Learning Gude Wood Work Machine Oeration

Foundry Works
Level II
Learning Guide -41

Unit of Perform General Woodworking Machine
Competence: Operations
Module Title: Performing General Woodworking Machine

Operations
LG Code: IND FDW2 M11 LO1-41

TTLM Code: IND FDW2TTLM 1019v1
LO 1 Determine work requirements.
Page 1 of 87 Federal TVET Agency Version -1

FONDARY LEVEL II
Author/Copyright October 2019
Instruction Sheet Learning Guide 41
This learning guide is developed to provide you the necessary information regarding the following content
coverage and topics:
 Interpreting and understanding work requirements, instructions and
specifications.
 Selecting appropriate wood working machines.
 Selecting and preparing materials including consumables
 Using personal protective equipment and follow safe work procedures
This guide will also assist you to attain the learning outcome stated in the cover page. Specifically, upon
completion of this Learning Guide, you will be able to:
 Interpret and understood work requirements, instructions and specifications
 Select appropriate wood working machines to meet specifications
 Identify / Materials including consumables following standard procedure
Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below 3 to 6.
3. Read the information written in the information “Sheet 1”2,3,4
4. Accomplish the “Self-check1,2,3,4,
5. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation Sheet 1,” in page -20
6. Do the “LAP test” in page – 20 (if you are ready).

FONDARY LEVEL II
Interpreting and understanding work requirements, instructions and
Information Sheet-1
specifications.
1.1. Introduction
 It is customary in pattern shops to furnish the pattern maker with a mechanical drawing or blue
print of the part to be made.
 This is very important, in fact almost an indispensable part of the work, and yet often this drawing
falls far short as a reliable guide to the pattern maker; for while it may indicate clearly enough the
style of casting desired, it may contain no directions or suggestions which will govern or assist the
pattern maker in the construction of the pattern.
 Although the office drawing may be a perfect representation of the casting itself, the pattern
maker’s drawing should show not only the casting, but also the cores, core prints, etc. and where
practicable the pattern maker’s drawing should be full size, in order that the dimensions may be
taken directly from the drawing with the dividers.
 The pattern shop should always contain sufficient space to provide for the free and comfort able
execution of its greatest volume of production and should be arranged with a view to afford ample
room for the advantageous distribution and location of machinery, benches , trestles, clamps ,
tools, etc.
 The room should be so arranged that a proper temperature can be maintained in winter to insure
the successful gluing of work, as cold destroys the adhesive quality of glue and is detrimental to
good work in many ways.
 The Shop should be equipped with a band saw or at least a jig saw, a pattern lathe and suitable
clamps for gluing up material.
 In large shops a rip saw and wood worker will be found very useful. The highest grade of glued
work, such as piano and organ cases, sleeping car bunks and fine furniture generally, is made by
using hot glue applied to wood which has been heated to receive it; the work being done in a
room heated for the purpose

FONDARY LEVEL II
 It is recognised that a pattern maker is likely to work in a variety of different roles and this
standard allows for the apprentice to demonstrate a full range of skills across a variety of job roles
within the occupation.
Requirements
 A Furniture Wood Machinist produces components for furniture using a wide range of wood working
machinery.
 This includes setting up, operating and maintaining wood working machines such as saws, planers,
moulders, lathes, routers and CNC/NC machines.
 Apprentices will take raw materials and produce components to a given specification to be used in the
manufacture of furniture.
1.2. Pattern Shops General safety instructions
 The faculty or staff member in charge of the shop will ensure that all appropriate safety rules are
followed.
 Only trained and approved persons will be permitted to use any piece of powered equipment.
 For shops that are intended to be used by students:
 Training is to be done and documented by the designated shop owner (faculty, staff member).
Training should consist of both classroom instruction (including reading the Operator’s Manual for
each piece of equipment) and hands on competency training.
 Training will be documented and record retention will be the responsibility of the department.
 Shops are to be kept clean and orderly.
 Shop safety rules are to be posted.
 Horseplay is forbidden.
 .Machines is to be inspected prior to use.
 Machines should never be used if all guards are not in place.
 Machines should be placed out of service if:
 Guards are missing or damaged
 Machine is damaged or not operating properly
 Power cords are damaged or plug is not properly grounded
 Use the right tool for the job. Do not force a tool or attachment to do a job for which it was not
designed.

FONDARY LEVEL II
 Wear proper attire. Do not wear loose fitting, gloves, jewellery, watches, ties, ID badges or
anything else dangling that might get caught in a piece of moving equipment. Long hair should be
in a protective head covering such as a hair net
 No student shall operate a powered piece of equipment in a shop alone.
 Use a buddy system in the shops.
 Shops should have designated and posted operating hours.
 Never use a powered machine when impaired.
 This includes when you are sick, too tired, stressed or hurried to work carefully or on medication
that could make you drowsy.
 .Never is shy about seeking help.
 Always ask if you’re unsure about the safe operation of a tool or any aspect of a job.
 Have Shop Staff check the tool or work with which you are unfamiliar.
 Exercise common sense and clarify before starting work.
 All injuries should be assessed and appropriate medical treatment or first aid administered
immediately.
Self-Check -1 True false item
Directions: write true if the statement is correct and false if the statement is not correct on the space provided
(10%)
1. _____Pattern shops should be furnished with a mechanical drawing or blue print of the part to be
made.
2. ____ In the pattern shop only trained and approved persons will be permitted to use any piece of
powered equipment.
3. ____It is no problem wearing of loose fitting, gloves, jewellery, watches, and ties in the process of
machining operation.
4. ____Use the right tool for the job and force a tool or attachment to do a job for which it was not
designed
5. ___The pattern Shop should be equipped with a band saw or at least a jig saw, a pattern lathe and
suitable clamps for gluing up material
Note: Satisfactory rating -5 points Unsatisfactory - below 5 points

FONDARY LEVEL II
Answer for true false item
Selecting appropriate wood working machines.

Information Sheet-2
2.1. CARPENTRY MACHINES
Wood working machines are employed for large production work. These possess the following advantages over
the hand tools.
1. The carpentry machines help to reduce fatigue of carpenter.
2. The carpentry machines are used for production work.
3. The carpentry machines save time and are used for accuracy work.
4. They are used for variable job variety and more designs are possible.
Different machines are needed to save time and labor in carpentry work for various quick wood working
operations especially for turning and sawing purposes. The general wood working machines are wood working
lathe, circular saw and band saw.
 Wood Working Lathe
A general wood working lathe is shown in Fig. 2.1 which resembles roughly to an engine lathe. It consists of a
cast iron bed, a headstock, tailstock, tool rest, live and dead centres and drawing mechanisms.
The long wooden cylindrical jobs are held and rotated between the two centres.
The tool is then fed against the job and the round symmetrical shape on the jobs is produced. Scrapping tool and
turning gauge are generally used as a turning tool on a woodworking lathe.

FONDARY LEVEL II
Fig. 2.1 wood lathe
 Band Saw
Band saw is shown in Fig. 2.2. This generally used to cut the heavy logs to required lengths, cutting fine straight
line and curved work. It consists of a heavy cast bed, which acts as a support for the whole machine, a column,
two wheel pulleys, one at the top and other at the bottom, an endless saw blade band, a smooth steel table and
guide assembly. It is manufactured in many sizes ranging from little bench saw to a larger band saw mill.

FONDARY LEVEL II
Fig. 2.2 Band saw
 CIRCULAR SAW:
 A circular saw is a power-saw using a toothed or a abrasive disc or blade to cut different materials
using a rotary motion spinning around an arbour. In woodworking, the term “circular saw” refers
specifically to the hand-held type and the table saw and chop saw are other common forms of
circular saws. “Skilsaw” has become a generic trademark for conventional hand-held circular
saws.
 Circular saw blades are specially designed for each particular material they are intended to cut
and in cutting.
 A circular is used to perform various operations such as grooving, rebating, chamfering etc.
 It consists of a cast iron table, a circular cutting blade, cut off guides, main motor, saw guide,
elevating hand wheel, tilting hand wheel etc.
 The work is held on the table and moved against the circular saw to perform the quick and
automatic sawing operation and other operation on wood as said above.
 The principal parts include the frame, arbour, table, blade, guides for taking cuts, guards and
fencing.

FONDARY LEVEL II
Fig 2.3. Hand-held circular saw
 THE TABLE SAW:

A table saw or saw bench is a woodworking tool consisting of a circular saw blade, mounted on an arbour, that is
driven by an electric motor (either directly, by belt, or by gears).
The blade protrudes through the surface of a table, which provides support for the material, usually wood, being
cut.
Fig.2.4. table saw

 Jointers
 Jointers come in different sizes and perform functions similar to those of a hand plane.
 Small jointers are portable and large jointers are stationary.

FONDARY LEVEL II
 Main parts of a jointer include an on/off switch, in feed table adjustment levers, in feed table, tilting fence,
cutter guard, and out feed table. See Figure 2.5. The three main adjustable parts are the in feed table,
tilting fence, and out feed table.
 The out feed table must be set at the same height as the cutter edges at the highest point of their
rotation. See Figure 2.5. This adjustment is important to avoid tapering or biting the surface.
Fig.2.5: Jointer.
 The Drill Press
 The drill press provides you with the ability to do precision drilling and deliver especially
accurate large-diameter holes.
 One of the best features of a drill press is the ability for you to set the depth of the hole.
 This is especially useful when you have a number of holes you need to drill, all to the same
depth.
 The drill press also allows you to use forstner bits, hole saws and spade bits, drilling large
diameter holes
 to depths that would be very difficult to drill by hand

FONDARY LEVEL II
Fig .2.6: floor drill press
 Portable Hand drill
 Drills are commonly used in woodworking, metalworking, construction and do-it-yourself projects.
Specially designed drills are also used in medicine, space missions and other applications.
 Drills are available with a wide variety of performance characteristics, such as power and capacity.
Fig.2.7: Portable hand drill

Safety considerations for a portable power drill include the following:

FONDARY LEVEL II
 Choose the right drill bit for the job. For example, do not use a square-shank bit in an electric
drill.
 Make sure the bit is tight in the chuck. Use the chuck key in each hole of the chuck to tighten the
bit. Be sure to remove the key before starting the drill to avoid throwing the key.
 Use a center punch to mark stock when working with metal. The indentation helps guide the bit.
 Make sure the work is held securely in place. Use a clamp or vise to hold a small piece.
 Hold the drill perpendicular to the piece to avoid binding the bit.
 Remove the bit from the drill after completing the job.
 ORBITAL SANDER
 Orbital sanders (also known as finishing sanders) sand in a circular motion, and are used to
achieve a fine, smooth finish on timber surfaces.
 They are not suitable for ‘flushing off’ joints or removing wood quickly.
 A reciprocating sander is very similar to the orbital sander but its motion is back and forth rather
than circular.
 The base of the sander has a soft rubber pad and the abrasive paper is held to it by a spring
clip.
Fig.2.8: sander machine

Bench Grinders
 A bench grinder does work similar to a portable grinder, but it is a stationary machine mounted on a
bench.
 Main parts of a bench grinder include an on/off switch, grinding wheels, safety shields, and adjustable
tool rest. See Figure 2.9.
 The adjustable tool rest is used for supporting and guiding small objects for grinding. See Figure 2.10.
Bench grinders are used for sharpening and reconditioning tools and for shaping and cleaning metal.
Another type of stationary grinder is called the pedestal grinder. It is similar to a bench grinder but is
larger and is anchored to the floor.
 Both a bench grinder and a pedestal grinder have a double-shafted motor, which allows a wheel to be
mounted on each side.
 Usually one wheel is coarser in texture and is used for removing material from the surface of the piece.
The other wheel is finer in texture and is used for finishing work.
Safety considerations for a bench grinder include the following:
 Wear appropriate eye and face protection.

