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WT4603Wood Processing Safety & PracticeLecture Unit 4 (Week 5),[object Object],[object Object]
 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,[object Object]
Surface Planer,[object Object],WT4603,[object Object],Planers can have 2,3,4,6……. Cutter knives.,[object Object],Most smaller machines such as those found in schools will have 2,3 or 4 knives.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Surface Planer,[object Object],WT4603,[object Object],Knives can be made from Chrome Vanadium steel alloy. ,[object Object],This is suitable for machining softwoods and non abrasive hardwoods. ,[object Object],However with advances in machining technology better materials have been developed to machine wood and wood composites. ,[object Object],Chrome Vanadium knives dull quickly on harder more dense material. ,[object Object],This requires more sharpening, setting up and leads to a lot of time wastage.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Surface Planer,[object Object],WT4603,[object Object],High Speed Steel (HSS) is a cobalt steel alloy with a small percentage of Tungsten added. ,[object Object],It is more suitable for machining all types of wood than the chrome steel compounds.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Surface Planer,[object Object],WT4603,[object Object],Abrasive stock should be machined using solid or tipped cutters.,[object Object],Tungsten Carbide (TC) is the best tool compound for machining manufactured boards.,[object Object],For general work HSS cutters are preferred to TC ,[object Object],Cutters can be re-sharpened easily.,[object Object],A keener edge can be achieved on HSS giving a better finish,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Surface Planer,[object Object],WT4603,[object Object],The reason for this is that steel compounds are smelted and shaped by rolling and forging while the metal is close to melting point.,[object Object],The molecules of the compound flow and align themselves in response to this pressure giving the material maximum strength and edge holding capabilities,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planer,[object Object],Tungsten carbide is a sintered compound. The fine grain powder from which the cutter will eventually will be made is compressed into a mould ( the ‘blank’ un-edged cutter required) under extremely high temperature (1500C) and pressure to form a solid block.,[object Object],Tungsten does not flow – it retains a granular structure and will chip rather than deform if abused.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Surface Planer,[object Object],WT4603,[object Object],Because if its brittle nature TC cutters require a more obtuse sharpness angle than the HSS cutters (more support for the cutting edge). ,[object Object],This makes it less satisfactory for cutting softwoods than HSS knives which can be ground to a more acute cutting angle.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planer,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife Cutter geometry,[object Object],Rake or Cutting angle,[object Object],Angle created between the face of the cutting knife and the centre of the cutter block,[object Object],Can have a wide range,[object Object],Softwoods	27° to 35 °,[object Object],Hardwoods	15° to 25 °,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife Cutter Geometry,[object Object],Bevel or Lip Angle,[object Object],Angle formed to give the cutting edge,[object Object],Minimum of usually 35°,[object Object],Greater for tipped cutters,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife Cutter Geometry,[object Object],Clearance Angle,[object Object],Angle formed between a line tangential to cutting circle and the bevel angle of the knife,[object Object],Must be present,[object Object],Has a bearing on the life of the cutting edge,[object Object],Usually 10° to 15°,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife Cutter Geometry,[object Object],Peripheral Cutting Speed,[object Object],A constant speed in the range of 35-45 m/s will give best results,[object Object],Increase in speed may cause loss of dynamic balance due to vibrations,[object Object],Poor finish,[object Object],Increased noise levels,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Pitch distance,[object Object],Combination of a rotary cut and a linear feed will leave the surface of the material with a series of arcs on it called Curtate Trochoids,[object Object],The pitch and depth of these arcs will determine how smooth the surface finish will be,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Department of Materials Science & Technology,[object Object],University of Limerick,[object Object],WT4603,[object Object],Pitch Distance,[object Object],2mm to 3mm for non obvious joinery and painted external work.,[object Object],  ,[object Object],1mm to 1.5 mm for internal painted work.,[object Object],0.5mm to 1mm for hardwood joinery and furniture.