W3 3. Risk Assessment + Labs W4 4. PPE + Labs 4 W55. Planing Machines + Labs W66. Circular saws + Labs W77. Material Management & Sustainable Use + W8 Labs + (Machines

Exam Prep.)8. Bandsaw + Labs W9 + (Machines Exam Prep.)9. Morticer +Labs W1010. Routers + Labs W1111. Other Machines and Equipment + Labs W1212. Dust, Noise, Manual Handling

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Laboratory Sessions Permitted entry to timetabled labs only! Labs will take place in SR2058 & SR2047. Lab coat and safety glasses are a prerequisite to gaining

entry to the lab. You must have your lab booklet during all labs. Groups are divided and timetabled

Labs will begin on Week 2 Labs are mandatory – 100% attendance Absence in the case of illness must be explained with a

doctors note. Other reasons must be explained to the lecture/TA.

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Laboratory Sessions 2 X 2 Hours per Week (Week 2 --- Week 13 incl.) Labs begin on the hour and finish at 10 minutes before the hour,

e.g. 9:00am to 10:50am Late arrivals will not be permitted to join the lab session. Lab Rules and Requirements:

Report for lab on time White lab coat Safety glasses Students must sign the attendance sheet Students will be assigned a work bench I.D. cards to be submitted to T.A. for locker keys Students must follow instructions of T.A. Students under the influence of alcohol will not be permitted.

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Laboratory Sessions House Keeping Students have a responsibility for the care of the tools in their locker At thee beginning and end of the lab students must:

Check tools list and condition Report to T.A. if any tools are missing Report to T.A. if tools are damaged

At the end of each lab session: Benches must be brushed down Bench hooks returned to the underneath of each bench. Vices must be in the closed position. The floor area is swept and/or all waste material is removed from the ground area. Wood waste and paper waste to be segregated. If stools are used during a lab session, they must be removed from the floor and

placed on top of the bench. I.D. cards will only be returned to students when they have complied with these

regulations.

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Health & Safety Lab coats must be worn at all times in the workshop. Safety glasses must be worn at the appropriate times as laid out

by the T.A. in charge. Students must report damage to tools and equipment to the T.A.

in charge. 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 and University disciplinary procedures will be put in place.

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Lab Requirements – Week 2 Students must present at labs on Week 2 with the items requested

on the 2nd Year Tools List, namely: 2B Pencil

Max 3M Measuring Tape

150mm Steel Rule

Masking Tape

Lab Book (Available from Snap Printing on 07/09/2011 (Wednesday))

Failure to present this equipment at the beginning of the lab will result in you not being able to participate in the lab

You must bring all equipment & PPE to all labs

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Date Lab 1 Tech. Students Lab 2 Tech. Students

Week 1 No Labs No Labs

05-Sep No Labs No Labs

09-Sep No Labs No Labs

Week 2 Component A TECH 6 SR2-047 Component A TECH 6 SR2-047

12-Sep Planer and Thicknesser TECH 6 SR2-047 Planer and Thicknesser TECH 6 SR2-047

16-Sep Band Saw TA 12 SR2-058 Band Saw TA 12 SR2-058

Week 3 Component A TECH 6 SR2-047 Component A TECH 6 SR2-047

19-Sep Cutting List/Plans/Procedure TECH 6 SR2-047 Rip Saw TECH 6 SR2-047

23-Sep Cutting List/Plans/Procedure TA 12 SR2-058 Morticer TA 12 SR2-058

Submission 1 TA ALL

Week 4 Component A TECH 6 SR2-058 Cutting List Component B TA 24 SR2-058

26-Sep Rip Saw TECH 6 Planer/Thicknesser/Rip-Saw

24

30-Sep Morticer TA 12

Week 5 Marking TA 12 SR2-058 Marking TA 12 SR2-058

03-Oct Router 1 TECH Router 2 TECH

07-Oct Processing Component B TECH 2 SR2-047 Processing Component B TECH 2 SR2-047

Week 6 Router 3 TA 12 SR2-058 Router 4 TA 8 SR2-058

10-Oct Table Manufacture TECH Table Manufacture TA 8 SR2-058 14th + 15th *

14-Oct Table conponent processing TECH 12 SR2-047 Table conponent processing TECH 8 SR2-047 Fri & Sat Open days

Project Manufacture

Week 7 Table Manufacture TA 8 SR2-058 Submission 2 TA ALL SR2-058

17-Oct Table Manufacture TA 8 SR2-058 Table Manufacture TA 8 SR2-058

21-Oct Table conponent processing TECH 8 SR2-047 Table conponent processing TECH 8 SR2-047


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Project Manufacture Project Manufacture

Week 8 Pillar Drill TA SR2-058 Lathe (DEMO) TA SR2-058

31-Oct Table Manufacture LOUISE SR2-058 Table Manufacture SR2-058 Bank Holiday Monday