FONDARY LEVEL II
 Wear additional protective clothing, such as a leather apron or an appropriate filter or respirator, if
needed.
 Adjust the tool rest for the job.
 Stand to the side of the wheel when starting the grinder and let the wheel run for a short period before
using it. Wheels that are going to break usually do so within the first minute of use.
 Move the work slowly back and forth across the face of the wheel to avoid overheating the metal.
 Do not forces work into the grinding wheel. Allow the speed and grit of the wheel to do the work.
Fig.2.9. bench grinder
Figure 2.10 - Reconditioning a Screwdriver on a Bench Grinder, With Tool Supported by the Tool Rest

FONDARY LEVEL II
self-check -2 multiple choices
Part I choose the best answer and write the letter of your choice son separated answer sheet. (10%).
1. ___Types of machine which is used to produce round symmetrical shape on the work pieces is ;
A. Jointer
B. wood lathe
C. vertical band saw
D. plane
2. ___Machines which used to achieve a fine, smooth finish on timber surfaces.
A. Bench grinder B. sander C. jointer D. portable drill
3. ____Which one of the following machine is used for cutting holes on wood surface?
A. Floor drill press B. grinder C. plane D. jointer
4. ____Cutting fine straight line and curved work, heavy logs to required lengths on wood stock is done
by?
A. Bench grinder B. Band Saw C. drill press D. All
5. ______is used to sharpening cutting tools
A. Portable drill B. bench grinder C. floor type drill D. none
Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points
You can ask you teacher for the copy of the correct answers.
Information Sheet-3 Selecting and preparing materials including consumables.

FONDARY LEVEL II
Materials Used in Carpentry:
Basic materials used in pattern making shop are timber and plywood. Auxiliary materials used are nails, screws,
adhesives, paints, varnishes, etc.
 Timber:
Timber is the name given to wood obtained from exogenous (outward growing) trees.
In these trees, the growth is outward from the centre, by adding almost concentric layers of fresh wood every
year known as annual rings.
After the full growth, these trees are cut and sawed to convert into rectangular sections of various sizes for
engineering purposes.
Timber is available in market in various shapes and size. The common shapes and sizes an: given below:
 Log: This is the trunk of die tree which is tree from branches.
 Balk: This is the log after sawing roughly to square cross section.
 Deal: This is the log after sawing into rectangular cross section of width about 225 mm and
thickness up to 100 mm.
 Plank: This is the timber piece having width more than 275 mm and thickness 50 lo 150 mm.
 Board: This is the timber piece below 50 mm in thickness and above 125 mm in width,
 Batten: This is the timber piece below 175 mm in width and thickness between 30 mm to 50 mm in
thickness.
 Scantlings: These are timber pieces of various assorted and nonstandard sizes other than the
types given above
 Classification of Wood
 The timber used for commercial purposes can he divided into two classes as soft wood and hard
wood
 Soft wood
 A soft wood is light in weight and light colour.
 They may have distinct annual rings but the medullar rays (radial lines) are not visible and the
colour of the sap wood (outer layers) is not distinctive from the heart wood (inner layers).
 These woods cannot resist stresses developed across their fibres; hence, not suitable for wood
working.
 Hard wood

FONDARY LEVEL II
In this type of wood the annual rings are compact and thin and the medullar rays (radial lines} are Visible in most
cases. Hard woods are nearly equally strong both along and across the fibres.
Hand wood is the material used for wood working
 Classification of timber
 According to the manner of growth of trees, timber can be classified as
 Exogenous or out ward growing ) Endogenous or in ward growing
 Exogenous or out ward growing
 In exogenous trees the growth take place from the centre by the addition of concentric layers of
fresh wood every year, known as annual rings.
 These varieties of trees are suitable for building and other engineering uses the exogenous trees
are again classified as
 Conifers or ever green trees
 The conifer give soft woods and the deciduous gives hard wood common example of hard wood
are Sal, teak, rose wood, sandal, shisham, oak beach, ash ebony, mango, neem, babool, etc.,
soft wood include kail pine, deodar chair, walnut seemal etc.
 Endogenous or in ward growing timber
 These trees grow in wards i.e. .every fresh layer of sap wood is added inside instead of outside
cane, bamboo, coconut
 Seasoning
 Seasoning of wood carried out for removing the sap and reducing the moisture content the
presence of sap and moisture will render the wood unsuitable for engineering works due to
uneven shrinkage, crack, wrapping and decay.
 Different methods of seasoning
 Air seasoning or Natural seasoning
 Water seasoning
 Electrical seasoning
 Kiln seasoning
 Ply wood
 Thick sheet formed by pasting veneers of wood is called ply.
 Three or more ply joined by glues is called plywood.

FONDARY LEVEL II
 The grains of adjacent layers are kept at right angle to each other in order to get better
strengthening both directions the outer layer are called facing ply and good hard wood veneers
are used for this inner ones are called core ply and low quality wood is used for this the ply wood
is made by either cold pressing or hot pressing.
Self-Check -3 Written Test
Matching: match the word or phrase under column “A’’ with words or phrase which have similar meaning from
under column “B”(10%)
Column A Column B
1. __ Seasoning A. Nearly equal strong both a long and across the fiber
2. __ Plywood B. Three or more ply wood joined by glue
3. __ Exogenous tree C. light in weight & light colour
4. __ Soft wood D. outward growing
5. __ Hard wood E. removing the sap & reducing the moisture content
Using personal protective equipment and follow safe work

Information Sheet-4 procedures

FONDARY LEVEL II
4.1. Common safety in wood shop
There are some general safety precautions to be taken care of while working in carpentry shop. Some of which
are discussed as under.
 Before starting any wood working machine, it should be ensured that all the safety guards are in
proper places and secured well.
 While working on a circular saw, one should not stand in a line with the plane of the rotating
blade and always keep your fingers always away from the reach of blade.
 The wooden pieces should not be fed to the sawing machines faster than the cutting speed of the
machine.
 While working on wood lathes, the job should be properly held.
 One should not use defective or damaged carpentry tools while carrying out carpentry work.
 Nails, screws should be properly kept in a box for proper housekeeping.
 Sufficient safety precautions are to be taken for preventing fire in the carpentry shop.
 No carpentry tools should be thrown for saving time in handling.
 Avoid drugs and alcohol
 Wear appropriate clothing
 Use sharp blades and bits while working
 Disconnect power before blade changes when replacing g blades in the power hack saw.
 Always check for nails, screws and other metal on y our wood or work piece.
 Never put your hands anywhere near the moving blade especially when attempting to remove
waste or cut-offs.
 Avoid distractions.
 Always listen carefully to the teacher and follow instructions. Ask questions if need be.
 Avoid horse play in the workshop.
 Wear good strong shoes, training shoes are not allowed.
 Bags should not be brought into the workshop as people can trip over them.
 Always be patient, never rush in the workshop.
 Use hand tools carefully, keep both hands behind the cutting edge.
 Report any damage to machines/equipment as this could cause accident.
 Only use woodworking machines that you have been trained to use properly and safely.
 Always wear safety glasses or goggles or a face shield (with safety glasses or goggles).

FONDARY LEVEL II
 Wear hearing protection that is suitable for the level and frequency of the noise you are exposed
to in the woodworking area.
 Use gloves to protect hands from splinters when handling wood but do not wear them near
rotating blade and other machinery parts where the gloves can be held.
 Make sure the equipment is properly grounded before use.
 Turn the power off and unplug the power cord (or lock out the power source) before inspecting,
changing, cleaning, adjusting or repairing a blade or a machine.
Part I: write true if the statement is correct and false if the statement is not correct on separated answer sheet.
(10%)
1. ______When starting wood work machine operation the advisable work procedure is removing safety
guards and perform any operation.
2. _____ Using any wood working machines that you have been not trained properly and safely is not safe
work.
3. _____In the process of operation never put your hands anywhere near the moving blade especially
when attempting to remove waste or cut-offs.
4. _____Inspecting changing, cleaning, adjusting or repairing a blade on a machine is performed with the
machine is turn on.
5. _____The wooden pieces should not be fed to the sawing machines faster than the cutting speed of the
machine
Operation Sheet 1 Determining job requirements

FONDARY LEVEL II
Procedures
1. Wear personal protective equipment

2. Prepare working drawing for pattern making
3. Select and prepare materials to be used for pattern making
4. Identify machines and check its performance for specific work
LAP Test Practical Demonstration
Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the following
tasks within 4 hour.
Task 1. Wear proper personal safety cloth
Task 2.idenify and select proper raw materials and machines.
List of Reference Materials

FONDARY LEVEL II
1. Introduction to Basic metal manufacturing process and work shop technology ,RAJENDER SINGH,
2006 New Age International (P) Ltd., Publishers
2. General workshops- wood work (ENG207),federal university OYE-EKITI,Faculty of engineering and
technology
3. Machine Shop Policies and Procedures, college of engineering And computation science Colorado
school of mines.
4. Teaching Woodturning Basics, American Association of Wood turners, Phil Brennion ,Kip Christensen,
Bonnie Klein Alan Lacer, Michael Mocho (2009)
Foundry Works

FONDARY LEVEL II
Level II
Learning Guide -42

Unit of Competence: Perform General Woodworking Machine
Operations

Operations

LO 2 Set up woodworking machines

FONDARY LEVEL II
 Selecting tools/cutters appropriate to task requirements.
 Sharpening or shaping cutting tools.
 Installing tools/cutters correctly.
 Setting or adjusting guards/stops.
 Setting-up woodworking machines.
 Select tools/cutters appropriate to task requirements.
 Sharp and/or shape cutting tools to specification.
 Install tools/cutters correctly using standard operating procedures.
 Set and adjust Guards/stops as required.
 set-up woodworking machines in accordance with company standard operating
procedures and safety requirements
3. Read the information written in the information “Sheet 1”2,3,4and 5
5. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation Sheet 1-4 in 48
6. Do the “LAP test” in page –49 (if you are ready).
Information Sheet-1 Selecting tools/cutters appropriate to task requirements
1.1. Types of tools and their use

