Embedded Files
PREPARATION OF MATERIALS
SHOW KNOWLEDGE OF AVAILABLE:
MARKET FORMS -
WOOD: Log, Balk, Boar, Batten, Plank, Pole, Deal, Scantling, End, Quartering
METAL: Angle sections, Channel sections, T- sections, I-sections, Round bars, Square bars, Flat bars, Corrugated sheets, Expanded metal, Plates, Ribbed bars (HYSD), Ribbed bars (mild steel), Thermo-mechanically treated bars, Welded wire fabrics
PLASTICS: Acrylic or Polymethyl Methacrylate (PMMA), Polycarbonate (PC), Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PETE or PET), Polyvinyl Chloride (PVC), Acrylonitrile-Butadiene-Styrene (ABS)
UNDERSTAND METHODS OF CUTTING BY USE OF:
HACKSAW - A hacksaw is a type of hand tool designed specifically for cutting through materials such as plastic, steel, and other metals. They are a variant of the traditional hand saw, typically used for cutting wood, and have become a staple tool for professionals and hobbyists alike.
JUNIOR HACKSAW - Junior Hacksaws and Mini Saws are commonly used for cutting small metal pipes or plastic tubing. Junior hacksaws are commonly just six inches long and these tools have much smaller blades than their full-sized equivalents which enables the user to complete finer, more precise cutting with a much neater finish.
GUILLOTINE - They are used to cut sheet metal or wood into needed sizes where precision is vital, the thickness of metal/wood can vary and the sheets can be large. Sheet metal guillotines use a blade to cut through sheet metal with even pressure on both sides of the blade.
TENON SAW - Tenon saws are commonly used to make the tenons used in mortise and tenon joints. These saws can be used on hard and soft woods. As standard a Tenon saw will have between 10 and 14 teeth per inch (TPI), this allows you to have more control over the depth and direction of the cut you are making.
CROSS-CUT SAW - The crosscut saw is ideal for cutting ‘planks’ / ‘boards’, to the correct length. It has a relatively coarse blade with eight teeth per inch (8 TPI). The saw has an s-shaped back and is usually 600mm in length.
PANEL SAW - The panel saw is ideal for cutting manufactured boards ( also known as man-made boards). It is suitable for sheet material, such as MDF and chipboard. The panel saw is regarded as a requirement, of a typical woodworking / cabinet making workshop. These saws have a greater TPI (teeth per inch) than ripsaws and crosscut saws and are usually 500mm in length.
PORTABLE POWER TOOLS -
ROUTER: Machine routers are extremely versatile machines. They are generally used to cut grooves in natural wood and manmade boards. They have a cutter that rotates at high speed - as the operator pushes the router forwards the cutter removes the wood in its path. They can be very dangerous if not used with care and attention to safety rules.
CORDED HAMMER DRILLS - A hammer drill delivers more power in the form of a hammering action. The force of the hammer drill is applied directly to the bit. They are most commonly used for drilling in concrete and masonry. The hammering portion of this motion can be turned off, allowing the tool to function more like a standard drill.
BATTERY DRILL/SCREWDRIVER - A cordless drill is an electric drill which uses rechargeable batteries. Drills are primarily used for drilling circular holes in material, or for inserting screws and other threaded fasteners into material.
MACHINE PLANERS - Electric hand planers can make your life much easier especially if you have a lot of project planing doors. This tool makes smoothing out wood an easy job and there are plenty of budget option to consider if you want to make this aspect of woodworking easier.
ORBITAL HAND SANDER - sander, portable power tool used for smoothing, polishing, or cleaning a surface, as of wood, plastic, or metal. Sanders are also used to roughen surfaces in preparation for finishing.
PALM SANDER - Palm sanders are extremely useful tools and they fit into the palm of one hand comfortably. They are relatively light, easy to control and cheap. The glasspaper sheet is normally fixed to the pad with velcro and this means that it can be replaced easily. Because they are quite small and have a ‘triangular’ shape to the pad, they can be used to sand into corners.
BELT SANDER - A belt sander or strip sander is a sander used in shaping and finishing wood and other materials. It consists of an electric motor that turns a pair of drums on which a continuous loop of sandpaper is mounted. Belt sanders can have a very aggressive action on wood and are normally used only for the beginning stages of the sanding process, or used to rapidly remove material. Sometimes they are also used for removing paints or finishes from wood. Fitted with fine grit sand paper, a belt sander can be used to achieve a completely smooth surface.