04-Nov Table component processing Table conponent processing SR2-058

Project Manufacture Project Manufacture

Week 9 Table Manufacture TA SR2-058 Table Manufacture TA SR2-058

07-Nov Table Manufacture SR2-058 Table Manufacture SR2-058

11-Nov Machines EXAM SR2-058 Machines EXAM SR2-058

Week 10 Table Manufacture TA SR2-058 Submission 3 TA ALL SR2-058

14-Nov Table Manufacture SR2-058 Table Manufacture SR2-058

18-Nov Machines EXAM TECH SR2-058 Machines EXAM TECH SR2-058

Week 11 Table Manufacture TECH SR2-047 Table Manufacture TECH SR2-047

21-Nov Table Manufacture TA SR2-058 Table Manufacture TA SR2-058

25-Nov

Week 12 Table Manufacture TECH SR2-047 Table Manufacture SR2-047

28-Nov Table Manufacture TA SR2-058 Table Manufacture SR2-058

02-Dec Table Manufacture Table Manufacture

Week 13 Submission 4 TA ALL

Machines Repeat Exam

05-Dec Machines Repeat Exam

09-Dec


Week2: Lab 1 & 2•Table

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Week 2: Lab 1 & 2• Machine Exposure:▫ Surface Planer▫ Planer Thicknesser▫ Bandsaw

• Material Process – Component A:▫ Each student will receive an unprocessed plank of red deal measuring 750 x

245 x 50 (mm)

▫ Aim of week 2 labs is to square the material to a clean workable condition of required dimension.

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740

242


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Surface Planer


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Surface Planer 1 Guide Fence

2 Infeed Table

3 Isolator

4 Infeed Dept Adjustment Wheel

5 Start/Stop Control

6 Infeed Adjustment Lock Handle

7 Blade Guard

8Blade Guard Clamp/Release Mechanism

9 Outfeed Table

10 Guide Fence Adjustment Wheel

11 Guard Guide

12 Guide Fence Lock Handle

2

1

3

4

57

9

8

6

11

12

10


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Step 1:Isolate machine

Step 2: Squaring guide fence• Set up surface planer guide fence @ 90⁰ to

table surface• Note infeed and outfeed table. • Square to infeed using right angle square.• Use red lock handles to open and adjust fence.• Lock gently when fence is perpendicular to

infeed table.

Infeed Table

Out feed Table


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Step 3: Setting infeed dept• This machine is calibrated in metric.• Maximum recommended material removal is 1-

2mm/pass• Dept stop to be set at 2mm• Open infeed lock handle• Turn wheel to left to drop table to 2mm• Lower you drop, the more the planer cutting

block is exposed• Close infeed lock handle when required dept is

achieved.• * Do not adjust outfeed table level, this is for

maintenance purposes only*

Infeed Infeed


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Step 4: Setting the guide fence width• Minimum blade exposure• Width of material + 10mm is recommended• This results in 10mm blade exposure - Safety• Adjust lock handle to wind in or out guide fence• Lock in appropriate position

242 + 10

242 + 10


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Step 5: Guard adjustment• Guard set for face side = handle up – 10mm

blade exposure• Guard set for face edge = handle flat – no blade

exposure


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Step 6: Material Inspection• Inspect material for the following defects

• Cupping• Bowing• Twist• Knots• Loose grain

• Example - if material is bowed, set the bowed face to the surface planer table surface and process. Material should never be run through hump side down.


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Step 7: Determining face side and face edge• Use machine surface to check square• Select appropriate face side and face edge

based on inspection• Preliminary surface marking using an ‘X’ with

no less than a HB pencil• Ensure extraction gate valve is open and

extraction is on• Proceed to plane material – face side and face

edge only!Gate Valve locate on extractor pipe just above surface planer

X X


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Step 8: Planing face side• Material position • Hand positions

Ensure Guard Guide is in a vertical position to plane face side

Dept of Hand Dept of Hand


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Note Hand Positions in relation to material


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Step 9: Planing face edge• Material position• Hand position

Ensure Guard Guide is in a horizontal position to plane face edge

Dept of Hand Dept of Hand


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Note Hand Positions in relation to material

Split second blade ExposureBlade guard flat onto table


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Thicknesser


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Thicknesser

1

2

4

3

1 Extractor Pipe

2 Control Panel

3 Adjustment Lever

4 Thicknesser Bed


• Lab sequence – Thicknesser• Step 1:

1. Unlock twist release stop mechanism2. Press green button to start3. Allow machine to build up, this can be determined by

noise consistency4. When noise is consistent flip delta switch to on position5. Feed rate, i.e. Speed at which material is passed, is set.6. Adjust table height as required7. Feed material as directed

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Delta Switch

Twist Release Stop

Display Panel

Feed Rate Control

Stop/Start

Thicknesser Bed Adjustment

Control

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Bandsaw


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The bandsaw


See you all next week!•Next week:▫Machine Provision▫Risk assessment▫Week 3 ripsaw labs

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Wt4603 unit 0-week1-05-09-2011

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Transcript of Wt4603 unit 0-week1-05-09-2011