ME 1070

Familiarization with woodworking

NAME: COURSE: INDEX NO:

N.P.A.Gunasekera BSc. Mechanical Eng. 090160U

DATE OF SUB: 17/05/2013

Part 1 Practical Work

We were asked to make both mortise with shoulder and half lap dovetail joint. First we took the timber piece and check the flatness of the timber piece. Then do the planing one surface until the surface is flat using the hand plane tool and the work bench. This must be done carefully applying evenly distributed force throughout the stroke for smooth, even flatness. After flattening I made a mark to avoid mixing up with the free surface. Turn the timber piece and plane the adjacent side until the surface is flat. Next step is to mark the necessary lines according to the dimension. Take the marking gauge and mark in the two surface yet to plane. For marking I used the flatten surface as the reference surface. Then I planed the surface until I reached the desired thickness. In this material removing process you must check the flatness adjust the force regularly. If it goes out of shape without your awareness it cannot be recovered. After planing for required amount turn the adjacent side and follow the similar procedure and obtain the timber block with required dimension.

Now we have to part the block in to three sections. We need two identical blocks. For that we measure the required length from the steel ruler and mark the same length from both ends to create identical blocks. Then using the try square draw the parting line in all four surfaces. Before parting the block mark the necessary heights in the side surface. One block must divide into two and the other part must divide into three as shown in figure. Then I clamped the block using the carpentry vice and parted the blocks using the rip saw.

1.1 Mortise and Tenon joint

Then I took the middle piece and one identical piece to make the mortise and the tenon joint respectively. First I made the mortise. Since the tenon joint has no shoulder, I cut a through hole in the other block using the width of the block as the reference. I removed the chips carefully using the mortise chisel, firmer chisel and striking the chisels with mallet by clamping the timber block horizontally. From one side I grooved into half of the thickness and rotate the work piece and grooved the through hole. This must be done very gently and carefully unless you want to crack the piece. After making the hole, I smooth the edges carefully. This operation takes time to make a smooth accurate hole.

Next step is to make the tenon. I took the middle block and mark the width of the block from one end. Then using the rip saw I parted the part in the following order showed in figure. When cutting I kept in a vertical position slightly angled for away from me. You must keep some allowance for the interference fit and for smoothing surface using the firmer chisel.

After removing the unnecessary parts smooth the surface using the firmer chisel. When smoothing the surface it needs your skills to adjust the force when cutting. Check for the interference fit allowance and shape it until the required amount of material is removed. Now the mortise and tenon joint is finished, but assemble it after making the dovetail joint.

1.2 Dovetail joint

Now take the middle block and mark the dovetail shape according to the drawing. Then follow these steps to create the dovetail as shown in following figures.

After making the dovetail, draw the edges of the dovetail hole on the other piece using the shape of the existing dovetail piece. When marking keep allowances for the interference fit. Then remove material carefully in the following order using the firmer chisel and mortise chisel. Check for the fit by fixing the two joints and remove unnecessary materials accordingly.

Finally fix the three pieces and complete the joint.

Part 2
2.1 Safety precautions in wood workshop
1. Always wear safety equipment. 2. Wear appropriate clothing ( avoid loose fitting clothes ) 3. Always be on alert and stop working when feeling a sleep when using power tools. ( Avoid drugs and alcohol ) 4. Check for nails, screws and other metals 5. Always work against the cutting when working with power tools. 6. Never reach over a blade to remove cut-offs. 7. Use sharp blades and bits ( Maintain the tools ) 8. Clean the area after you complete the work

2.2 Mortise gauge

The mortise gauge is a special type of marking gauge and it is used to mark wood so that a mortise can be cut into it. We can draw two parallel lines in required distance to the surface by adjusting the distance between fixed spur and adjustable spur. The mortise gauge is normally made from a hardwood such as rose wood with brass being used for the parts that slide along the stem.

The stock of the mortise gauge is pressed against the side of the wood. It is then pushed along the wood until the mortise is marked out correctly.

