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