Tools and Machines

1. Tools and Machines What different tools can be used in production?

2. What is Manufacturing? • What different tools can be used in production? • What is the purpose of each tool? • Take notes on your note sheet as we proceed through the presentation.

3. Stationary Machines What different tools can be used in production?

4. Work Practices Use proper blade for cutting action (for example, don't use crosscut blade for ripping). Operate saw at speed specified by the manufacturer. Maintain and sharpen blade Leave sufficient clearance for stock. Stand to side of the saw blade to avoid injury due to kickback. Guide stock parallel to the rip fence to minimize the potential for kickback. Avoid crosscutting long boards on table saws. Considerable hand pressure is required close to the saw blade, and the boards create a safety hazard to other people. Use a filler piece between the fence and the saw blade when necessary (e.g., when there is little clearance on the fence side). Properly support all pieces of stock, including the cut and uncut ends, scrap, and finished product. Keep hands out of the line of the cut. Use a push stick for small pieces of wood and for pushing stock past the blade. Table Saw Purpose: Used for straight sawing. Boards can be cross-cut or ripped. Possible Hazards: Injuries can occur if an operator's hands slip as he or she is feeding the stock into the saw or if the operator holds his or her hands too close to the blades while cutting. The operator can also be injured when removing scrap or finished pieces from the table.

5. Work Practices Use a blade of an appropriate size and type (for example, do not force a wide saw to cut on a small radius). Set the guard to just clear the stock when it is near the blade. Use a push stick to control the stock when it is near the blade. Use a special jig or fixture when cutting small pieces of stock. Possible Hazards The most common injury is caused by contact with the blade. Contact with the blade at the point of operation occurs because the operator's hands may come close to the blade during cutting, and band saws cannot be completely guarded. Band Saw Purpose: Band saws use thin, flexible, continuous steel strips with cutting teeth on one edge. They are used primarily for cutting curves in stock.

6. Work Practices Make turns slowly; do not make sharp turns with a wide blade; use a narrow blade for sharp turns. Potential Hazard Contact with the blade Scroll Saw Purpose: Scroll saws are useful for precision-cutting intricate curves and patterns on thin stock. They have thin blades that move rapidly up and down through the opening in the saw table. The blade is held in upper and lower chucks that pull it tight and keep it from bending. A hold-down adjusts to the thickness of the wood being cut.

7. Work Practices For automatic wood-turning lathes with rotating knives, cover the cutter head with a metal shield or hood that completely covers the knives and material, except at the contact points, when the machine is in operation. A hinged shield permits adjustments when needed. For manual lathes, cover the cutter heads as completely as possible with a hood or shield. Cover lathes used for turning long stock with long curved guards extending over the top of the lathe. Such guards prevent the stock from being thrown from the machine, should the stock come loose. On hand-fed lathes, guard the tool and point of operation with a Plexiglas tool guard, as shown in Fig. 1. Enclose the power transmission with a fixed guard. Possible Hazards The primary hazards of lathes are contact with rotating parts and contact at the point of operation. Operators' hands, clothing, or jewelry may be caught on the rotating parts and pulled into the machine. The danger is greater with hand-fed lathes, because the operator works in such close proximity to the rotating stock and the cutting tool. With automatic lathes, the operator can contact the rotating parts if he or she reaches into the work area to adjust components while the machine is running. Flying chips are also a hazard on lathes. Lathe Purpose: Lathes are used for shaping round parts, such as table legs.