2.3 Wood working operations

Most difficult time consuming wood working operation is paring. Paring is a process of using the knife edge of a sharp chisel to slice small amounts of wood off. With a little technique and a sharp chisel, you can get into places inaccessible to a plane or knife. Paring is basically the finest work you can do with a chisel. Trimming the cheeks of a mortise to fit a tenon thats too large. In the absence of a shoulder plane, paring the tenon to fit the mortise. When you lay out a hinge mortise, after chopping the mortise sides, you basically have to pare the waste out to the edges of the hinge layout. If the space between dovetails is large enough (i.e. the pins) for a chisel, they can be pared, on their sides, to fit.

2.3.1

Defects in timber

Category

Defect Chemical stain

Reason The wood is discoloured by the chemical action caused with some external agency.

Rind galls

The rind means bark and gall indicates abnormal growth. Hence peculiar curved swelling found on the body of the tree is known as rind gall. They develop at points from where branches are improperly cut off. These are the bases of branches or limbs which are broken from the tree. The portion from which the branch is removed receives nourishment from the stem for a pretty long time and it ultimately results in formations of dark hard rings which are known as knots. Eg: dead knot, decayed knot, live knot, loose knot, round knot, tight knot The timber which is obtained from dead standing trees contains dead wood. It is indicated by light weight and reddish colour. These are longitudinal separations in wood between the annual rings. These are cracks which partly or completely separate fibres of wood. The separations make the wood undesirable when appearance is important. These are known as wandering heart and caused by twisting of young trees by fast blowing wind. These are not suitable for sawing. These indicate wood fibres which are injured by crushing or compression. The upsets are mainly due to improper felling of tree and exposure of tree in its young age. This defect is indicated by mark or signs placed on finished surface of timber. They may be formed by planing machine. This defect is denoted by presence of original rounded surface on manufactured part of timber The defect is formed due to improper sawing of timber. It is indicated by diagonal marks on straight grained surface of timber. This defect is indicated by curvature formed in direction of length of timber. This defect is indicated by the curvature formed in transverse direction of timber. A crack which seperates fibres of wood. It does not extend from one end to the other. When a check extends from one end to the other it is known as a split.

Knots

Natural defects

Dead wood

Shakes

Twisted fibre

Upsets

Chip mark Wane Diagonal grain Bow

Defects due to conversion

Defects due to seasoning

Cup

Check and split

Part 3 Wooden chair design

I considered the dimensions for ergonomics considering the average student height for girls and boys as 163cm (5ft 4in). Since this is used for the examination hall and considering the cost I thought hand rest wouldnt be necessary since it doesnt help in writing. Dimensions of the chair are shown in following figure. Part No. Link 1 Link 2 Link 3 Link 4 Link 5 Link 6 Link 7 Link 8 Qty 2 1 1 1 2 2 2 1

Now prepare your work space, working table, with your carpentry tools available: hammer, jigsaw, finishing nails, wood glue, chisels, sand paper 120 grit, and try square. Then draw a pattern of the chair in actual size measurement. It can be used for cutting tapered links such as link 1. Then cut the links and plane it keeping allowance for joints. Following table describes about the joints of the links.

Link No. Link 1 Link 2 Link 3 Link 4 Link 5 Link 6 Link 7 Link 8

Fastening method Four stub mortises curved for link 8,2,5 & 7 Two identical stub tenon joints with shoulder at the both end No joints. Fastening method is nailing No joints. Fastening method is nailing Two dovetail joints curved in both ends Two dovetail joint in the top end adjacent sides Two dovetail joints curved in both ends Two identical stub tenon joints with shoulder at the both end

These joints are illustrated in figures as following.

Tapered dovetail joint is useful since it is restricting the vertical movement along the joint. Mortise, tenon and dovetails can be curved using techniques described in the part 1 of the report. For a better smooth surface finish apply sand paper. When assembling the each joint apply glue for better fastening. Then nail link 3 and link 4 to the frame created by 2x link 5 and 2x link 7 along with the four legs. You can also use dovetail pattern joint for that purpose. When considering the cost and the time it wont be necessary for a chair which is going to keep in the examination hall. The backrest has a curved shape for ergonomic purpose as well as aesthetic appearance. It will be supportive for the backbone when you lean back in the chair. When we are sitting in an examination hall for 3 hours it will be confortable to lean back in time to time.