UNDERSTAND THE USE OF:
DATUM SURFACES/ EDGES - Good practice when marking out timber therefore is to choose the straightest edge and mark this as the Face Edge. Similarly, select the best or flattest surface and mark this as the Face Side as shown. Throughout any subsequent marking and measuring, the Face Side and Face Edge are used as the Datum Surfaces from which all measurements are taken and against which the stock of a tool such as a Try Square or Marking Gauge is pressed. When marking out joints for a rectangular frame for example, a combination of ensuring Face Sides are always on top, Face Edges always on the inside, and the joints numbered, will ensure the frame is always assembled the same way and will be flat on its Face Side even if the joints are not exactly in the centre of the timber thickness.
DATUM LINES - The horizontal or base line, from which the heights of points are reckoned or measured.
PRODUCE THEM (DATUM SURFACES/LINES/EDGES) BY:
PLANING - Generally, all planes/files are used to flatten, reduce the thickness of, and impart a smooth surface to a rough piece of lumber or timber.
EXPLAIN THE PREPARATION FOR MACHINE PROCESSES AND SAFE METHODS OF SECURING MATERIALS TO:
WORK SURFACES/TABLES -
FACEPLATES - A wood lathe faceplate makes a secure mechanical attachment between a lathe and a wood bowl blank using screws. There are no moving parts within a wood lathe faceplate.
SETTING, MEASURING, MARKING OUT , TESTING
MEASURE AND/OR MARK OUT USING:
STEEL RULE - What is a steel rule? A steel rule is exactly what it sounds like... a rule manufactured from either spring or stainless steel that feature either metric or imperial (or both) scales along its length. One end is usually flat whilst the other end (frequently including a hole for hanging) is usually round.
CARPENTERS PENCIL - The rectangular or elliptical cross-section allows easier grip than standard pencils and prevents the pencil from rolling on slanted surfaces such as roofs. In addition, a carpenter pencil can be used as a gauge.
MARKING KNIFE - A marking knife is used for creating crisp layout lines in wood materials. It lays down a finer line than the thinnest pencil tip, and although all knives will slowly dull and eventually require a little honing or even replacement, good marking knives hold their edges and fine points for a very long time.
SCRIBER - A scriber is a hand tool used in metal work to mark lines on workpieces, prior to machining. The process of using a scriber is called scribing and is just part of the process of marking out.
TRY SQUARE - A try square or try-square is a woodworking tool used for marking and checking 90° angles on pieces of wood. Though woodworkers use many different types of square, the try square is considered one of the essential tools for woodworking.
BEVEL - A sliding T-bevel is an instrument that is used for both laying out and transferring angles. These tools are pivotal for many different kinds of construction jobs, especially for those in which the ideal 90° angles are not possible.
MITRE SQUARE - A miter square or mitre square is a hand tool used in woodworking and metalworking for marking and checking angles other than 90°. Most miter squares are for marking and checking 45° angles and its supplementary angle, 135°.
CENTRE SQUARE - A tool used to find the center of a circle, consisting of two perpendicular straight-edges, both placed tangent to the circular piece, and a third straight-edge which bisects the angle between the other two.
CENTRE PUNCH - A center punch is used to mark the center of a point. It is usually used to mark the center of a hole when drilling holes. A drill has the tendency to "wander" if it does not start in a recess. A center punch forms a large enough dimple to "guide" the tip of the drill.
DOT PUNCH - The dot punch is a lighter and thinner version of the centre punch and is used basically for the same job. However, it is more accurate as the dot produced is smaller. Centre punches are often supplied as a set, with the diameter of the 'tip' being the size.
DIVIDERS - Instrument for measuring, transferring, or marking off distances, consisting of two straight adjustable legs hinged together and ending in sharp points.
INSIDE CALIPERS - A caliper whose legs turn outward so that it can accurately measure inside dimensions, as the inside diameter of a pipe.
OUTSIDE CALIPERS - Outside calipers measure thicknesses and outside diameters of objects; inside calipers measure hole diameters and distances between surfaces.
ODD-LEG CALIPERS - The two calipers seen here are similar. They are manufactured from tool steel and each scriber / scriber point, has been hardened and tempered. They are for marking out the surface of sheet metal and for checking parallel edges.
TEMPLATE - Templates are often used in woodworking, sewing and other physical crafting projects to ensure that pieces are cut out of materials correctly.