8. Work Practices Use hold-down push blocks when jointing wood narrower than 3 inches. As a general rule, never joint pieces of material that are less than four times the width of the bed opening. Avoid deep cuts. They increase the likelihood of kickbacks and require a larger table opening. Check knives regularly for proper setting and adjustment, but be sure to shut off the power first. Enclose the power transmission with a fixed guard. Possible Hazards Injuries can occur if the operator's hands and fingers come in contact with the knives. This can happen when the operator is jointing narrow lengths of stock, particularly when not using a jig or other holding device. Injuries can occur when the operator's fingers ride along the surface of the jointer while feeding the wood. Also, stock may be accidentally kicked away, exposing the operator's hands to the cutter head. Jointer Purpose: Jointers face or flatten wood and are used primarily to joint small pieces of material. The operator passes stock over a cylindrical, multiple-knife cutter head, while keeping the stock flush against a guide. The depth of the cut is achieved by adjusting the front table.

9. Planer Purpose:Planers, also called surfacers, are woodworking machines used to dress and size rough-sawed lumber on one or more sides - planing boards to an even thickness. Planers are similar to jointers except that the cutter head is above, or above and below, the stock. Stock passes under or between cylindrical cutter heads with multiple knives. An operator's hands can come in contact with the point of operation while adjusting the blades. Operators' hands also may be pinched between the stock and in-running rolls if the feed system is not properly guarded.

10. Work Practices The drilling machine operator may or may not be a skilled worker. The common drill press is used often by anybody in the shop and injuries can occur because of carelessness. The operator must position the stock, install the drill, operate and observe, and maintain housekeeping. The operator also must change speeds and feeds when required. Possible Hazards One of the most common causes of accidents that occur on a drill press is poor operator judgment. Often the operator will attempt to hand-hold the stock while drilling. When the drill enters the work, it can catch and twist the stock from the operator, which results in an uncontrolled rotating piece of wood. Other point-of-operation hazards include the rotating drill, which is rarely guarded, and hot chip generation. Operating controls often are simple on-off push-buttons with no emergency stop devices. Power transmission components often are exposed. Because the drill press is such a commonly used machine, it often is cluttered with chips and scraps, which create a hazardous work area. This machine is less hazardous than others only because of its simple operation; nevertheless, familiarity with its operation is required. Drill Press Purpose: A drill press is a wood cutting machine that uses a multiple-cutting-edged rotating tool to remove wood and produce a hole in the stock.

11. Work Practices Keep hands away from abrasive surfaces. Sand on the downward-moving side of the disk or belt. Replace torn, frayed, or excessively worn belts or drums. A worn-out belt, disk, or drum can cause massive heat buildup, which can cause the belt, disk, or drum to tear or break and pelt the surrounding area with projected bits. Possible Hazards The primary safety hazard of belt sanders is that workers may catch their hands, clothing, or jewelry in the in-running rolls. Also, contact with an abrasive surface can cause abrasions and lacerations. Belt Sander Purpose:Sanders finish stock by using a coated abrasive surface to remove material.

12. Work Practices Keep hands away from abrasive surfaces. Use quality stock that is unlikely to break. Avoid feeding the stock into the tool too abruptly or in the wrong direction. Always secure the stock to the template. Use tools only as intended. Possible Hazards Inadvertent contact with the rotating tool or cutter head when handling the stock or removing scrap from the table may cause injuries. Clothing or hair may be caught on a rotating cutter head. Tools can be flung from the cutter head if they are poorly fastened in the tool holder, if the wrong tool is used, or if the tool speed is too high. Kickback may be caused by poor-quality lumber such as if the stock breaks or incorrect work method, such as feeding the stock into the tool too abruptly or in the wrong direction, or poorly fixing the stock to the template. CNC Router Purpose: Routers often are used for cutting and shaping decorative pieces, making frame and panel doors, and milling moldings.

13. Handheld Tools What different tools can be used in production?

14. Work Practices Use safety bit chucks with no projecting screws Enclose boring bits with a guard that encloses the bit and chuck above the material being worked Enclose the top of the cutting chain and driving mechanism Cover operating treadles with inverted U-shaped guard to prevent accidental tripping Sand on the downward-moving side of the disk or belt. Replace torn, frayed, or excessively worn belts. A worn-out belt can cause massive heat buildup, which can cause it to tear or break and pelt the surrounding area with projected bits. Possible Hazards In-running nip points - Clothing, hands, or hair may get caught by and pulled into the in-running rolls on automatic sanders or sanding belts. Wood splinters and chips may be thrown from the sanding action. Belt Sander Purpose: Handheld sanders finish stock by using a coated abrasive surface to remove material.