FONDARY LEVEL II
 Tools for wood working
 The principle hand tools used in a carpentry workshop can be classified into
 Marking and measuring tool
 Cutting tool
 Planning tool
 Boring tool
 Striking tool
 Holding tool
 Marking and measuring tool
 Rules are used for measuring dimensions. For measuring and setting out dimensions various types of
rules are used in carpentry shop. Steel Rule, Stainless Steel Rule of length 30cm and 60cm.
 Flexible Measuring Rule- for measuring large dimensions as well as curved or angular surface
dimensions.
 Straight Edge and Squares
This is a machined flat piece wood or metal having perfectly straight and parallel edges.
 Steel Tape: It is used for large dimensions, such as marking on boards and checking the overall
dimensions of the work.
 Gauges are used to mark lines parallel to the edges of a wooden piece.
 It mainly consists of a wooden stem sliding inside a wooden stock. The stem carries a steel point for
marking lines. The stock position on the stem can be varied and fixed rigidly by tightening the thumb
screw.
To mark a line parallel to an edge the gauge stock is held freely against the edge and pushed along it, pressing
the steel points to the surface
Fig. 1.1 steel rule

FONDARY LEVEL II
Fig.1.2 measuring steel tape
Fig.1.3 marking gauge
Fig.1.4. mortise gauge

 Try square
Try square consists of rectangular steel blade fixed rigidly to cast iron stock. The length of blade varies from
150mm to 300mm.
 Marking Knife or Scriber
Marking Knives are used to convert the pencil lines drawn on the wooden surface into deep scratch lines on the
surface. They are made of steel with a sharp point at one end and flat blade at the other end.
Fig.1.5 try square Fig1.6 Marking knife

FONDARY LEVEL II
Fig, 1.7 Bevel square
Holding tools
 Work Bench
This is a table of having size and raised construction made of hard wood. The size ranges from 50- 80 cm in
length and about 90cm in width. Two or four carpenters can work at a time on the work bench.
 Carpenters Bench Vice
It consists of jaw fixed on the table side and movable jaw kept in position by means of screw and handle. The
body of vice is made of cast iron or steel. The jaws are lined with hard wood which can be removed when it is
damaged.
Fig. 1.8 Work bench with bench hook
The screw moves inside the fixed half nut which can be engaged or disengaged by operating the lever. This is
made up of a bar of steel. The work is clamped between jaws by rotating the screw using the handle. It is used
for clamping glued pieces or holding the work piece of larger size together for various operations.

FONDARY LEVEL II
 C Clamp: The clamp of the shape of letter C or G is used to clamp short pieces together as the bar
clamp. These clamps are available is sizes varying from 70 mm to 800 mm. it is used for holding the
planks after gluing.
Fig1.9 .Carpenter vice Fig 1.10 C-clap
Fig. 1.11 Bar or T-clap

1.2. Cutting tools
 Saws
Saw is a cutting tool which has teeth on one edge and cutting is affected by reciprocating motion of the edge
relative to the work piece. Cutting occurs during the forward motion; such a saw is called push type saw, the
cutting occurs during the backward motion.
I. Hand saw- This saw is used for short straight cuts. It has a blade of 25-40cm length 6- 10cm width. The number
of teeth per cm length ranges from 3-5.
II. Tenon Saw (Back saw) - It has a parallel blade of 25-40cm length and 6-10cm width. The number of teeth per
cm length ranges from 5-8.
 Chisels
The common type of chisels used is briefly explained below.

FONDARY LEVEL II
 Firmer Chisels- they are most common and general purpose chisel used by a carpenter. They have flat
blade of 15-50mm width and 125mm length.
 Dove Tail Chisel (bevelled edge firmer chisel) - These chisels are used for fine and delicate works as well
as for cutting corners.
 Mortise chisel – These chisels are used for heavy and deep cut to remove large quantity of wood. These
chisels have width of about 15mm but the blade thickness may range from 6- 15mm.
Fig 1.12 Saws
Fig1.13. parts Rip saw

FONDARY LEVEL II
Fig 1.13: Parts of chisel
Fig1.14: types of chisels
 Claw Hammer
This is a hammer having steel head and wooden handle. The flat face of the head is used to drive nails and claw
portion for extracting nails out of the wood.
Fig1.15 . claw hammer

FONDARY LEVEL II
 Wood rasp files: it is a finishing tool used to make the wood surface smooth, remove sharp edges, and
finish fillets and other interior surfaces. Sharp cutting teeth are provided on its surface for the purpose.
This file is exclusively used in wood work.
Fig 1.16 .Rasp file
 Common Drill Bits

Drill bits are available in many shapes and sizes for various functions.
Besides basic hole drilling bits, there are specialized bits such as countersink bits for recessing screw heads or
screwdriver bits for driving and removing screws.
The two basic types, based on the back of the bit or shank, are the round- or straight-shank bits and square-
shank bits.
The latter have a tapered square tang on the end.
The round-shank bits are used in hand drills and portable electric drills, whereas the square-shank bits are used
in braces.
Some of the common bits (auger, expansive, Forstner, spade, and twist drills) are discussed below.
See Figure 1.17 Note that the auger, expansive, Forstner, and spade drill bits are available in both square and
round shanks for use in braces and portable power drills.
Figure 1.17 - Common Types of Drill Bits

FONDARY LEVEL II
Directions: match the word or phrase which is written under column ‘’A’’ with words or phrase which have similar
meaning from under column’’ B’’ (14%)
Column ‘’A ‘’ column’’ B’’
1. _____knife or scriber A. used to make the wood surface smooth

2. _____steel tape B. Used for measuring large dimension
3. _____C-clap C. General purpose chisel
4. _____ firmer chisel D. used for fine and delicate work
5. _____Dovetail chisel E. used to clap short pieces together
6. _____Mortise Chisel F. convert the pencil line on the wood surface into deep scratch line
7. ______Rasp file G. used for heavy and deep cut to remove large quantity of wood
Note: Satisfactory rating – 7 points Unsatisfactory - below 7points

FONDARY LEVEL II
Information Sheet-2 Sharpening or shaping cutting tools.
2.1 Machines for Tool Grinding

 In order to efficiently use the woodworking machines, their tools and cutters have to be periodically
sharpened and kept trim.
 It is not possible to grind or sharpen all the diverse types of tools by hand grinding.
 Equipment that is essential includes a circular saw and band saw blade sharpener (either in two separate
machines or in the same machine); a band saw blade butt welder; a planer knife grinder; a tool and cutter
grinder; and a double- ended tool grinder.
 Nowadays many people who use hand tools such as chisels, planes, scrapers and hand saws for
ambitious carpentry work are neither poor nor backward, but privileged.
 The times of unrelenting, heavy physical work in the woodworking trades are fortunately long past and it
will be the rare woodworker who will do completely without some support from machines and power
tools.
 Sharpening chisel and plane blades is not really difficult. But what complicates the start for newcomers is
the unbelievable variety of sharpening tools, working techniques and processes.
 Every hand tool user will eventually develop from these a more or less individual sharpening method.
2.2. Sharpening cutting tools.
 How do chisel and plane blades cut?
 A chisel blade has a bevel on one side and a flat back on the other.
 These two surfaces intersect to form the acute-angled wedge with its sharp cutting edge.
 The most important feature of the wedge is its wedge angle β (beta) that includes the back and bevel.
For most chisel blades this angle is around 30°.
Common Tools Used for Sharpening
 Files are common tools used to sharpen the blades on other tools.
 They are available in different styles and coarseness, including files for specific jobs such as chain saw
files.
 Coarser files are used to sharpen larger blades, such as those of a lawn mower or ax.
 Fine-toothed files are used for smaller tools, such as a wood chisel.

FONDARY LEVEL II
 Before filing a tool, the worker should put on gloves and secure the tool in a vise or other device to hold it
firmly in place.
 A file cuts on the forward stroke only, so it should be lifted off the object on the backward stroke
 Another type of sharpening tool, a stone, is commonly used after grinding to bring knife blades to a fine
edge. See Figure 1.18.
 These stones are made from natural or synthetic materials and are available in different configurations.
Some synthetic stones have two types of grit, a coarse side and finer side.
 Bench stones are typically kept in a box that is set on a bench for use. Hand stones are held in the hand
during use, and stone wheels are mounted on a power grinder.
 Stones are often used with water or oil to clean the stone and facilitate sharpening.
 When sharpening a tool on a stone, the worker should put on gloves and hold the blade away from
himself or herself.
Fig2.1. Sharpening stone
The bench grinder is a common power tool used for rough sharpening and to produce the correct bevel on tool
blades.
Using a Bench Grinder to Sharpen or Recondition Tool
Selecting the Wheel

 In selecting the wheel, it is important to use the right grit (degree of coarseness) for the job.
 For example, a wheel with fine grit would not be efficient for removing burrs and sharpening a large tool.
 As the grit number increases, abrasives become finer; therefore, a 120-grit wheel is finer than a 60-grit
wheel. Medium-grit wheels are acceptable for most tool-sharpening jobs.

FONDARY LEVEL II
 In addition, the wheel must be the correct rating for the speed of the motor; check the owner’s manual for
this information.
Following Safety Procedures
 Ensure the grinder is unplugged when changing the wheel and follow instructions in the owner’s manual.
A face shield, leather apron, and appropriate filter or respirator is recommended when using the grinder.
 Inspect the wheel and do not use a wheel that is damaged or out of round.
 If damaged, consult you instructor about dressing or replacing the wheel.
 Dressing the wheel means to use a tool to make the diameter perfectly round and the face square. It also
involves cleaning debris from the abrasive material.
 Because a defective wheel generally breaks within the first minute of use, stand to the side of the wheel
when starting the grinder and let the wheel run before using.
Preparing to Grind
 Examine the tool to be sharpened or reconditioned and compare it to a similar tool in good condition to
determine the correct design and shape to be attained. See Figure 1.20. Always grind the tool back to its
original edge or shape.
 For example, if reconditioning a screwdriver, use a screw slot to gauge the thickness and width of the
blade. See Figure 1.21. Before grinding the tool, adjust the tool rest so it will be 1/16 in. from the wheel
and at the proper angle.
Fig 2.2 - Different Shapes of Tool Edges Fig 2.3 - Checking Shapes of Screwdriver
Tip and Fit in Screw Slot
Grinding the Tool
 It is important to move the tool slowly across the face of the wheel to avoid overheating the metal. Do not
apply extreme pressure to the tool; allow the grinding wheel to do the work.
 Only grind on the face of the wheel, never the sides. See Figure 1.22 Use cutting oil or water as needed
to clean the stone or cool the blade of the tool.
 Overheating the tool and allowing it to cool slowly will draw its temper, or soften the tool.