MARKING GAUAGE - A marking gauge is used in woodworking to mark out lines for cutting or other purposes. The main purpose is to scribe a line parallel to a reference edge. A marking gauge's advantage over a pencil is that its pin, which is sharpened to a knife edge, it produces a very fine mark that does not broaden, and it scores the workpiece for chiseling and saw cuts (preventing splintering)
CUTTING GAUAGE - A cutting gauge has the same structure as a marking gauge, but uses a knife instead of a pin to mark the wood. This allows it to mark the wood against the grain keeping the same level of accuracy as going with the grain. A cutting gauge can also be used to cut thin pieces of veneer, which is a thin type of vinyl.
MORTISE GAUAGE - A mortise gauge or mortice gauge is a woodworking tool used by a carpenter or joiner to scribe mortise and tenon joints on wood prior to cutting. Mortise gauges are commonly made of hardwood with brass fittings.
PRODUCE DATUM LINES BY:
SURFACE PLATE - Surface plates are flat and plane surface used as a horizontal reference space for dimensional measurement, it's a base for inspection, toolmaking, gauging, spotting, marking, and layout. They can be made from granite, metal, cast iron, or glass. A surface plate is used to test the flatness of other surfaces or to provide a truly flat datum surface in marking off work for machining. The flat surface provides stability. It is also used for the inspection of gauges, jigs, and fixtures
SCRIBING BLOCK (SURFACE GAUGE) -
MEASURE USING A:
MICROMETER - a gauge that measures small distances or thicknesses between its two faces, one of which can be moved away from or towards the other by turning a screw with a fine thread.
VENIER GAUGE/CALIPERS - also spelled calliper, measuring instrument that consists of two adjustable legs or jaws for measuring the dimensions of material parts.
DIGITAL CALIPER - A digital caliper is a precision instrument used to take very accurate measurements. The caliper is easy to use with a digital display. Most are able to measure up to 0.01 mm (0.0005 inches).
SHAPING
a) DEFORMING/REFORMING - UNDERSTAND THE FOLLOWING PROCESSES:
BENDING (METAL) - Metal sheet, such as aluminium, steel and copper, can be bent using jigs with the metal clamped in place during bending. These examples can be bent in straight lines quite easily by hand, machine or using a hammer.
BENDING (PLASTIC) - A line bender has a heated element that provides heat, concentrated to just a few millimetres wide, along the length of the long machine. These are used to heat polymers along this line so that they can be bent. Once the polymer softens, it will bend easily into shape around a former before being left to cool. It is a fast and easy process but can only form basic shapes. Heated polymers can be placed in a cooling jig so that the bend produced is the same each time.
SAND CASTING - Sand casting is a manufacturing process in which liquid metal is poured into a sand mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. When casting, a liquid material is poured into a mold, which then solidifies to give the desired shape.
DIE CASTING - Die casting is a metal casting process that involves feeding molten nonferrous alloys into dies under high pressure and at high speed to rapidly create molded products. The main materials used in die casting are alloys of aluminum, magnesium and zinc.
Die casting is often used to make components for the automotive industry or decorative hardware and many other small components. In fact, die-cast parts can be found in many things; you are probably just unaware that they are made from die-cast metal. Locks and gears are common finished products.
LAMINATION - Laminated timber is made by drying out pieces of wood and bonding them together with moisture resistant glue. It's typically made with at least three pieces of stress graded wood that are all the same size and thickness and is coated in a special water repellent sealant.
VACUUM FORMING - Vacuum forming is a manufacturing method used to shape plastic materials. During the vacuum forming process, a sheet of plastic is heated and then pulled around a single mold using suction. The process involves heating a plastic sheet until soft and then draping it over a mould. A vacuum is applied sucking the sheet into the mould. The sheet is then ejected from the mould.
BLOW MOULDING - Blow molding is the forming of a hollow object by inflating or blowing a thermoplastic molten tube called a “parison” in the shape of a mold cavity. The process consists of extruding or “dropping” a parison on which female mold halves are closed. The female mold halves contain the shape of the product to be produced.
EXTRUSION - Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Extrusion is a process where a material undergoes plastic deformation by the application of a force causing that material to flow through an orifice or die. The material adopts the cross-sectional profile of the die and if the material has suitable properties, that shape is retained in the final extrudate.
PRESS FORMING - Press forming is used in industry to make 3D shapes from sheet metal, the level of complexity varies from simple domes to whole car door panels. The metal used needs to be ductile so that it can take the shaped without rupturing or fracturing.
Page updated
Google Sites
Report abuse