15. Work Practices Keep hands away from abrasive surfaces. Sand on the downward-moving side of the disk. Replace torn, frayed, or excessively worn belts. A worn-out belt can cause massive heat buildup, which can cause it to tear or break and pelt the surrounding area with projected bits. Possible Hazards Contact with disc may occur. Wood splinters and chips may be thrown from the sanding action. Orbital Sander Purpose: Handheld sanders finish stock by using a coated abrasive surface to remove material.

16. Work Practices Guard the blade with an adjustable or self-adjusting guard. Guard the portion of the blade below the stock that is being cut. Make turns slowly Do not make sharp turns with a wide blade Use a narrow blade for sharp turns. Possible Hazards Contact with the moving blade may occur. Wood chips and splinters may be thrown by the cutting action. Jig Saw Purpose: Handheld jig saws are useful for precision-cutting intricate curves and patterns on thin stock.

17. Work Practices Never start routing end grain first. Use Jigs or guards whenever possible. Increase the router speed if possible. Make sure the work piece is secure. Use proper means of wood dust collection. Always wear eye protection. Possible Hazards The most common hazards occur when routing end grain. The router bit can grab the work piece, causing the operator to lose control. Kickbacks can occur when operating the router at slow speeds. The cutting action of the handheld router may expose operator to splinters, sawdust, and flying chips. Handheld Router Purpose: Handheld routers are used for cutting and shaping decorative pieces, making frame and panel doors, and milling moldings.

18. Work Practices The drill gradually feeds into the work, it is changed very often, chips must be able to escape, and the stock must be moved around. Whenever possible, a hold-down fixture should be used rather than the hands. Good housekeeping and operator training are absolute musts. Possible Hazards One of the most common causes of accidents involving a drill is poor operator judgment. Often the operator will attempt to hand-hold the stock while drilling. When the drill enters the work, it can catch and twist the stock from the operator, which results in an uncontrolled rotating piece of wood. Other point-of-operation hazards include the rotating drill, which is rarely guarded, and hot chip generation. Handheld Drill Purpose:A handheld drill uses a multiple-cutting-edged rotating tool to remove wood and produce a hole in the stock.

19. Work Practices Use proper blade for cutting action (for example, don't use crosscut blade for ripping). Operate saw at speed specified by the manufacturer. Maintain and sharpen blade Leave sufficient clearance for stock. Properly support all pieces of stock, including the cut and uncut ends, scrap, and finished product. Keep hands out of the line of the cut. Good housekeeping and operator training are absolute musts. Possible Hazards Injuries can occur if an operator's hands slip while cutting the stock or if they are too close to the blade during cutting. Kickbacks can result if the blade height is not correct or if the blade is not maintained properly. Kickbacks are more likely to occur when ripping, rather than crosscutting. Kickbacks also can occur if safeguards are not used or if poor-quality lumber is cut. Circular Saw Purpose: Circular saws are used for straight sawing. Depending on the blade, they cut either across (crosscut) or with (rip) the grain of the wood.

20. Work Practices Compressed air guns should never be pointed toward anyone. Workers should never "dead-end" a pneumatic gun against them selves or anyone else. A chip guard must be used when compressed air is used for cleaning. Possible Hazards There is always the danger of getting hit by one of the tool's attachments or by some kind of fastener the worker is using with the tool. Like other pneumatic tools, there is a hazard of flying concrete, wood chips, and/or nails. Handheld Nail and Staple Guns Purpose: attach materials together using compressed air to staple or nail the material.

21. Demonstration Time You will now participate in a demonstration of each piece of equipment and try to operate it yourself.