Instruction Example 01.3.

Nailing of a Tool Kit

In this instruction example, the simple nailing techniques in long wood and nailing with overlong nails are practised. Material 2 boards thickness: 14 mm width: 200 mm length: 500 mm 2 boards thickness: 14 mm width: 200 mm length: 250 mm 1 bottom board thickness: 14 mm width: 278 mm length: 468 mm 4 laths thickness: 16 mm width: 40 mm length: 210 mm countersunk-head nails 45 mm long. The complete wood is planed out, surface-shaped and cut to size.

Figure Tools hammer, pincers Measuring and testing means back square, folding rule, vernier caliper Auxiliary means

firm, non-springy bench top at working height (joiner's bench), steel bar 20 x 10 mm, 300 mm long, packing blocks of wood 25 mm thick, tacking nails 25 mm long, screw clamp 200 mm Required previous knowledge reading of the drawing, measuring and scribing Sequence of operations 1. Prepare the workplace, make the working materials available. 2. Check the material for accuracy to size and angularity. 3. Tacking of the boards with a length of 250 mm Comments Check the completeness of tools an materials!

All boards must be accurate to dimensions, cut at right angles and even!

Place both boards with the right-hand board surface onto the working plane. Put a lath flush onto the cross-cut surfaces and pin! Do not drive in the nails completely! 4. Determine the nailing Nailing is done in the form of a triangle according to the work points and mark them a pencil drawing! 5. Nailing of lath and board Put packing blocks of wood between the board and the according to points 3. and 4. supporting surface and drive the nails at the nailing points vertically through the lath and the board until the nail head is flush with the wood surface! 6. Remove the tacking nails 7. Prepare the nails for Put the nail head surfaces firmly onto the bench top and fasten clinching. them with the screw clamp! 8. Clinch the nails in the Press the steel bar firmly against the nail shank driven through, direction of the grain of wood then clinch the projecting shank and the nail point at an angle of 90. 9. Drive the nail ends into the Take the steel bar off and drive the nails back into the wood wood like staples until they are flush with the wood surface. 10. Mark the nailing points at The nails shall be driven into the narrow surface of the laths the boards with the and not into the cross-cut wood! dimensions 200 mm and 500 mm 11. Tack the boards of Nos. 5. The board of operation No. 10. with the cross-cut edge being and 10. so as to produce two flush and at right angles is put onto the lath (5.) and tacked. nailed comers 12. Nail and pull out the Drive in the nails vertically and flush with the surface. tacking nails 13. Put both nailed corners together, tack and nail them 14. Determine the nailing points at the bottom and mark them with a pencil 15. Lay in the bottom board Drive in the nails at an angle alternately towards the left-hand

and nail 16. Final check

and the right-hand side. Check with your eyes whether: - all nail points stick completely in the wood; - the wood has been nowhere splitted visibly; - no wood fibres have been torn out.

Nailing of a Tool Kit

Instruction Example 01.5. Screwing of a Carrying Handle on a Tool Kit

In this instruction example, the joining of two boards by means of wood screws is practised. Material - tool kit from instruction example No. 3 - finished carrying handle, board thickness: 20 mm - 8 pcs. countersunk-head wood screw 3 x 30 mm

Figure Tools screw driver 6 mm, wood drill 2 mm and 3 mm, bit brace with rose bit Measuring and testing means back square, folding rule, vernier caliper Auxiliary means joiner's bench, screw clamp, pencil Required previous knowledge reading of the drawing, measuring and scribing, drilling Sequence of operations 1. Prepare the workplace, make the working materials available 2. Apply the handle holder according to the drawing and scribe it, determine the screwing points and mark them Comments Check the completeness of tools and materials

The handle holder is situated centrally to the box. The screwing points shall enclose a surface as large as possible, shall be staggered with the grain and have a distance to the edge of about 20 mm! 3. Bore the handle holder 12 mm deep with the Fasten the screw clamp so that at least three

drill 3 mm dia. and ream it, fasten it with the screw clamp to the box according to the scribed line and go on boring and the predrilled holes with the drill 4. Screw in the countersunk-head screw with the screw driver

holes can be drilled without hindrance. Observe the boring depth!

The blade of the screw driver must completely fill the slot in the screws so that it is possible to drive in the screws without damaging the slot and the wood edge!

5. Screw on the second side of the handle holder (see operation 2. to 4.) 6. Final check

When visually checking, take heed of the following: - the screw heads be must flush with the wood surface - all screws must be firmly screwed in - bores and screws must not be through, i.e. they must not be visible on the opposite side!