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Pitch Distance,[object Object],The SI unit of time is the second , but the minute is acceptable.,[object Object], ,[object Object],Feed rate on wood working machines is expressed in metres per minute. (m/min),[object Object], ,[object Object],The formula for the pitch of the cutter marks is given by:,[object Object], ,[object Object],	       			f,[object Object],			p   =   -------,[object Object],nR,[object Object], ,[object Object],where 		p  =  pitch of cutter mark,[object Object],			f  =  feed rate,[object Object], ,[object Object],n  =  number of effective cutters,[object Object], ,[object Object],			R  =  revolutions per minute of block,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Pitch Distance,[object Object],WT4603,[object Object],The unit for “p” will be metres  (m)   ,[object Object], ,[object Object], ,[object Object],f 	m/min	 m	   min,[object Object],p = ----  =    ---------  =     -----  x  ------  =  m,[object Object],       nR      1/min 	min        1,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Pitch Distance,[object Object],Problem 1,[object Object],	Calculate the cutter pitch of a 4 cutter block revolving at 4200 rev/min with a feed speed of 24m/min.,[object Object], ,[object Object], ,[object Object],	      F	      24	     24,[object Object],p  =  ------- = ------------ = --------- = 0.0014m  =  1.4mm,[object Object],nR       4 x 4200    16800,[object Object],(Internal painted work),[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Pitch Distance,[object Object],WT4603,[object Object],	If a graded surface is specified and the machine has a multi-speed feed gearbox, the same formula is used but “f” is expressed in terms of n ,p, and R.,[object Object], ,[object Object], ,[object Object],	       	    f                  ,[object Object],		p   =   -------     f  =  nRp,[object Object],nR,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Pitch Distance,[object Object],Problem 2,[object Object], ,[object Object],	From a cutter block which rotates at 4200 rev/min and has two cutting knives, a surface finish of a 4mm pitch is required. At what speed should the feed gearbox be set.,[object Object], ,[object Object],f  =  nRp    =  2 x 0.004 x 4200  =  33.6 m/min,[object Object], ,[object Object],WT4603,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Chip formation,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Riving,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Riving,[object Object],WT4603,[object Object],Cracking occurs below the cut depth,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],A,[object Object],On the surface planer the in-feed table (A) acts as chip breaker and the downward pressure exerted by the operator also makes it act as the pressure bar.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Chip formation,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Chip formation,[object Object],Chip breaking aid and pressure bar prevent riving and splintering,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Square cutter blocks,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Square cutter blocks,[object Object],[object Object]
Tension force increases with rotational speed
Will be ejected at failureDepartment of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Square cutter blocks,[object Object],Clamping bolts are in tension,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Circular cutter block,[object Object],Clamping bolts are in tension,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Circular cutter block,[object Object],[object Object]
Better balance
Safer clamping mechanism
Can run head at higher speeds (RPM)
Can produce better finish
Easier and quicker maintenanceDepartment of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife clamping mechanism,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife clamping mechanism,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife clamping mechanism,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Cutter projection,[object Object],WT4603,[object Object],Round form tool with limited cutter projection,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Cutter projection,[object Object],WT4603,[object Object],Use of a limiter to achieve limited cutter projection,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Cutter design,[object Object],WT4603,[object Object],Cutters should preferably be designed to be used in dimensionally similar pairs, formed to the same profile. ,[object Object],Pairs should be mounted directly opposite one another. The manufacturer should ensure that instructions on balancing the pairs of cutters after grinding are given to the user.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Cutter projection,[object Object],WT4603,[object Object],The design of cutter blocks should, as far as is practicable, be such as to prevent excessive cutter projection. ,[object Object],Where the mounting arrangement permits projection which could subject the cutter to unsafe stresses, the maximum permissible projection for given cutter types should be specified in the user’s instructions.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Hand-fed machines,[object Object],WT4603,[object Object],For machines designed for hand-fed operations, where cutters are necessarily exposed, the use of chip limiting cutters should be recommended ,[object Object],For other hand and semi-mechanical feed operations, cutter blocks should have as little cutter projection as is practicable.