FONDARY LEVEL II
Figure 2.4 - Reconditioning a Screwdriver
Finishing the Task

Check the edge or shape of the tool for accuracy; a tool sharpening gauge can be used to check the angle of a
number of tools. (Figure 1.23).
Fig2.5. Tool sharpening gauge
1: back
2: bevel
3 : cutting edge
4: mortising
5: paring, sliding on the bevel
6: paring, sliding on the b
Fig. 2.6: How a chisel blade cuts v: movement of blade
β (beta): wedge angle of cutting
edge

FONDARY LEVEL II
 You can use a chisel for mortising (the edge is driven into the wood by hammer blows to separate it and
force it apart) or for paring (the blade slides on the wood and lifts off a chip that is deflected via the
leading face of the wedge, also referred to as the rake face.
 If the blade slides on the bevel (the back acts as rake face), the depth of cut can be varied by raising or
lowering the handle. If it slides on the back (the bevel acts as rake face), the cut is exactly straight ahead.
 Precise paring depends on the guiding function of the long, flat back extending all the way to the cutting
edge. Chisels with bevels on both sides are carving tools, not suitable for joinery.
Drill bit grinding procedures
1. Dress grinding wheel with dressing tool

2. Hold drill bit against face of wheel at 590
3. Carry drill bit up the drill face by dropping end and rotating very slightly in clockwise direction
4. make slow deliberate strokes, the full width of the cutting lip
5. do not lower cutting lip below the horizontal position as this will round the cutting edge
6. when one lip is ground ,rotate the drill one half turn and grind the other lip
7. Use tool gauge to check equal lengths of lips, 590 angle cutting lip and 12-150 lip clearance.
8. Test bit by boring hole in mild steel plate.
9. Stop while drilling, turn drill press in reverse direction to release drill bit from hole. note depth of cut of
each lip.
10. Make grinding correction on drill bit as indicated by hole.
11. Submit drill bit and metal for evaluation.
Fig2.7 drill bit grinding procedure

FONDARY LEVEL II
Directions: choose the best answer and write the letter of your choices on the separated answer sheet (8%).
1. Which one of the following is true in sharpening cutting tools?
A. Coarser files are used to sharpen larger blades
B. Fine-toothed files are used for smaller tools, such as a wood chisel.
C. Before filing a tool, the worker should put on gloves and secure the tool in a vise
D. All of the above
2. Common sharpening tools ;
A. Bench grinder
B. Hand file
C. Grinding stone
D. All of the above
3. What is the difficulty in sharpen cutting tools?
A. An availability variety of sharpening tools.
B. Work techniques or process
C. A and B
D. None
4. How we measure the angle of sharpened tool?
A. By guessing B. Using angle measuring gauges C. by using measuring callipers D.all

FONDARY LEVEL II
Information Sheet-3 Installing tools/cutters correctly.
3.1. Procedures for installing tools and cutters

 Circular table saw
Safe use of woodworking machinery" would require
 Lock-off master stop control that can be operated quickly in an emergency.
 If not already fitted a braking device (manual or electrical) which allows the saw blade to come
to rest within a maximum of ten seconds of operating the stop control.
 Ensuring the position of the riving knife is no more than 8mm from the back of the saw blade at
bench height. Also its curvature should conform as closely as possible to shape of the saw
blade and its thickness no more than 10% thicker than the saw blade body thickness.
 Information, by way of a sign, indicating the smallest diameter saw blade allowed (i.e. 6/10ths of
maximum) must be prominently displayed.
 Set the blade so it extends no more than ½’’ above the surface of the work piece .this minimize
strain on the motor and produces better cutting result.
 Fitting a band saw blade
 Fitting or replacing a saw blade will mean opening the upper and lower guard doors for the
purpose of access; therefore, before the start of any such work, the machine must be isolated
from its electricity supply.
Then, and only then, the work may begin.
 Open and move aside the top and bottom guard doors.
 Remove or move aside other obstructions, for example the blade top guards, guides and the
table mouthpiece.
 Using the appropriate hand wheel lower the top wheel enough to enable the blade to fit on to
both wheels.
 Fit the blade on to the wheels, making sure the teeth at the table cutting point are facing
downwards, and then raise the top wheel sufficiently to hold the blade on to the wheels.
 Track the saw blade
 Tension the saw blade.

FONDARY LEVEL II
 Reset thrust wheels and guides.
 Reposition and secure guards.
 Blade length when measuring the length of a band saw blade, the amount of tensioning
adjustment should be taken into account.
 The following formula can be used: Length of blade is equal to 3.14D +2* Maximum distance
between wheel centres Tension allowance for most industrial saws, a tension allowance of 50
mm is adequate.
 Wood lathe
 Check that all locking devices on the tailstock and tool rest assembly (rest and base) are tight
before operating the lathe.
 Position the tool rest close to work, almost touching the wood.
 Check tool rest position often and as wood is removed, turn off the lathe and re-position the rest.
 Rotate your work piece by hand to make sure it clears the tool rest and bed before turning the
lathe “on.” Be certain that the work piece turns freely and is firmly mounted.
 A hand wheel on the outboard side of the headstock simplifies this process of spinning the lathe
by hand before turning on the switch.
 Be aware of what turners call the “red zone” or “firing zone.”
 This is the area directly behind and in front of the work piece — the area’s most likely for a piece
to travel as it comes off the lathe.
 A good safety habit is to step out of this zone when switching the lathe to the “on” position.
 When observing others turn stay out of this area.
 Hold turning tools securely on the tool rest, holding the tool in a controlled and comfortable
manner.
 Always contact the tool rest with the tool before contacting the wood.
 It is safest to turn the lathe “off” before adjusting the tool rest or tool rest base (banjo).
 Remove the tool rest before sanding or polishing operations.
 Never leave the lathe running unattended. Turn the power off.
 Don’t leave the lathe until it comes to a complete stop.
 Drive centre

FONDARY LEVEL II
 The drive canter is placed in the headstock and rotates with the lathe to drive the wood while
turning.
 The most common type of drive centre is the Spur Centre which consists of a centre point and
four spurs that penetrate into the end of the spindle to provide traction.
 When teaching beginning turners, some instructors prefer to use a Cup Drive instead of a spur
drive.
 The cup drive has a centre point inside a supporting cup, but no spurs. When turning with cup
drive, if the tool begins to catch the wood, the cup drive acts similar to a clutch and allows the
wood to slip.
 This stops the rotation o f the wood rather than forcing the tool to dig in and tear the surface
Fig3.1drive center
 TAILSTOCK CENTERS
 The tailstock centre, which mounts in the tailstock spindle, centres the work and exerts force through
itself to the drive centre in the headstock.
 It also gives radial support to the work, thereby holding it in the lathe.
 As with drive centres, the tailstock centre has a Morse-taper shaft, but the business end is quite
different.
 There are two types of tailstock centres: dead centres and live centres .
 The simplest dead centre is a 60° point, but the more traditional design-a cup centre-consists of a
simple pivot bearing surrounded by a raised ring.

FONDARY LEVEL II
Directions: write true if the statement is correct and false if the statements is not correct on separated answer
sheet (10%)
1. ____While using circular saw the position of the riving knife is no more than 8mm from the back of
the saw blade at bench height.
2. ____ Tail stock centre gives radial support to the work, thereby holding it in the lathe.
3. ____The drive canter is placed in the headstock and rotates with the lathe to drive the wood while
turning.
4. ______While turning on wood lathe Use higher speeds for larger diameters or rough pieces, and
lower speeds for smaller diameters and pieces that are balanced
5. ____while turning on wood lathe, we should hold turning tools securely on the tool rest.
Note: Satisfactory rating – 5 points Unsatisfactory - below 5 points
Information Sheet-4

FONDARY LEVEL II
Setting or adjusting guards/stops.
Any machine part which can cause injury must be guarded.

Machine guards help to eliminate personnel hazards created by points of operation, ingoing nip points, rotating
parts and flying chips.
 Types of guards commonly.
 Fixed guard
 Interlocked guard
 Adjustable guard
 Self adjusting guard
 Pull back device
 Two-hand control
 Fixed guard-is kept in place permanently by fasteners that can only be released by the use of a tool
Fig:4.1 gurd
 Interlocked guard-shuts off or disengages power to the machine and prevents it from starting when the
guard is removed/opened.
 Adjustable guard-provides a barrier which can be adjusted to suit the varying sizes of the input stock.
 Self adjusting guard-provides a barrier which moves according to the size of the stock entering the
danger area.
 Two hand controls -concurrent use of both hands is required to operate the machine, preventing the
operator from reaching the danger area.

FONDARY LEVEL II
 Pull back -the device is attached to the wrist of the operator which pulls the operator's hands away from
the point of operation or other hazardous areas when the machine operates
 Shields can be used to provide protection from flying particles, splashing metal working fluids or
coolants.
 Holding tools can be used to place and remove stock. Example, reaching into the danger area of a
power press.
 Holding tools must not be used as a replacement of machine guards
 Ensure that the guards are in position and in good working condition before operating.
 Know the location of emergency stop switch.
 Do not wear loose clothing or jewellery that can be caught in the rotating parts.
 Confine long hair.
The keys and adjusting wrenches must be removed from the machine before operating it.

FONDARY LEVEL II
Directions: match the word or phrase which is written under column ‘’A’’ with words or phrase which have similar
meaning from under column’’ B’’ (10%)
Column “A “ column ‘’B’’
1. __Self adjusting guard A. kept in place permanently by fasteners
2. __Two hand controls B. used as a replacement of machine guard
3. __Pull back C. Provide a barrier which moves according to the size of.
4. __Holding tools the stock entering the danger area
5. __Fixed guard D. use of both hands is required to operate the machine
Preventing the operator from reaching the danger area.
E. attached to the wrist of the operator which pulls the operator's hands away
from the point of operation or other hazardous areas

FONDARY LEVEL II
Information Sheet-5 Setting-up woodworking machines.
 Setting up wood lathe

 Always check the speed of the lathe before turning it on.
 Use slower speeds for larger diameters or rough pieces, and higher speeds for smaller diameters and
pieces that are balanced.
 Always start a piece at a slower speed until the work piece is balanced.
 If the lathe is shaking or vibrating, lower the speed.
 If the work piece vibrates, always stop the machine to check the reason.
 Check that all locking devices on the tailstock and tool rest assembly (rest and base) are tight before
operating the lathe.
 Check tool rest position often and as wood is removed, turn off the lathe and re-position the rest.
 Rotate your work piece by hand to make sure it clears the tool rest and bed before turning the lathe
“on.” Be certain that the work piece turns freely and is firmly mounted.
 A hand wheel on the outboard side of the headstock simplifies this process of spinning the lathe by
hand before turning on the switch.
 Be aware of what turners call the “red zone” or “firing zone.”
 This is the area directly behind and in front of the work piece — the areas most likely for a piece to
travel as it come off the lathe.
 A good safety habit is to step out of this zone when switching the lathe to the “on” position.
 When observing others turn stay out of this area.
 Hold turning tools securely on the tool rest, holding the tool in a controlled and comfortable manner.
 Always contact the tool rest with the tool before contacting the wood.
 It is safest to turn the lathe “off” before adjusting the tool rest or tool rest base (banjo).
 Remove the tool rest before sanding or polishing operations.
 Never leave the lathe running unattended.
 Turn the power off. Don’t leave the lathe until it comes to a complete stop.
Before turning on the lathes