Screwing of a Carrying Handle to a Tool Kit

Instruction Example 01.6. Screwing on of a Screw-on Brace

In this instruction example, the fastening of a door hinge to a board leaf by means of countersunk-head wood screws and round-head bolts is practised. Material 1 plank door leaf 2 screw-on braces with screw holes 6.4 mm dia. and a punched hole for each screw hole of 8.4 mm dia. 6 off round-headed wood screws dia. 6 x 50 mm 2 off round-head bolts with square neck M 8 x 60 mm with washers and nuts

Figure Tools screw driver 12 mm, wood drills 4; 6; 8 mm, screw wrench 13 mm Auxiliary means joiner's bench, support, pencil Required previous knowledge reading of the drawing, measuring and scribing, drilling Sequence of operations Comments 1. Prepare the workplace, make the Check the completeness of the required tools and working materials available materials, put the door leaf onto the joiner's bench and support! 2. Put on the braces to be screwed The screw-on braces are centrally aligned above the on, align and mark the screw bores crosspieces which hold the board cover and are screwed with a pencil on. The required projecting length of the idler is to be observed/Check the proper position of the screwed on braces with a large back square! 3. Remove the screw-on braces, Drill through the 1st hole after the idler with a drill 8 mm, bore the screw holes further holes are pre-drilled with a drill 6 mm, 20 mm deep, then bore 20 mm deeper with a drill 4 mm!

4. Put on the screw-on brace, insert Tighten the nuts with a screw wrench. The washer shall the round-head bolts and fasten be pressed 1 mm into the wood. Firmly tighten the wood them with washers and nuts, drive screws but do not overturn them! in the wood screws with the screw driver 5. Final check The long braces fir tightly to the wood, all screws are tightened, not overturned and not sheared off, bores for the wood screws are not visible on the inside of the door!

Screwing on of a Screw-on Brace

Instruction example 5.1.: Receiving piece

Mill a rectangular groove into a strip-shaped workpiece of steel on a milling machine with a cylindrical cutter. Material St 50 (mild steel with a tensile strength of approx. 500 MPa)

Figure Dimensions 36 x 50 x 160 mm Milling machine Horizontal milling machine Tools Cylindrical cutter (with staggered teeth), cutter arbor (long), machine vice, clamping bolts, chuck-key, fiat file (medium) Measuring and testing means Vernier caliper, vernier depth gauge, slip gauges Auxiliaries Stop block, chip brush, hand-broom, cleaning rag, T-slot cleaner, tongues, parallel strips Required previous knowledge Reading of drawings, measuring and testing, setting and operation of horizontal and vertical milling machines, milling of plane and parallel surfaces Explanations to the working drawing

Rz 20: Average roughness of machined surface = 20 m (0.020 mm) // 0.10 A: Maximum deviation from parallelism related to the surface A is 0.10 mm. Sequence of operations 1. Check quantity of parts to be machined and perform visual examination. Remarks Compare with details on work-accompanying data sheet.

2. Functional test and lubrication of milling Lubricate and check oil level according to machine. lubrication schedule. 3. Fix and align machine vice (across the machine table). 4. Fix cylindrical cutter on cutter arbor. Align and determine position with tongues. The width of the cylindrical cutter is 16 mm. Secure cylindrical cutter on cutter arbor by means of fitting key. Direct coolant jet directly on the point where the chips are produced. When clamping the workpiece, make sure that it is clean and free from burrs. Load the workpiece on parallels in the machine vice. Take values from nomogram or a table.

5. Set coolant system and cutter safety device. 6. Clamp workpiece into machine vice and set up a stop block for determining and securing position of workpiece in its longitudinal direction. 7. Set cutting values (speed and feed rate). 8. Position workpiece into machining position.

Bring knee, saddle and work table into machining position by rapid traverse. By means of slip gauges make fine setting (size 24 mm) to side surface. 9. Scratch the surface of the workpiece with Scratch by manually feeding the knee. rotating cutter and feed necessary cutting depth. 10. Mill groove with mechanical feed. 11. Unclamp, Deburr. Watch machining operation. Check dimensions with vernier caliper and vernier depth gauge (dimensions 12 and 24 mm). Check groove width of 16 - 0.2 mm by means of slip gauges.

12. Continue the process of milling grooves Constant dimensional and surface inspection is on the remaining workpieces. necessary. 13. Complete work order and transfer workpieces to the next machining step. Transfer workpieces only after having them cleaned and checked.

Receiving piece

Instruction example 5.2.: Clamp

Mill an elongated slot for receiving clamping bolts into a strip-shaped workplace on a milling machine. Material 15 Cr 3 (carburizing steel with a tensile strength of 600 to 900 MPa) Dimensions 25 x 45 x 180 mm

Figure Milling machine Vertical milling machine Tools Shank cutter with a diameter of 18 mm with taper shank, griping collet for cutter with taper shank, machine vice, clamping bolts, chuck-key, fiat file (medium) Measuring and testing means Vernier caliper Auxiliaries Stop block, chip brush, hand-broom, cleaning rag, T-slot cleaner, parallel strips, tongues Required previous knowledge Reading of drawings, measuring and testing, setting and operation of horizontal and vertical milling machines, milling of plane and parallel surfaces

Explanations to the working drawing Rz 40: Average roughness of machined surfaces = 40 m (0.040 mm) Sequence of operations 1. Check quantity of parts to be machined and perform visual examination. 2. Functional test and lubrication of milling machine. 3. Fix and align machine vice (across the machine table). 4. Chuck shank cutter into griping collet and fix into cutter spindle. 5. Set coolant system and cutter safety device. Remarks Compare with details on workaccompanying data sheet. Lubricate and check oil level according to lubrication schedule. Align and determine position with tongues. When chucking the cutter, make sure that it is clean (the taper collet must be clean as well). Free discharge points for the coolant from impurities.