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planer,[object Object],Cutter and Machine Maintenance,[object Object], ,[object Object],Involves:,[object Object], ,[object Object],Grinding and setting of knives,[object Object], ,[object Object],Roller and pressure bar setting,[object Object], ,[object Object],Prevention of resin build up on table and rollers.,[object Object], ,[object Object],Attention to:	bearing wear,[object Object],			feed complex adjustments,[object Object],			rise and fall table,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Surface Planer,[object Object],WT4603,[object Object],The grinding angle of a cutter can vary between 30 to 35,[object Object],This is increased to 40 for hardwoods (cutting edge lasts longer),[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planer,[object Object],Overheating,[object Object], ,[object Object],May produce micro cracks in the cutting edge which can run into gaps when the cutter is used.,[object Object],May cause the cutter to bow due to expansion.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planer,[object Object],Overheating can be avoided,[object Object],By taking light cuts.,[object Object],By ensuring that the grind wheel is ‘dressed’ when required to ensure that the face is open and not glazed when grinding the knives.,[object Object],By using a ‘soft’ grinding wheel on HSS cutters – the soft structure of the wheel allows its grains to break away as soon as they are blunt revealing sharper ones.,[object Object],By wet grinding – this is the grinding of cutters while partially submerged in a mixture of water and soluble oil. The water is a coolant to prevent frictional heat developing and to disperse it should it occur. The oil prevents rust in the cutters and it provides a degree of cutting lubrication.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planer,[object Object],Setting Cutters in Block ,[object Object],Before setting the following points should be checked.,[object Object], ,[object Object],The out feed table and cutter block must be clean and free from dust resin.,[object Object], ,[object Object],Method of adjusting cutters.,[object Object],Area where setting device is used from should be free from resin and damage.,[object Object],Straightness of cutters.,[object Object],Cutters correctly balanced both in weight and end for end.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planer,[object Object],Setting devices,[object Object],There are a number of cutter setting devices.,[object Object],This device and procedure will often be supplied with the machine.,[object Object],They can be loosely placed into the following four categories:,[object Object], ,[object Object],Bridge device,[object Object], ,[object Object],Precision cutter setter device,[object Object], ,[object Object],Pin locater device,[object Object], ,[object Object],Wooden straight edge device,[object Object], ,[object Object],Cutters require accurate setting in the block because if the knives are not revolving in the same cutting circle a poor finish will be produced.,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Surface Planing,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Setting Planer Knives,[object Object],When planing wooden material a number of factors combine to generate the flat surface.,[object Object],Number of cutting knives in the block,[object Object],Speed of the revolving block,[object Object],Feed speed of the material,[object Object],Knife cutter design,[object Object],Chip breaking aids,[object Object],Nature and species of the material,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Knife cutter design & Chip breaking aids,[object Object],These factors combine to produce an acceptable surface finish,[object Object],Tip of the cutter splits away the chip,[object Object],The chip is forced away from the stock and up along the face of the cutter which is exerting a tearing effect on the grain fibre,[object Object],As the knife exits the stock the chip is either cut or will “rive” or tear deeply along the grain line and lift as a long heavy splinter,[object Object],WT4603,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
Knife cutter design & Chip breaking aids,[object Object],The cutter projection and the shape of the block face cause the severed chip to bend back causing a crack across its width,[object Object],This makes long grain riving less likely,[object Object],(Chip breaker not shown),[object Object],WT4603,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Knife cutter design & Chip breaking aids,[object Object],Sharp tooling (a) will aid in the chip bending back and cracking across its width,[object Object],Blunt tooling (b) will aid riving,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Chip Formation,[object Object],Before knife makes its cut,[object Object],Department of Manufacturing & Operations Engineering,[object Object]
WT4603,[object Object],Chip Formation,[object Object],Chip to be formed,[object Object],Department of Manufacturing & Operations Engineering,[object Object]

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