Wt4603 unit2 week3

WT4603 Wood Processing Safety & Practice Lecture Unit 2

Risk Assessment & Week 4 Labs (Component B & Routers) Lecturer: Mr. Joseph Lyster joseph.lyster@ul.ie Notes prepared by: Mr. Donal Canty, Mr. Des Kelly and Mr. Joseph Lyster Notes available on www.slideshare.net/WT4603

Department of Manufacturing & Operations Engineering

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The Safety Management Process

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Importance of being able to Assess Risk

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Risk Assessment

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Risk Magnitude

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Perceptions of likelihood & Severity

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Risk Magnitude Matrix

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Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw

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RISK ASSESSMENT

Location: Date: Assessment Carried out by:

Assessment of: CE Marking (Machines): Yes □ No □

of 1 Assessment Review Date:

HAZARD RISK MAGNITUDE PERSONS AT RISK EXISTING CONTROLS REQUIRED CONTROLS PERSONS RESPONSIBLE TARGET DATE

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RISK ASSESSMENT

Location: SR2-047 Date: 24-09-2010 Assessment Carried out by: Mr. Joe Lyster

Assessment of: PILLAR DRILL CE Marking (Machines): Yes □ No □

of 1 Assessment Review Date: 24-09-2010

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RISK ASSESSMENT

Assessment of: PILLAR DRILL CE Marking (Machines): Yes □ No □

1. Entanglement

2. Violent Ejection

3. Piece Spinning

4. Electric Shock Hazards

5. Cuts

6. Inadvertent Starting

7. Space around Machine

8. Tripping/Slipping

9. Pinch Point

10. Falling Table

11. Noise Levels

12. Crushing

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1. ENTANGLEMENT SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Trivial Tolerable Tolerable Moderate Moderate

Quiet 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

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2. VIOLENT EJECTION SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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3. PIECE SPINNING SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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4. ELECTRIC SHOCK SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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5. CUTS SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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6. INADVERTENT STARTING

SEVERITY Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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7. SPACE AROUND MACHINE

SEVERITY Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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8. TRIPPING/SLIPPING SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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9. PINCH POINT SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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10. FALLING TABLE SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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11. NOISE LEVELS SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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12. Crushing SEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

Highly Unlikely

Quiet Unlikely

Quite Likely

Highly Likely

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RISK ASSESSMENT

Assessment of: PILLAR DRILL CE Marking (Machines): Yes □̷ No □

1. Entanglement Intolerable User of Machine Securing Clothes/Hair Chuck Guard Teacher/Students 24-09-2010

2. Violent Ejection Moderate All in Class Spring Loaded Chuck Chuck Guard Teacher/Students 24-09-2010

3. Piece Spinning Moderate All in Vicinity Clamp Correct Clamping Teacher/Students 24-09-2010

4. Electric Shock Hazards

Moderate User of Machine Inspection of Equipment

Regular Inspection of electrical components

Teacher/Students

24-09-2010

5. Cuts Moderate User of Machine Training

Exclusion zones marked clearly in

relation to work area Teacher/Students 24-09-2010

6. Inadvertent Starting Moderate All in Vicinity

Lockable Isolator Switch

Lock isolator in the off position when not in

Teacher/Students

24-09-2010

7. Space around Machine Substantial User of Machine Nothing

Safe work area exclusion zone marked

around machine

Teacher/Students

24-09-2010

8. Tripping/Slipping Moderate User of Machine Nothing Sign posts Teacher/Students 24-09-2010

9. Pinch Point Substantial User of Machine Nothing Chuck Guard Teacher/Students 24-09-2010

10. Falling Table Moderate User of Machine Pillar Post Lock

Handle Correct Locking/Clamp Teacher/Students 24-09-2010

11. Noise Levels Trivial All in Class Nothing PPE & Sign posts Teacher/Students 24-09-2010

12. Crushing Intolerable All in Vicinity Nothing Secure Fixing Teacher/Students 24-09-2010

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Creating a cutting list

• A cutting list is a document that allows the material processor to calculate volumes of material and to formulate a processing procedure

• The list must contain the critical dimensions of the material

• Cutting lists must have a standard format to enable the processor to operate efficiently

• The next slide shows the UL format for compiling a cutting list.

• This template must be used when making a submission for material.

• Lists that are outside this template will not be processed.

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Cutting list template

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Standards

• Cutting list must be submitted on an A4 sheet(s) of paper

• Students must use the UL template

• Submissions must be printed or typed • Submissions that are sloppy, untidy, scribbled, crossed out or outside the standard

format will not be accepted.

• The descriptions section must illustrate the shape and detail of the piece. • Secondary processing should be illustrated in this section e.g. grooving etc.

• Lists should be filled out beginning with larger cross-sections and working your

way down in cross-sectional size. • (This can aid material optimisation)

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Good Example

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Good Example

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Unacceptable examples

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COMPONENT B:

Component B: To be outlined in the second lab of week 4

(next week)

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Hand Router Consists of cutter rotating at between 800 to 30,000

RPM being driven by a vertically mounted motor set on a flat based framework

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Hand Router

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• Cutting grooves

• Cutting rebates

• Cutting slots and recesses

• Cutting beads or mouldings

• Cutting dovetails

• Cutting dovetailed slots and grooves

• Edge trimming

• Profiling (jigs/formers)

Hand Router

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• Large powerful routers are heavy and can be difficult to handle for light work.

• Generally in schools the type of work that the router will have to perform will be light to medium work.