FONDARY LEVEL II
 A short checklist will assure that students are ready to turn on the lathe:
 Eye protection on
 Blank properly mounted between centres: drive centre point engaged in the end-grain
 Tailstock base firmly locked.
 Tailstock ram not extended too far out, and live centre pressed into the end grain
 Tailstock ram locked
 Tool rest base locked firmly in position
 Tool rest set at proper height and distance from the wood to avoid contact
5.1. Exercise blank mounted on lathe

Proper Tool Grip
The simple over-hand grip is the easiest for roughing gouge use:
 Right hand: grip near the end (butt) of the handle, thumb pointing forward and on the top
 Left hand: grasp the steel within the first few inches down from the cutting edge. The left hand should be
in contact with the tool rest.
Fig 5.2 Left hand grip fig 5.3 Right hand grip

FONDARY LEVEL II
Self-Check 5 Written Test
Directions: write true if the statement is correct and false if the statements is not correct on separated answer
sheet (10%)
1. ___In the wood lathe turning operation the red zone refers to the area directly behind infront of the work
pieces
2. ___Before turning on the late short check list will assure that students are ready to turn.
3. ___It is important to remove the tool rest before sanding or polishing operation.
4. ___While turning on the wood lathe if you use left hand, grasp the steel with in the first few inch down
from the cutting edge and the left hand should be in contact with the tool rest.
5. ___Tailstock ram extended too far out, and live centre pressed into the end grain ensure that the stock is
held properly.

FONDARY LEVEL II
Operation Sheet 1 Sharpening cutting tools
Procedures for sharpening:

Step 1- wear PPE.
Step 2- select required proper tools and machine for sharpening
Step 3. Adjust or set up speed and guards
Step 4- sharpen tools to specified dimension
Step5- check the angle of cutters using tool measuring gauge
Step 6.clean the machine
Operation Sheet 2 Fitting blade on table circular saw
Procedure
Step 1- select required cutting blade
Step 2-open the gourds.
Steps 3- break set the blade so it extends no more than ½ above the surface of the work pieces
.
Operation Sheet 3 Fitting the blade on band saw
Procedure
Step 1- wear PPE.
Step 2- unplug the cable of the machine from electric source
Steps 3- open the upper and lower guards
Step 4- lowers the top wheel enough to enable the blade to fit on to both wheels
Step 5. Fit the blade on to the wheel
Step 6. Tension the saw blade

FONDARY LEVEL II
Step 7. Reset thrust wheel and guide
Step 8. Reposition and secure guards.
Operation Sheet 4 Wood lathe tool set up

Step 1- wear PPE.
Step 2- check that all locking devices on the tail stock and tool rest
Steps 3- position the tool rest cloth to the work
Step 4rotate the work piece by hand to make sure it clears the tool rest and reposition the rest
Step 5adjust the drive center and tail stock center when required
LAP Test 1 Practical Demonstration
Name: _____________________________ Date: ________________

tasks within --------- hour.
Task 1. Sharp or shape the cutting tools for the required job.
Name: _____________________________ Date: ________________

tasks within --------- hour.
Task 1. Fit the blade of the table saw following correct procedure
Task 2. Adjust or fit the blade of band saw depend up on standard operation procedures.

FONDARY LEVEL II
Task 4. Set all required tools on wood lathe for predetermined job
1. Sharpening of the drill bit, department of agricultural engineering of Minnesota.
2. Sharpening chisel and plane blades ,Friedrich Kollenrott Schladen am Harz, January 2019
Bonnie Klein Alan Lacer, Michael Mocho (2009
technology
5. https://www.youtube.com/watch?v=KZ6trlIHF68
6. https://www.youtube.com/watch?v=72syhJoOsHM

FONDARY LEVEL II
Foundry Works
Level II
Learning Guide -43

Unit of Competence: Perform General Woodworking Machine
Operations

Operations

LO 3: Operate woodworking machines

FONDARY LEVEL II
 Poisoning and Securing material to be machined effectively.
 Machining materials to specification
 Optimizing materials and minimize wastage
 Position and secure material to be machined effectively.
 Machine materials to specification using standard operating procedures.
 Optimize material use and minimize waste.
3. Read the information written in the information “Sheet 1”2,3,
5. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation Sheet 1,” in page -68

FONDARY LEVEL II
Information Sheet-1 Poisoning and Securing material to be machined effective
 Holding the Work.

 Now that you have your lathe set up and running, it's time to think about turning something. But first
you need a way to hold the work in the lathe
 Technically, a chuck is any device that holds work in the lathe.
 It can be a set of centres, a faceplate, an elaborately manufactured jaw type chuck, or a simple shop
made glue block.
 Understanding the difference between spindle turning and face plate turning is central to the concept
of chucking. In spindle turning, the grain of the wood being turned runs between the centres of the
lathe, that is, parallel to the axis of the lathe.
 In face plate turning, the grain of the work runs at right angles to the axis of the lathe
 Although turning between canters is commonly associated with spindle turning, it's possible to hold
work this way and yet be faceplate turning.
 Similarly, it's possible to have something screwed onto a faceplate and still be spindle turning.
 The screws in this case would be into the end grain of the wood. Remember that the orientation of
the grain, not how the work is held, dictates the type of turning.
 Each type of work also requires different tools and turning techniques,
 Centres
 The oldest and simplest way to hold work in the lathe is between a set of centres, one mounted in the
headstock and the other in the tailstock.
 Most spindle work is held this way. Centres are a fast and reliable way to mount work, and they allow
unlimited chucking and upchucking, which is an advantage when you want to trial-fit turned fu rniture
parts or to allow stains and finishes to dry between lathe operations.
 drive centres
 The drive centre, or spur centre, mounts in the headstock spindle.

FONDARY LEVEL II
 It both holds the work and transmits power to it. Except on very inexpensive lathes (where the center
screws on the headstock spindle), the shank of the centre is a Morse taper that fits into a matching
socket in the spindle.
 The business end of the centre is a small central point surrounded by spurs (also called tines).
 The central point should protrude I/ 6 in. to 1 in. beyond the face of the tines to ensure cantering of the
work before the tines bite in. On better drive centres, the central point is removable and adjustable for
the amount it stands proud of the tines.
 Drive centres are sold in two-spur and four-spur models.
 A two-spur centre is generally better because it drives as well as a four-spur one and can be oriented
to give positive drive no matter what the contour of the end of the turning billet (see the If the surface is
irregular, a four-spur centre will drive on only one tine, which can cause the work to go off-centre and
even kick out of the lathe in extreme cases.
 If your lathe comes with a four-spur centre, you can easily modify it by grinding away two of the tines.
Mini centres are also available, which are used where a small footprint is desired, as in the turning of a
knob.
 The diameter of the tines is so small that minis are much less sensitive about how square the end of a
billet is.
 Each tine of a spur centre comes to a chisel edge. These edges must not be in line with each other or
the centre will become a wedge and split the work. If the tines become dull or damaged, you can grind
them back to a chisel edge, making sure you grind on the bevel side only.
 You should also keep the central point sharp. If it is removable, it's easy to sharpen it by mounting it in
a cordless drill and simply touching it to a running grinder.
 It's normally not necessary to pound the centre into the work or to saw lines in the end of the billet, as
some turners recommend, achieving positive drive.
 Pressure from the tailstock is generally sufficient to drive the tines into the work. Even on small lathes,
there is tremendous mechanical advantage in the screw-thread mechanism of the tailstock hand
wheel.
 It's a good idea to grind a nick on the outer radial surface of one of the tines.
 Whenever you remove work from the lathe but plan to rechuck it, make a pencil mark on the work
piece next to the nick so you can reposition it accurately. With wear, sharpening, and mishaps such as
drops on concrete, each tine gets to be a different length.

FONDARY LEVEL II
 Unless the work is repositioned on the drive centre exactly the way it was removed, perfect centering
will be difficult. Your pencil mark and nick make rechucking simple.
Fig 1.1 drive center
Fig. 1.2 hold sock on lathe

FONDARY LEVEL II
If the billet end is not square, a four-spur drive centre drives on only one tine and the work constantly walks off-
centre. A two-spur centre can be turned to drive on both tines, eliminating the problem.
Fig 1.3 Tight and fix stock with tail center

Place the centre-punched end of the billet on the centre pin of the step centre, and catch the other centre-punch
mark with the tailstock centre. Once you tighten the tailstock, the work is securely held.
To inspect your work, simply loosen the tailstock a bit and place your open hand against the spinning billet.
It will stop instantly. To continue with your work, tighten the tailstock again.
Standard drive centres are available in Morse-taper sizes # 1 , #2, and #3 .
 Because the centre is stationary, it needs to be lubricated to reduce friction and heat build up from
the rotating work piece.
 The benefit of a cup centre is that the ring around the point retains grease, so lubrication is better
and makes the work less prone to splitting.
 Holding the Work
 There is one advantage to using a dead centre: You can touch it with a tool (lightly) and it will not dull
the edge as a live centre will.
 Occasionally a turning situation, such as when you have to turn around the end of the billet right up
to the centre, makes a 60° dead centre worth using.
 Dead centres are inexpensive, and lathes have traditionally come with a dead centre in the
accessory kit.

FONDARY LEVEL II
 Live centres are a great improvement over dead centres because the centre point is mounted on a
ball bearing and rotates with the spinning work, eliminating the need for lubrication and the risk of
burning
 . In addition, you can exert much greater force on the work with a live centre, which means that the
work is held more securely. Because of these overwhelming advantages, even entry-level lathes
generally come with a live
 centre in the accessory kit these days.
 Unfortunately, it's typically not a very good live centre-in fact, you often would be better off with a
dead one.
Fog.1.4 Tail stock center

 Faceplates
 Faceplates are used to hold work that can't be supported (or that you don't want to be supported) by a
tailstock. Since this situation encompasses most faceplate work, the type of turning has been named for
the chucking method. As mentioned previously, however, it's the orientation of the grain that makes it
face work, not how the work is held.
 A faceplate is simply a metal disk with a threaded hub that screws onto the headstock spindle.
 Circles of holes around the periphery allow work to be fastened to the plate with screws.
 Most faceplates have a flat surface, but the better models have a ledge around the outer edge that allows
the plate to better seat flat on uneven surfaces.

