Wt5912 lab manual_2012
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WT5912: Technology Education & Workshop Practice 2 Materials and Construction 2012 Mr. Joseph Lyster University of Limerick: Dept. of Design & Manufacturing Technology 1/1/2012 U L
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Lab Manual
Transcript of Wt5912 lab manual_2012
WT5912: Technology Education & Workshop Practice 2 Materials and Construction
2012
Mr. Joseph Lyster University of Limerick: Dept. of Design & Manufacturing Technology
1/1/2012
U
L
TABLE OF CONTENTS: TABLE OF CONTENTS: .............................................................................................................................. 2
1.1 INTRODUCTION: ........................................................................................................................ 3
1.2 MODULE DETAILS: ......................................................................................................................... 3
1.3 AIM: ............................................................................................................................................... 3
1.4 OBJECTIVES: .................................................................................................................................. 3
1.5 RESOURCES: .................................................................................................................................. 3
1.6 LABS: ............................................................................................................................................. 3
1.7 LAB REQUIREMENTS: .................................................................................................................... 4
1.8 HEALTH & SAFETY: ........................................................................................................................ 4
1.9 MODULE ASSESSMENT: ................................................................................................................ 5
1.9.1 Table Project: ......................................................................................................................... 5
1.9.2 Lab Booklet: ............................................................................................................................... 5
1.9.3 Construction Teacher Resource: ............................................................................................... 5
1.9.4 Section Detail Drawings: ........................................................................................................... 5
1.9.5 Machines Exam: ........................................................................................................................ 6
1.9.6 Building Science & Experimentation: ........................................................................................ 6
1.9.7 Group Presentations: ................................................................................................................ 6
1.9.8 Day Practical Exam: ................................................................................................................... 6
1.9.9 Written Exam: ........................................................................................................................... 6
2.1 WOOD PROCESSING SAFETY & PRACTICE: IMPORTANT TERMS .................................................. 8
Risk Magnitude .................................................................................................................................. 10
2.2 QUESTIONS ...................................................................................................................................... 11
2.3 SURFACE PLANER (300MM) ............................................................................................................. 16
Introduction ....................................................................................................................................... 17
Parts of the Surface Planer ......................................................................................................... 18
2.4 THICKNESSER (630MM) ................................................................................................................... 23
Introduction ....................................................................................................................................... 24
Parts of the Thicknesser ..................................................................................................................... 25
2.5 RIP SAW (Ø450MM BLADE) ............................................................................................................. 31
Introduction .................................................................................................................................... 32
Parts of the Rip Saw ...................................................................................................................... 33
2.5 PROCESS SHEETS: COMPONENT NOTES ....................................................................................... 2
2.6 Built Section Detail Drawings: ....................................................................................................... 5
1.1 INTRODUCTION:
Students will be introduced to the Construction related syllabi at senior cycle level and develop strategies to teach their concepts and content. Students will draw on their knowledge base from their primary degree and content of this module to formulate a coherent approach to teaching construction based subjects at second level.
In addition to the Construction syllabi students will be involved in extensive laboratory work to ensure the competent and effective implementation of wood processing safety and practice in second level technology education settings. This is a core issue regarding the management of the classroom 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/WT4603
1.3 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 setting
1.5 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. Any additional materials to be incorporated into any element of your practical project work must be sourced at your own expense. In addition to hand tools provided, you will be required to purchase a small 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.
o You must have your lab booklet during all labs. o Groups are divided and timetabled o Labs will begin on Week 1 o Labs are mandatory – 100% attendance o 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 time o White lab coat o Safety glasses o Students must sign the attendance sheet o Students will be assigned a work bench o I.D. cards to be submitted to T.A. for locker keys o Students must follow instructions of T.A. o Students under the influence of alcohol will not be permitted. o House Keeping o Students have a responsibility for the care of the tools in their locker o At the beginning and end of the lab students must: o Check tools list and condition o Report to T.A. if any tools are missing o Report to T.A. if tools are damaged o At the end of each lab session: o Benches must be brushed down o 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 and University disciplinary procedures will be enforced.
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/procedures
1.9.2 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 machinery
1.9.3 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.
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 saw
1.9.6 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 completed
1.9.7 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 plans
1.9.8 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 each
Important Submission Dates:
Refer to Module Matrix
LAB BOOK
MOST FAVOURABLE SOLUTION
LEAST FAVOURABLE SOLUTION
2.1 WOOD PROCESSING SAFETY & PRACTICE: 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.
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.
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:
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
________________________________________
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“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?
____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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______________________________________________
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
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
2.3 SURFACE PLANER (300MM)
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
Parts of the Surface Planer
Identify the parts of the bandsaw as indicated below:
1____________________ 2____________________ 3____________________ 4 ____________________ 5 ____________________ 6 ____________________ 7 ____________________ 8 ____________________ 9 ____________________ 10 ___________________ 11 ___________________
11
10
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?
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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 material
shown: (Guarding not shown for clarity only)
S
Stage 1 Stage 2
Stage 3
NOTES
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2.4 THICKNESSER (630MM)
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 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
Parts of the Thicknesser
Name the parts of the Planing Machine (Thicknesser) as indicated above:
1. ____________________ 5. ____________________ 9. ____________________ 2. ____________________ 6. ____________________ 10. ___________________ 3. ____________________ 7. ____________________ 11. ___________________ 4. ____________________ 8. ____________________
1
2
4
3
5
11
8
7
6
109
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?
__________________________________________________________________________________
__________________________________________________________________________________
1 2 5
6
3 4
10
8
7
9
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 diagram
below)?
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
What is the purpose of the chip breaker?
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
What is the function of the pressure bar?
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
NOTES
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2.5 RIP SAW (Ø450MM BLADE)
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
1
2
3
8
6
7
4
5
Parts of the Rip Saw
Name the parts of the Rip Saw as indicated:
1____________________
2____________________
3____________________
4 ____________________
5 ____________________
6 ____________________
7 ____________________
8 ____________________
9 ____________________
10 ___________________
4
5
6
10
9
8
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?
Sliding Table:
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
OUTFEED
TABLE SLILDING
TABLE
Out feed Table:
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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
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?
NOTES
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2.5 PROCESS SHEETS: COMPONENT NOTES
2.6 Built Section Detail Drawings:
C.C. = Concrete Cavity T.F. = Timberframe
–