• As a rough guide to classifying routers:

400 W to 600W are for light duty

750 W to 1200W are for medium duty

1250 W upwards are for heavy duty

Hand Router: Power

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Collet

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Collet

A tapered sleeve that is made in a number of segments that is used to hold the shaft of a cutter or bit.

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• Collet needs to be cleaned regularly

• Must prevent rust

• Must prevent wear

• Can clean with solvents but must spray with WD40 afterwards

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Cutters (Router bits) • Two types of cutter

• High Speed Steel (HSS)

• Tungsten Carbide Tipped (TCT)

• HSS work well on softwood because of their keen edge but will blunt quickly

• TCT cutters perform much better than HSS on hardwoods and MDF

• Cutters should be cleaned regularly with white spirit and fine scraper to remove dirt, resin and debris.

• Cutters should also be inspected for damage prior to operating.

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A router bit is a tool for woodworking giving a quality finish to the

material. It cuts wood providing a way to give a clean and even a

decorative edge to woodwork.

The following is some basic information about router bits to get you

started in your woodworking efforts.

Here are the there main parts of a router bit:

1. The shank- the part of the router bit that is inserted into the collet (the

sleeve of the router).

2. The cutting edge- this part cuts and removes the wood. They are

available in several sizes and shapes.

3. The pilot- the guide for the router in order to make a correct cut. It can be

an extension of the shank or a ball bearing attachment.

Cutters (Router bits)

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Cutters can have disposable or interchangeable profiles.

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Cutter diameter will have a direct effect on the power required form the router motor.

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Cutter selection & feed direction

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Feed direction • If you feed a router into a piece of

material without using a guide fence or bearing guide you will find that the router will pull to one side.

• If you push the router into the material from position (A), the router will pull to your left.

• If you pull the router into the material toward you from position (B), the router will pull to your right.

• This occurs as the cutter will climb on the material in front of the cutting edge.

• This motion must be utilised when using guide fences.

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Feed direction & the fence

To process a straight housing or trench you can use a straight edge guide (A) or the guide fence that is supplied with the router(B).

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Feed direction & the fence • In the photo the fence is securely

clamped in position.

• The router is being fed in the direction (F).

• The router will try to pull to the operators left hand side.

• With the fence clamped on the left of the router, the router will push against it as it is fed into the material.(Green arrows)

• If the fence were on the right hand side (when viewed from the operators position) of the router, it would pull away from the fence and result in the trench being crocked.

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Feed direction & the fence • The groove is produced as the router is

moved forward.

• Local extraction will remove the bulk of the dust produced.

• Some may be blown back in the direction of the operator.( )

• A suitable lab coat will protect the operators clothing.

• Appropriate dust mask should be used.

• Feeding the router in the opposite direction will cause any dust to be blown away from the operator.

• This will require the guide fence to be set up on the right hand side of the router and operator.

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Guide fence

Guide fence fixed to the router. Can be fixed from either side.

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Using the guide fence

When feeding the router forward (F) the router will tend to pull to the operators left hand side.

The fence should be set on the right hand side of the router.

When the cutter engages in the material it will pull to the left as indicated by the green arrow (P) and keep the fence tight against the materials edge.

Material should be securely calmped or placed on a non-slip router mat.

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Using the guide fence

• Procedure • Select appropriate PPE • Set guide fence. • Set plunge depth. • Set depth turret if multi pass

is required. • Safely secure work piece. • Place at starting position. • Start router. • Plunge to depth. • Feed into the work.

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• Profiles can be processed on material using templates.

• Templates can have the required profile as an internal shape or an external profile.

• To process the section marked (A)

• In the photo an internal template can be used to guide the router to produce the profile.

• Feed direction can be established using the right hand rule.

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Feed direction with template

Securely fix work to the template.

Establish and mark the feed direction for router.

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Fit the template guide to the router base plate.

Set cutter plunge depth.

Place over template at the starting position (A).

Switch on the router and then plunge to depth (B).

Feed router in a clockwise direction.

Using the template guide

Router Station 1 Carry out the following operations:

1. Isolate the router.

2. Select V- groove cutting bit.

3. Fit the bit in the router securely.

4. Set the depth of the cut to 3mm.

5. Machine the profile shown on the drawing using the guide fence. (Note: Guide fence is set. Do not adjust.)

7. Remove the cutter from the router.

FEED DIRECTION

ROUTER PULLS TO THE LEFT

FENCE PULLED TOWARDS

WORKPIECE

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2. Select the bearing guided chamfer bit.

4. Set the depth of the chamfer to half the thickness of the material provided.

5. Machine the chamfer profile on the outer edges of the material.

7. Remove the cutter from the router

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2. Select Ø 6mm cutting bit.

5. Set the depth turret to machine to a depth of 10mm on the second pass.

6. Fit the guide fence to the router.

7. Set the guide fence to the dimension shown on the drawing.

8. Machine the profile shown on the drawing using the guide fence.

10. Remove the guide fence and Ø 6mm cutting bit from the router.

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2. Select Ø 12mm cutting bit cutting bit.

4. Fix the template guide to the base of the router.

5. Set material in the template.

7. Set the depth turret to machine to a depth of 10mm on the second pass.

8. Machine the profiles of the template using the template guide.

10. Remove the template guide and Ø 12mm cutting bit from the router.

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SEE YOU ALL NEXT WEEK!!!

Wt4603 unit2 week3

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assessment review date

risk existing controls

hazard risk magnitude

joe lyster assessment

entanglement severity

cuts severity

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