6. Clamp workpiece into machine vice and set up a Stop block ensures that the spacing stop block for determining position of workpiece in dimension to the left end face is longitudinal direction. maintained. 7. Set cutting values (speed and feed rate). 8. Position workpiece into the machining position. 9. Bring cutter to centre of workpiece, set dimensions of length and spacing. Take values from nomogram or a table. Bring knee, saddle and work table into machining position by rapid traverse. Set length of elongated slot by means of table dogs.

10. Sample cuts (cutting depth approx. 1 mm) and Make corrections, if necessary. dimensional inspection (length, width and spacing). 11. Mill elongated slot by plunging into existing bore hole at the end of the elongated slot. 12. Mill elongated slots into workpieces with constant dimensional and visual inspection. Select feed rate according to cutting depth (large cutting depth = small feed). Deburr and clean workpiece before measuring it.

13. Transfer workpieces to the next machining step. Transfer workpieces only after having them cleaned.

Clamp

Instruction example 5.3.: Stop bar

Mill a rectangular groove into a strip-shaped workplace on a horizontal milling machine. Then mill the undercut (cross slide to the T) into the existing rectangular groove on a vertical milling machine. Material GGL 25 (cast iron, unalloyed, with a tensile strength of approx. 250 MPa and a compressive strength of approx. 1000 MPa) Dimensions 30 x 50 x 240 mm

Figure Milling machine Horizontal milling machine, vertical milling machine Tools Cylindrical cutter (cemented-carbide-tipped), shank cutter for T-slots (slitting cutter), cutter arbor (long), cutter chuck, collet, machine vice, clamping bolts, clamp, chuck-key, flat file (medium) Measuring and testing means Vernier caliper, vernier depth gauge, slip gauges Auxiliaries Stop block, chip brush, hand-broom, cleaning rag, T-slot cleaner, parallel strips, tongues Required previous knowledge

Reading of drawings, measuring and testing, setting and operation of horizontal and vertical milling machines, milling of plane and parallel surfaces Explanations to the working drawing Rz 10: Average roughness of groove surfaces = 10 m (0.010 mm) // 0.03 100: Maximum deviation from parallelism is 0.03 mm on 100 mm of length. Sequence of operations Milling of a rectangular groove 1. Check quantity of parts to be machined and perform visual examination. 2. Functional test and lubrication of milling machine. 3. Fix and align machine vice (across the machine table). 4. Chuck cylindrical cutter and fix cutter arbor into milling spindle. 5. Mount cutter safety device. 6. Set cutting values (speed and feed rate). 7. Position workpiece into machining position. Compare with details on work-accompanying data sheet. Lubricate and check oil level according to lubrication schedule. Align, determine position with tongues and check for necessary accuracy with dial gauge. Place steady bracket bearing as close as possible to the cutter. Cutter width of 14 mm must be checked before. Because or the material of the workpiece the coolant system need not be used. Take values from nomogram and table. Bring knee, saddle and work table into machining position. Remarks

8. Clamp workpiece and scratch it with Scratch by means of manual adjustment at knee. rotating cylindrical cutter. 9. Start milling the groove with a cutting depth of approx. 1 mm for measurement of groove width and distance to long side. Correct according to specifications, if necessary.

10. Mill groove to necessary depth, Use vernier caliper, vernier depth gauge and slip deburr, clean and perform dimensional gauges for measuring and testing. and surface check. 11. Mill groove (14 x 20 mm) into all If the number of workpieces is large, the cylindrical workpieces with constant dimensional cutter is subject to wear. Replace cutter, if necessary. inspection and visual examination. Milling of undercut 1. Functional test and lubrication of milling machine. 2. Fix and align machine vice (across the machine table). Lubricate and check oil level according to lubrication schedule. Align and determine position with tongues.

3. Fix cutter chuck into cutter spindle and chuck shank cutter for T-slots. 4. Mount cutter safety device. 5. Set cutting values. 6. Set workpiece into machine vice. 7. Position workpiece into machining position (set cutter to groove depth) 8. Scratch, infeed to final depth size (20 mm) and mill undercut. 9. Perform dimensional and surface inspection of the first workpiece. 10. Mill undercut on all work-pieces.

Chuck in cutter chuck by means of collets according to shank diameter of cutter. Keep feed rate low. Danger of cutter breakage. Set workpiece in such a way that the rectangular groove is not compressed. Bring knee, saddle and work table into machining position. Important! After having milled the undercut it is absolutely necessary to unclamp the workpiece before rapid return. Otherwise the cutter will break. Make corrections, if necessary. Clean workpiece before measuring. In case of cutter breakage it is absolutely necessary to remove the broken pieces from the groove. Otherwise the cutter may break again and the workpiece may become unserviceable.

11. Complete work order and transfer Transfer workpieces only after having them cleaned workpieces to the next machining step. and checked.

Stop bar