FONDARY LEVEL II
Fig1.5: Face plate
 Plates are made from cast aluminum, which works fine for most operations but is not suitable for large-
diameter and heavy work. For heavy-duty face plate turning, there is no substitute for cast iron or steel.
 Faceplates are available in various diameters depending on the lathe manufacturer, but the most
common sizes are 3 in., 6 in., and 9 in.
 Most woodworkers think that they need a large faceplate, but for the vast majority of your work, a 3-in.
plate (often known as a "bowl chuck") will serve you much better.
SCREWS
 In the past, wood screws were used to attach work to a faceplate, but today's sheet-metal screws provide
a much surer hold.
 Sheet-metal screws have a straight body and 45° thread profile that bites into wood much better than
wood screws
 They are also mildly heat treated, which gives them added strength and toughness.
 As a minimum, you should use #10 sheet-metal screws to secure work to the faceplate.
Fig 1.6: screw

FONDARY LEVEL II
1. Directions: Match column A with column B. Select the letter of the correct answer from
column B and write your answer on the separated answer sheet. (10%)
Column A Column B
1. ___Face plate A. used to attach work to face plate
2. ___Drive centre B. to hold work that can be supported by the tail stock
3. ___Centre C. eliminate the need for lubrication &the risk of burning
4. ___Life centre D. Are fast &reliable way to mount work
5. ___Screw E. spure centre mounts in the head stock spindle
Note: Satisfactory rating -5 points Unsatisfactory - below 5points

Answer Sheet
Information Sheet-2 Machining materials to specification

FONDARY LEVEL II
2.1. Wood Turning Job (parallel turning)
Procedure:-
1. Cut the material as per length given in drawing.
2. Preparation:- if the wooden piece is not right angle then square it by plaining or sawing
3. Marking:- after planning mark diagonal of square piece at both ends of the piece.
Then divide the width and thickness in to three equal parts and joint the lines thus making octagon on both ends
join lines of both octagon lengthwise. Mark the waste.
4. Planning:- Plane down the waste till marking and prepare a octagon piece.
5. Fix the octagonal piece in the lathe machine at the centres between the live spur and dead spur.
6. Check for all the guards are in proper position.
7. Take dimensions on the outside caliper for the job. Start the machine and use outside gouge chisel to
make it fairly round. After that off the machine and check for roundness. Then take the flat chisel and
make it perfectly round to given dimensions of the job. Always leave a half inch distance from both the
ends. Check it without side caliper.
8. For final finishing use sand paper. After completion of job remove and clean the machine.
 Parting Tool (1/8") The Parting Tool is a special purpose tool used primarily to produce square
shoulders and to turn wood to a specified diameter.
 It is often used in conjunction with outside calipers when careful measuring is required. Parting tools
are available in a variety of cross-section shapes.
 For general purposes, parting tools are relatively easy to control and usually produce a scraping cut.
When making parting tool cuts deeper than 1/2”, the cut should be widened slightly to prevent the
tool from binding.
Fig 2.1 squaring using parting tool

FONDARY LEVEL II
 Safety Precaution
 Always make octagon for the piece to be used for turning work. Never directly use square piece in
lathe machine with sharp edges.
 Always sharpen the tools before using on lathe machine.
 Always use goggles and hand glows while working on lathe machine.1)Remove loose fitting outer
garments
 Always use proper sharpened tools
 Remove loose fitting out garments and ring, watch, Bengals while working on lathe machine
 Always check for all safety guards before starting the machine.
 Do not chisel loosely while turning. Always rest the tools on the tool rest while the machine is in
operation.
2.2 Operating the table bench saw:
 To rip stock, remove the cut-off gauges and set the rip fence away from the saw by a distance
equal to the desired width of the piece to be ripped off.
 The piece is placed with one edge against the fence and fed through with the fence as a guide.
 To cut Stock Square, set the cut-off gauge at 90° to the line of the saw and set the ripping fence to
the outside edge of the table, away from the stock to be cut.
 The piece is then placed with one edge against the cut off gauge, held firmly, and fed through by
pushing the gauge along its slot.
 The procedure for cutting stock at an angle other than 90° (called mitre cutting) is similar, except
that the cut off gauge is set to bring the piece to the desired angle with the line of the saw.
 For ordinary ripping or cutting, the saw blade should extend above the table top 1/8 to 1/4 inch plus
the thickness of the piece to be sawed.
 The vertical position of the saw is controlled by the depth of cut hand wheel, shown in figure 3-2.
The angle of the saw blade is controlled by the tilt hand wheel. Except when its removal is
absolutely unavoidable, the guard must be kept in place.
 The slot in the table through which the saw blade extends is called the throat. The throat is
contained in a small, removable section of the table called the throat plate. The throat plate is
removed when it is necessary to insert a wrench to remove the saw blade.

FONDARY LEVEL II
 Observe the following safety precautions when operating the tilt-arbour table bench saw:
 Do not use a ripsaw blade for crosscutting or a crosscut saw blade for ripping. When ripping and
crosscutting frequently, you should install a combination blade to eliminate constantly changing the
blade. Make sure the saw blade is sharp, unbroken, and free from cracks before using.
 The blade should be changed if it becomes dull, cracked, chipped, or warped.
 Be sure the saw blade is set at proper height above the table to cut through the wood.
 Avoid the hazard of being hit by materials caused by kickbacks by standing to one side of the saw.
 Always use a push stick to push short, narrow pieces between the saw blade and the gauge.
 Keep stock and scraps from accumulating on the saw table and in the immediate working area.
 Never reach over the saw to obtain material from the other side.
 When cutting, do not feed wood into the saw blade faster than it will cut freely and cleanly.
 Never leave the saw unattended with the power on.
2.3. Operating Drill press
 When making deep holes, clean the hole frequently.

 Use a clamp or drill vice to prevent work from spinning.
 The drill bit or cutting tool must be locked securely in the chuck.
 Remove the chuck key before starting the drill press.
 Lubricate drill bit when drilling metal.
 Reduce the drilling pressure when the drill begins to break through the work piece. This prevents
drill from pulling into the work and breaking.
 Do not force the drill with extra pressure.
 Do not hold the work by hand.
 Do not place hands under the stock being drilled.
 Observe the following safety precautions when operating a band saw:
 Keep your fingers away from the moving blade.

 Keep the table clear of stock and scraps so your work will not catch as you push it along.
 Keep the upper guide just above the work, not excessively high.

FONDARY LEVEL II
 Don’t use cracked blades. If a blade develops a click as it passes through the work, the operator
should shut off the power because the click is a danger signal that the blade is cracked and may be
ready to break. After the saw blade has stopped moving, it should be replaced with one in proper
condition.
 If the saw blade breaks, the operator should shut off the power immediately and not attempt to
remove any part of the saw blade until the machine is completely stopped.
 If the work binds or pinches on the blade, the operator should never attempt to back the work away
from the blade while the saw is in motion since this may break the blade. The operator should
always see that the blade is working freely through the cut.
 A band saw should not be operated in a location where the temperature is below 45°F.
 The blade may break from the coldness. Using a small saw blade for large work or forcing a wide
saw on a small radius is bad practice. The saw blade should, in all cases, be as wide as the nature
of the work will permit.
 Band saws should not be stopped by thrusting a piece of wood against the cutting edge or side of
the band saw blade immediately after the power has been shut off; doing so may cause the blade
to break. Band saws with 36-inch-wheel diameters and larger should have a hand or foot brake.
 Particular care should be taken when sharpening or brazing a band saw blade to ensure the blade
is not overheated and the brazed joints are thoroughly united and finished to the same thickness as
the rest of the blade. It is recommended that all band saw blades be butt welded where possible;
this method is much superior to the old style of brazing.
Self-Check -2 Matching

FONDARY LEVEL II
1. Directions: Match column A with column B. Select the letter of the correct answer from column B and
write your answer on the separated answer sheet. (10%)
Column A Column B
1. ___ Smoothing wood product A. prevent work from spinning
2. ___ Parting tool B. mitre cutting
3. ___ To rip stoke C. bench saw
4. ___ Cutting stock at an angle rather than900 D. used to produce square shoulder
5. ___ Drill vice E. sanding
Information Sheet-3 Optimizing materials and minimize wastage

FONDARY LEVEL II
3.1. Introduction
 A cutting stock problem (CSP) basically consists of cutting large pieces available in stock to produce
smaller pieces (called items) in order to meet a given demand.
 The cutting is planned to minimize waste of the stock material (other objectives may arise).
 These objectives may be to minimize trim loss, the number of cutting lines or production cost, maximize
profit and so on.
 In a cutting plan, the required set of pieces from the available stock lengths must be obtained.
 The objective is to minimize the number of used stock lengths or, equivalently, trim loss (waste.
 This type of problem occurs in several industries such as paper, aluminium, steel, glass, and furniture
industry among others.
 The standard problem is defined as follows: given a set of small and large objects, how the small
objects should be obtained from the large ones in order to optimize a given criterion.
 The typical restrictions to which a cutting or packing plan is submitted are the impossibility for the small
objects to overlap, and the limited capacity or length of the large objects
 Waste Management
 Management is the collection, transport, processing, recycling or disposal and monitoring of waste
materials.
 The term usually relates to materials produced by human activity, and is generally undertaken to reduce
their effect on health, environment and aesthetics.
 Waste management is also carried out to recover resources from waste.
 Being specific to construction industries, construction.
 Waste management deals with waste generated during manufacturing and allied activities
 Waste Reduction
 Waste reduction is primary step in waste management. Since reduction can be implemented without
special efforts rather small improvement in process can show substantial waste reduction.
 In order to reduce the cost of the project and to increase profit margin, all the organizations of the
industry need to have a positive attitude towards waste prevention
 Waste Reduction Techniques
 Good operating practices: Good operating practices generate less waste by making existing processes
more efficient.
 Therefore, they are also good business practices.
 Since many good operating practices are easy and inexpensive to implement they are practical for
businesses of all sizes.
 Material Substitution Using non hazardous or less hazardous materials in products and services can
reduce or even eliminate waste generation
.
 Process ( Technology) Modification
 Production changes that can decrease your company’s generation of wastes include:

FONDARY LEVEL II
 Changing the production process.
 Changing the placement or layout of equipment.
 Replacing existing equipment with more efficient models and Automating the production process
 Site sorting of waste
 Being specific to construction industry this technique can be implemented in construction industry. All the
material wasted or could not be used by any reason should be dumped at a single place and later the
sorting of the material shall be done so that the material, which can be reused like bricks, bar pieces,
stones, concrete at the site its lf, are taken away before the scrap goes for recycling process.
 In this way we can save some quantity of material without re transporting it to the site after the recycling
process.
 The main problem in sorting out the waste is even when high tipping fees imposed, they have little
incentive to perform onsite waste sorting which is considered to be time and labour demanding.
 Only through contractual requirements or legislation can onsite waste sorting be fully implemented and
becomes a long term solution to the landfill shortage problem.
 Recycling of material waste
 Many construction and demolition wastes can be recycled into new materials.
 Keep in mind that local recycling options vary across the world.
 Construction waste recycling is the separation and recycling of recoverable waste materials generated
during construction and remodelling
 This is the most common way of minimizing the material waste.
 Some materials which can be recycled and then reused at site are transported to the place where these
materials are recycled and made ready to use according to the requirement of the site.
 In the recycling process the main task for the people working at site, is to make out whether the material
can be recycled or not, as these people are not aware of the recycling process and hence require a
different team.
 Scrap lumber or wood can be processed and used for landscaping, compost, animal bedding, boiler fuel,
or engineered building products.
 Metals such as aluminium, copper, steel, and brass can be sold to scrap metal yards. This is some of the
easiest and most cost effective materials to recycle.
 Cardboard can be kept separate in cardboard only dumpsters at the job site and picked up by a local
recycling firm.
 Waste is a shared responsibility between all parties of the supply chain, from the client down to the waste
contractor.
Directions: write true if the statement is correct and false if the statement is not correct (10%)

FONDARY LEVEL II
1. _____Waste is a responsibility of only producers or manufacturer
2. _____Recycling is the most common way of minimizing the material waste.
3. ____-Changing the placement or layout of equipment can increase waste generation.
4. _____ Material Substitution Using non hazardous or less hazardous materials in products and services
can reduce or even eliminate waste generation.
5. _____ Scrap lumber or wood can be processed and used for landscaping, compost, animal bedding,
boiler fuel, or engineered building products.
Operation Sheet 1 Perform machining operation
Procedure

FONDARY LEVEL II
Step 1- wear PPE.
Step 2- measure and cut the wood stock on table saw machine
Steps 3- make it square to proper dimension on the jointer machine
Step 4- hold the squared stock and turn it to the shape according to the working drawing
Step 5. Using proper number of sand smooth the surface of the project
Step 6. Finish the work and clean the machine.
LAP Test Practical Demonstration
Name: _____________________________ Date: ________________

FONDARY LEVEL II
tasks within ---------hour.
Task 1. Adjust cutting tools and machine following proper procedures
Task 2. Cutting the stock and turn to prepare desired pattern
Task 3: finish the work to the required surface quality
.

technology

FONDARY LEVEL II
2. Porter, Brain 2001– Carpentry and joinery. – 3rd, Design and Typesetting by J&L Composition Ltd, Filey,
North Yorkshire Printed and bound in Great Britain.
3. Productivity Enhancement in a Wood Furniture Manufacturing Factory by Improving Work Procedures
and Plant Layout, Corresponding author: korrakot@eng.cmu.ac.th http://www.ie.eng.cmu.ac.th
Chiang Mai University, Chiang Mai 50200 THAILAND
Bonnie Klein Alan Lacer, Michael Mocho (2009)
5. https://www.youtube.com/watch?v=Vmz5BKXBGLA

FONDARY LEVEL II
Foundry Works
Level II
Learning Guide -44

Unit of Perform General Woodworking Machine
Competence: Operations

Operations

LO 4 : Quality assure finished component

FONDARY LEVEL II
4.1 This learning guide is developed to provide you the necessary information regarding the following content
 Evaluating machined component against specifications and predetermined finish.
 Meeting necessary rectification or comply with predetermined finish.
 Cleaning and maintaining machine and tools
 Performing housekeeping.
 Evaluate machined component against specifications and predetermined finish.
 Do Necessary rectification to meet specifications or comply with predetermined finish.
 Clean and maintain machine and tools following workplace procedures and standards.
 Perform Housekeeping in accordance with standard operating procedures.
3. Read the information written in the information “Sheet 1”2,3,4
5. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation Sheet 1,” in
page -85
Evaluating machined component against specifications and

Information Sheet-1 predetermined finish.

FONDARY LEVEL II
1.1 Quality Management Systems in pattern making shop.
 Quality management systems covers the procedures which are put in place to allow a manufacturer to
maintain consistency in quality and to keep records of non-conforming products, processes or materials,
in order to make improvements.
 These systems are essential in the running of any manufacturing business, whether developed as a
matter of experience or by following a set of formal principles.
 Having a written factory production control (FPC) system is an example of a quality management system.
 ISO 9001 is a standard that identifies the requirements for an organization’s quality management system
 The benefits of adopting ISO9001 can include increasing market share, driving down costs, managing
risk more effectively or improving customer satisfaction. To meet the requirements of ISO 9001:2008
(which is the latest version of the standard), manufacturers must:
 Identify the steps in their business processes.

Describe how these processes link together to satisfy customer expectations.
 Ensure sufficient resources are available to maintain the system.

Monitor how well the processes are working in order to help to identify future
improvements.
 This would mean showing how orders are dealt with from initial enquiry, through the stages of
manufacture, to delivery.
 For a joinery manufacturer, the standard will cover a wide range of obligations, all of which would have to
be documented. A small selection of these obligations could include:
 Control of measuring equipment.
 Recordings of non conforming products.

FONDARY LEVEL II
 Ensuring that staffs are aware of the product requirements.
 Reviewing each supplier’s performance.
 Properly maintaining key production machines
Directions: write true if the statement is correct and false if the statement is not correct. (8%)
7. ___Properly maintaining key production machines reduce quality of product.

8. ___Quality management is essential in the running of any manufacturing business.
9. ___ISO 9001 is a standard that identifies the requirements for an organization’s quality
management system.
10. ____Control of measuring equipment is one of quality controlling method in production shop.

FONDARY LEVEL II
Meeting necessary rectification or comply with predetermined finish.
Information Sheet-2
2.1. Identification of defects for determination of control points
 Constancy of production quality, especially when the furniture is produced in series, enables the industry
of massive furniture, while designing the quality management system whose segments or whole
production processes are repeated, to focus on those phases of product lifecycle where non conformity
is increased.
 Such process validation, in which the process is required to comply with the process window, is
accomplished by statistical process control.
 A way to define and implement the method of process validation is to develop optimum system
parameters by optimization combined with evaluation of the product quality.
 Make a statistical evaluation of the part quality variation over a sufficient amount of production runs with
fixed system control parameters utilizing des constructive testing of produced parts to verify that common
cause variations are always well within the process window that fulfils the product specification.
 Use statistical process control to ensure the absence of special cause variations in each production run.
 Implement strict quality control on all conditions outside the system control parameters such as raw
material quality, operator routines, system maintenance and support systems.
 Establishing the principle of quality, at very beginning of developing the new product spots where
increased nonconformity of critical control points is noticed, must be identified what requires the special
approach to quality management that would be directed toward points where occurrence of defects is
most likely.
 The defect can be occurred in each phase of production process.
 However, the experience shows that defects in some parts of production process are frequently occurred
than in others.
 Occurrence of defect will result in getting the product which does not meet customer’s demands neither
normative defined in the process of developing the new product and this product is consider as non
conformity product.

FONDARY LEVEL II
 While defining critical control points we cannot exclude the process as the reason for defect occurrence
what comes out of assumption that all processes are defined during the process of developing the new
product, that production is done with installed and checked technology, agreed materials and the chosen
process, itself, can be false and it can bring to non conformity of product.
 Due to this at very beginning of developing the new product and defining the production process it is
needed to determine critical control points for that product on the basis of:
 Experience of the previous projects, and On the basis of customer's demands which have to be
integrated into the product from its own creation.
 Defects in the production process are results of production of parts or assembly which do not meet
customers’ demands, standard requirements and specification built up on that ground.
 Such products cannot be delivered to customer or adjusted to acceptable quality.
 Defects on the products itself considered as waste which must be thrown away and repaired what
increase the production costs are not the only defects but it includes mistakes in documents, provided
false information about product, delay in delivery or making too much of waste during the processing.
 During one production cycle defects may appear before processing, during the processing, and after
processing.
Defects caused before the processing are the most commonly related to
 defects of input materials
 non quality preparation of production i.e., defects caused due to wrong chosen working method,
 defect of basing work piece,
 defects on tensioning of work piece,
 defects on adjusting of machines and
 defects on making the processing system.
 These defects occur at the beginning of production process and they can be eliminated during the entry
control and better preparation of production..
 The following is the most commonly checked during the entry control of material in the furniture
production of massive:
 Wood type of material and whether it is in accordance with the requested specification for certain
product, moisture of material which has to be within limits 8+2%, ordered number of pieces and
completeness in order to release product into production, accuracy of requested dimension and tolerance
and other specific demands for certain product that is defined during the preparation of production.

FONDARY LEVEL II
 Defects in production are necessity but the aim of each company is to minimize and identify them as
early as possible.
 Therefore, each company has to organize the control that will present compromise between control of
each operation, which is very unfavourable from the point of cots, and the final control that can have
major consequences if it is the only way of control.
 In order to avoid appearance of any defects during the processing and to promptly identify them, the
controls on specific spots must be organized and critical control points must be determined depending on
technological capability of company and chosen flow of processing.
 The research completed in this work was done in way to register defects during the process per t
 Types and frequency. Doing so, certain control pints were determined which have to be marked.
 Therefore, during the flow of production we have the following controls that are imposed as logical control
of accuracy of cutting measures control of accuracy of making elements of bounds control of grinding
quality control of lacquering or oiling quality (surface treatment of wood) and control of montage
possibilities
 Defects caused after the processing are mostly related to defects of measurement and defects caused
as a consequence of uncompleted series of delivery are being checked in the following controls as
follows:
 control of packaging and final control of delivery
 The most common defects caused during the production have the changeable character due to daily
different influences on the production process itself and the major influence on it has the man power.

FONDARY LEVEL II
Self-Check -2 Written test
1. ____A way to define and implement the method of process validation is to develop optimum system
parameters by optimization combined with evaluation of the product quality.
2. ____The most common defects caused during the production have the changeable character
3. ____Defects in the production process are results of production of parts or assembly which do not meet
customers’ demands, standard requirements and specification built up on that ground.
4. ____Defects caused after the processing are mostly related to defects of measurement.
5. ____These defects occur at the beginning of production process and they can be eliminated during the
delivery time customer.

FONDARY LEVEL II
Information Sheet-3 Cleaning and maintaining machine and tools
3.1. Add and test lubricants frequently.
 Lubricants reduce friction around any moving part.

 A schedule of good lubrication maintenance extends the life of large machinery equipment and parts.
 Lubrication is one of the first and most important of maintenance checks.
 Look for signs of excess oil or grease build-up on pistons.
 Check for leaks around oil seals.
 Be sure to use the right lubricant.
 There are specific kinds of oil and grease for every component.
 Check the manufacturer’s recommendations.
 Getting the lubricants checked is a good way to diagnose problems with large machinery.
3.2. Check for signs of wear
Vibration, shock, high temperatures, friction and age all contribute to the breakdown of parts in heavy machinery.
 Vibration can come from gears and belts that are out of alignment.
 Shock can come from accidents and from poor operator technique
 High temperatures can come from extended use, friction, poor lubrication and worn parts, among other
reasons
 Age affects many key components. Over time, belts will warp. Seals will dry and crack. Bolts will loosen
and stretch out of shape..
 Should you discover wear and tear on any moving parts within your heavy equipment, be sure to quickly
perform the necessary replacement of any worn parts.

FONDARY LEVEL II
3.3. Keep machinery clean, and maintain a clean environment
 There are many seals and filters in place on heavy machinery to keep working parts clean and free of
contamination. Seals should be inspected regularly to make sure they’re in good condition.
 Filters should be inspected and changed regularly.
 Breathers should be kept clean to avoid creating a vacuum in the cab which will suck contaminants into
the cab. The electronics in the cab are susceptible to breakdown if contaminated.
 This impacts the clutch, for example.
 Machinery should be covered in a shed or cloth if at all possible.
 Exposure to wind and weather can lead to rust and rot. The machinery should be run periodically if it is
not in use.
3.4. Have a maintenance and repair schedule, and keep good records
 Fluids, tires, tracks and electrical systems are among the components that have to be checked regularly
for preventive maintenance. Know what needs to be inspected and when.
Here are some examples.
 Power transmissions have many moving parts that need to be maintained in top condition. Gearboxes
need to be checked for lubrication, vibration and damage to parts.
 Friction materials, seals, gaskets and bearings all need to be inspected for wear and replaced. Gears
and shafts usually last a long time and don’t need to be replaced often, if at all.
 Drive train components need constant monitoring. Check pulleys and v-belts on CVT transmissions for
alignment and wear. Check sprockets for correct meshing with chains and for breaks.
 Test the oil to diagnose problems. Change filters frequently.
 Bearings keep great amounts of force running smoothly and are vital to large machinery performance.
Check bearing lubrication often. Maintaining bearings well extends their life.
 Lubricate gears frequently.
 Do a seal check to prevent bearing raceway contamination.
 Run torque checks on the bolts. Bolts can elongate and creep over time.
To conclude, following the above 5 steps can significantly extend the useful life of heavy machinery, improving
the Return on Investment from these important purchases.

FONDARY LEVEL II
Self-Check -3 True false
1. ___Lubricants increase friction.

2. ___Gearboxes do not need to be checked for lubrication, vibration and damage to parts.
3. ___High temperatures can come from extended use, friction, poor lubrication and worn parts,
among other reasons
4. ___Vibration can come from gears and belts that are out of alignment.
5. ___There are the same kinds of oil and grease for every component.

FONDARY LEVEL II
Information Sheet-4 Performing housekeeping.
4.1 Housekeeping safety precaution:-

 Keep always your workshop neat and clean.
 Stack the material neatly so that it will not fall when taking from the stock.
 Always keep Fire extinguisher at easily reach to hand in emergencies.
 Do not store any material in the way.
Poor floor conditions are a leading cause of Slips, Trips and Falls (STF) accidents at many workplaces.
 Ensure that floors are cleaned regularly and immediately if liquids (including water) or other materials
(e.g., oil, powder) are spilled.
 Provide areas that cannot be cleaned continuously (e.g., entrance ways) with anti-slip mats and/ or anti-
slip flooring.
 Use anti-slip flooring in work areas that tend to be wet or greasy (e.g., industrial kitchens and washing
bays).
 In work environments where wood is handled (e.g., woodworking workshops), implement measures to
prevent the accumulation of wood chips, shavings and dust as these can become slipping and fire
hazards.
 Repair or replace any uneven, torn, worn out or damaged flooring or carpets as soon as possible as
these are potential slipping or tripping hazards.
 Any mat or rug found loose or wrinkled should be secured accordingly.
 To prevent accidents due to poor floor conditions, always deploy barriers and warning signs around the
unsafe condition until it is repaired or replaced

4.2 Apply 5S
 Benefit of applying 5S

FONDARY LEVEL II
The5S system sounds so simple that people often dismiss its importance. However the fact remains that 5S:
 Makes your workplace safer, cleaner and more pleasant place to work.
 Makes your job more satisfying.
 Eliminates overburdens and disappointments.
 Makes it easier to communicate with everyone you work with.
 Gives you an opportunity to give creative input how your work place should be.
 Decreases and makes defects zero that brings higher quality
 Eliminates waste that reduces cost
 Avoids delays and bring reliable delivery
 Increases safety by decreasing accidents
 Increases productivity by decreasing breakdown
 Reduces complaint and brings greater confidence and trust
 Tools and materials used to implement Sort activity
Tools and materials are required to implement sort, set in order and shine activities in work stations. The
following are some tools and materials used to implement the first pillar of 5S-Sort.
 red tags sticker
 hook nails
 shelves chip wood
 sponge broom
 pencil shadow board/ tools board
Formats (for recording necessary and unnecessary items, plans etc.
 Tools and materials used to implement shine

The following are some tools and materials used to implement the third pillar of 5S-Shine.
 Sponge oil
 Broom detergent s
 Brush spade
 vacuum cleaner bolts
 garbage containers floor scrubber cleaning Pads
Sort: is the 1st of the five components of 5S. Sort means sorting out necessary and unnecessary items in
the workplace, dispose of the unnecessary and keeps only those items necessary for the current operations of
the workplace.
Set in order: is the 2nd of the five components of 5S. Set-in-order means deciding the place for
necessary items, arrange them to keep easy access, and display signs so that they can be found immediately
and returned or replenished properly.
Shine: is the 3rd of the five components of 5S. It means cleaning equipment, facilities and floor space in
the workplace, and ensures that they are in good operating condition

FONDARY LEVEL II
Figure 4.1: cleaning tools
Match column A with column B. Select the letter of the correct answer from column B (8%)
Column A column B
1. _____Shine A. industrial kitchens and washing bays
2. ____ Set in order B. 1st of the five components of 5S
3. ____ Sort C. deciding the place for necessary items, arrange them to keep easy access
4. ____Anti-slip flooring D. cleaning equipment, facilities and floor space in the workplace,

FONDARY LEVEL II
Operation Sheet 1 Performing housekeeping.
Procedures
Step 1. Wear proper safety cloth
Step 2. Select and prepare cleaning materials
Step 3. Sort necessary and unnecessary items in the workplace, dispose of the unnecessary and keeps only
those items necessary for the current operations
Step 4. Set in order the required tools on their proper place
Step 5. Apply cleaning equipment, facilities and floor space in the workplace, and ensures that they are in good
operating condition
Name: _____________________________ Date: ________________


FONDARY LEVEL II
tasks within___ hour.
:
Task 1- wears PPE.
Task 2- Identifies tools and equipment’s depends on their type.
Task 3- set in order by placing the tools and equipment’s in proper places.
Task 4- clean each tools and equipment
1. Maintenance Scheduling for Mechanical Equipment U.S, Department of the Interior Bureau of
Reclamation Denver, Colorado Volume 4-1A – (Revised 2009
2. https://blogs.3ds.com/delmia/2014/03/5-maintenance-tips-to-extend-equipment-life-and-roi/ISSN(Online)
: 23198753
3. Machine Shop Policies and Procedures, college of engineering And computation science Colorado
school of mines.

FONDARY LEVEL II
No Name of trainer Qualification Region E-mail
1 Thomas Mamo A Addis Ababa mamothom2009@gmail.com

2 Mustefa Aman A Oromia mustefaam@gmail.com
3 Garomsa Hailu A Oromia garuhailu@yahoo.com
4 Iyerus Tesema B Somali
5 Dechas Ahmed B Harar dechasahmed1.da@gmail.com

FONDARY LEVEL II

Learning Gude Wood Work Machine Oeration

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Learning Gude Wood Work Machine Oeration

Uploaded by

Copyright:

Available Formats

Foundry Works

Learning Guide -41

Module Title: Performing General Woodworking Machine

LG Code: IND FDW2 M11 LO1-41

Page 1 of 87 Federal TVET Agency Version -1

Page 2 of 87 Federal TVET Agency Version -1

Page 3 of 87 Federal TVET Agency Version -1

Page 4 of 87 Federal TVET Agency Version -1

Self-Check -1 True false item

Note: Satisfactory rating -5 points Unsatisfactory - below 5 points

Page 5 of 87 Federal TVET Agency Version -1

Selecting appropriate wood working machines.

2.1. CARPENTRY MACHINES

Page 6 of 87 Federal TVET Agency Version -1

Page 7 of 87 Federal TVET Agency Version -1

Page 8 of 87 Federal TVET Agency Version -1

 THE TABLE SAW:

Fig.2.4. table saw

Page 9 of 87 Federal TVET Agency Version -1

Page 10 of 87 Federal TVET Agency Version -1

Fig.2.7: Portable hand drill

Page 11 of 87 Federal TVET Agency Version -1

Fig.2.8: sander machine

Page 12 of 87 Federal TVET Agency Version -1

Fig.2.9. bench grinder

Page 13 of 87 Federal TVET Agency Version -1

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

Information Sheet-3 Selecting and preparing materials including consumables.

Page 14 of 87 Federal TVET Agency Version -1

Page 15 of 87 Federal TVET Agency Version -1

Page 16 of 87 Federal TVET Agency Version -1

Self-Check -3 Written Test

Note: Satisfactory rating - 5 points Unsatisfactory - below 5 points

Using personal protective equipment and follow safe work

Page 17 of 87 Federal TVET Agency Version -1

Page 18 of 87 Federal TVET Agency Version -1

Self-Check -4 True false item

Note: Satisfactory rating - 5 points Unsatisfactory - below 5 points

Operation Sheet 1 Determining job requirements

Page 19 of 87 Federal TVET Agency Version -1

1. Wear personal protective equipment

LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

List of Reference Materials

Page 20 of 87 Federal TVET Agency Version -1

Page 21 of 87 Federal TVET Agency Version -1

Learning Guide -42

Module Title: Performing General Woodworking Machine

LG Code: IND FDW2 M11 LO2-42

Instruction Sheet Learning Guide 42

Page 22 of 87 Federal TVET Agency Version -1

Information Sheet-1 Selecting tools/cutters appropriate to task requirements

1.1. Types of tools and their use

Page 23 of 87 Federal TVET Agency Version -1

Fig. 1.1 steel rule

Page 24 of 87 Federal TVET Agency Version -1

Fig.1.3 marking gauge

Fig.1.4. mortise gauge

Fig.1.5 try square Fig1.6 Marking knife

Page 25 of 87 Federal TVET Agency Version -1

Fig. 1.8 Work bench with bench hook

Page 26 of 87 Federal TVET Agency Version -1

Fig1.9 .Carpenter vice Fig 1.10 C-clap

Name: _____________ Date:

Name: _____________ Date:

Name: _____________ Date: