Green Training 2 PDF

OBJECTIVES Training Objectives: In fabrication, the order of operations Understand when to use each refers to the systematic sequence of tool and plan common steps or processes that need to be operations for safety, accuracy followed to create a...

OBJECTIVES Training Objectives: In fabrication, the order of operations Understand when to use each refers to the systematic sequence of tool and plan common steps or processes that need to be operations for safety, accuracy followed to create a part or product and precision accurately, safely, and efficiently. Demonstrate correct, safe use of Green tools: Bandsaw, Nail Guns, Drill Press, Drum Sander Troubleshoot common issues on each machine Fabrication Concept: Accuracy Vs. Precision Accuracy: Getting a measurement Jigs: Used to guide cutting tools correct on the first attempt. for more accurate results. Precision: Repeating the same Fixtures: Hold the workpiece in operation with the same result. place during operations to increase precision. Machines, such as the bandsaw and drill press, utilize jigs and fixtures to Use jigs and fixtures as often as create accurate and precise parts. possible to increase safe, reliable parts. Nail Guns: Purpose & Operation Nail Gun MEDIUM RISK Purpose Fastening materials quickly. Glue Set-Up Air release direction On Site Trim Work Quick release air-hose Grip Rapid Fire/single-shot button Safety trigger Nail Tray Safety lock Nail Guns: Safety Considerations A nail shot from an air-nailer can easily rebound or Air-gun nails are categorized in three ways: type, deflect towards the user OR innocent bystander, causing gauge, & length puncture wounds and lacerations. Use the following Types: precautions to prevent possible injuries: Pins: Low hold, but small, nearly invisible entrance Trigger Control: Never point the gun at anyone or at hole. yourself – the air-nailer can shoot nails unintentionally. Brads: Medium hold with small heads, great for general assembly tasks in small assemblies. Trigger Safety Lock: Never disengage the trigger safety Staples: High hold with a large entrance hole – mechanism (for larger nail guns), or trigger safety lock great for holding fabrics or trim decorations. (23 ga.) until ready to shoot. Nail Penetration: Once discharged, the nail may change its path in the workpiece. Often happens when the nail hits a knot in the wood, travels through hardwoods, or hits metal, such as another nail or screw. The nail may hit the operator's hand or body part. Nail Guns: Choosing the Right Nails Guage measures the thickness of the nail. Length is measured from the head of the nail to The smaller the number, the thicker the the tip. The length determines how far a nail will nail travel into a material (assuming the head remains at the surface) 23-Gauge: Reserved for very thin pin nails The longer the fastener, the lower the gauge 18-Gauge: Brad nails used for light number to prevent nails from bending under fastening, typically in combination with stress. Example: a 2” nail will be 16g, while a glue 5/8” nail will most likely be 18g. 16-Gauge: More robust brad nail for on- site fastening of trim, crown molding, Choose an appropriate length for your door frames, etc. application. Nail Guns: Basic Operation Choose the right nails for the nail gun you are using Place the nose of the nail gun against the workpiece (brads, pins, staples, or nails) based on the materials where you want to drive the nail. you’re working with and the fastening need Hold the gun perpendicular to the surface to ensure the Verify the correct gauge (thickness) and length of the nail enters straight. nails to match the project requirements. Press the safety tip against the material. Disconnect from the air source: Always ensure the Make sure the tip is fully depressed to disengage the nail gun is disconnected from power or air before safety mechanism. loading. Once the safety tip is engaged, pull the trigger to fire Open the magazine of the nail gun. the nail. Insert the nails, brads, or staples in the correct Keep firm pressure on the nail gun and maintain control orientation, point in the direction of the throughout the process. Close the magazine securely. Check the position and depth of the nail after firing. Connect the air hose from the wall to the nail gun. Adjust the depth setting if the nail isn’t seated properly. Check the mode (single shot vs. bump-fire) and select Repeat the process, ensuring each nail is driven securely single-shot, if not already selected. and in the correct position.  Drum Sander: Purpose Drum Sander LOW RISK Purpose Digital Readout Sanding flat and larger wood panels smooth. Height Adjustment Wheel Set Zero height Table Feed Conveyor Belt Emergency Stop Infeed/Outfeed Tables On/Off Switch for Drum Table feed Variable Speed Control Machine Power Switch Drum Sander: Safety Considerations Respiratory protection is required. Entanglement Hazard: The drum sander can pose a major entanglement hazard near the spinning drum and moving table. Do not wear gloves, loose clothing or jewelry while operating the drum sander Pinch Hazard: Fingers and hands can get pinched or drawn into the machine if positioned too close to the drum head. Keep fingers away from the drum head when feeding material. Drum Sander: Materials Hardwood Material Restrictions: Only use kiln-dried hard and softwoods. Check for and remove nails, staples, and other embedded objects. Wood must be longer than 6 inches. Wood must be under 44 inches wide Softwood Plywood Prohibited materials: Pressure-treated lumber MDF and melamine. Foams and other man-made materials. Metals. Drum Sander: Air Filtration Two Air Filter handlers are installed on the ceiling The Fab Lab provides a variety of sandpaper grits for and should be turned on whenever using sanders. use on the drum sander. These remove fine dust from the air caused when sanding. using the remote(s) to operate - point Lower Grits (60-80 grit): For heavy stock removal or the remotes to the back of each handler - the dimensioning rough surfaces. remotes are universal so you can use either for both air handlers Higher Grits (100-220 grit): For finer finishing and smoothing surfaces. * Contact a Fab Lab staff member if you need to change grits.  Drum Sander: Basic Operation 1. Open the dust collector blast-gate for the sander (make sure other blast gates are closed) 2. Raise the drum using the height adjustment crank to create a safe starting clearance for the workpiece. 3. Set the Conveyor Belt Speed depending on the sandpaper grit and your sanding needs: a. Coarser grit paper: faster speed, greater removal, harsher finish b. Fine grit paper: slower speeds, less removal, smoother finish 4. Turn off the conveyor belt 5. Raise the drum using the height adjustment crank to create a safe starting clearance for the workpiece. 6. Place your material flat on the outfeed table 7. Set the drum height slightly above the material for the first pass, ensuring the drum won't remove any material. 8. Turn on the dust collector before operating the sander. 9. Turn on the drum and wait for it to reach full speed. 10. Turn on the conveyor belt to start feeding the workpiece under the sanding drum. 11. As the material passes through the drum, slowly lower the drum height until the drum begins to sand the surface – STOP lowering the drum at this point. 12. After the first pass, lower the drum incrementally (about 1/32 inch per pass) to remove material gradually. Fine grits require shallower passes. 13. Continue sanding, adjusting the drum height and grit as necessary to achieve the desired smoothness and thickness Drum Sander: Tips and Tricks 1. Ensure the sandpaper is securely fastened around the Open-end sanding: You can sand drum and replace worn or damaged paper before wider workpieces by flipping starting. Contact Fab Lab staff to change sandpaper if them 180° and making a second needed. pass. Please contact Fab Lab staff if 2. Ensure that your material is free of nails, screws, or you need to access these advanced other metal objects that could damage the drum or features. sandpaper. 3. Keep an eye on the material to ensure it is moving smoothly through the drum without getting stuck or shifting. 4. For thicker or harder woods, make several light passes, rather than one heavy pass, to avoid damaging the material or machine. 5. Avoid removing too much material in one pass, which can result in gouging or burning the wood. 6. After each pass, inspect the surface of the workpiece. 7. If you see burn marks of small burning notify a staff member – it might be time to change the paper.  Drill Press Drill Press MEDIUM RISK Purpose: Drilling precise holes in wood in a safe, repeatable way. Entanglement Hazard: The drill press can Laceration Hazard: Workpieces, drill bits / tooling, pose a major entanglement hazard near the chuck. or clamps can become disengaged and rotate or be flung Do not wear gloves, loose clothing or jewelry across the room. while operating the drum sander. Long hair is especially dangerous and prone to Crushing Hazard: Insufficiently secured work pieces getting caught! can be rotated at high speed, potentially striking or crushing fingers, hands, or other close body parts. Drill Press: Purpose Digital Readout Motor On/Off Switch Feed Wheel Table Adjustment Chuck Fence & Stop Table Speed Adjustment Depth Stop Base Drill Press: Bits The Fab Lab provides a variety of bits for the drill Drilling Through Metals press. Always clamp metal down. DO NOT FREEHAND METAL. Twist Bits (with or without Pilot Point) can be used Use a center point punch to create a divot in on most materials (metal, plastic, wood) but often the metal to guide the bit. will not give the best results. Best choice for metal. Use twist bits with cutting fluid for best results. Brad Point Bits are the best choice for wood and plastics. Angled Holes Forstner Bits create wide, flat holes in woods and Use the “angle jig” to create holes plastics. at an angle Hole Saw Bits cut large holes through thin material. Repeatable Operations Masonry Bits cut through tile, stone, concrete & Use the fence and stop to repeated drill brick materials. precise holes Spade Bits cut large holes through rough Use the provided clamps to hold down construction. (Prohibited on Drill Press) material for drilling. Always use the stop to the right of the bit. Drill Press: Basic Operation The drill press spins at different speeds. Check yourself for entanglement hazards Use the chart to match the type, size of Check machine for obvious damage/loose parts. bit and speed to maximize cut quality and Articulate the chuck and feed mechanisms by hand, feeling tool life. for grit and mechanical issues. Check RPM, adjust if necessary. Rules of thumb: Adjust table to correct height and orientation. Larger bits need lower RPMs. Locate clamps, sacrificial boards as needed, and the chuck key Smaller bits need higher RPMs. Install drill into chuck. Tighten hand tight. Harder materials need lower RPMS. Run the quill down to check that the bit goes deep enough but does not hit the table. Tight the depth adjustment mechanism. Adjust fence. Clamp workpiece to table. Turn on. Check that drill spins straight. Begin operation  Bandsaw: Purpose Bandsaw HIGH RISK Alignment Window Purpose: Cut materials into manageable sizes. Blade Guard Height Cutting curves Tension Wheel Adjuster Cutting into corners Cutting imperfect materials (such as Blade Guard rough or warped) On/Off Switch Blade Freehand Operations Rip Fence Table Keep your fingers away from the cut line and blade. 2 inches minimum. Blade Guard When cutting a tight curve, first cut relief cuts then push the work piece slowly without twisting or bending the blade. Do not force the work into the blade. Do not cut a smaller radius than the blade width will allow. Bandsaw: Safety Considerations Laceration Hazard: Materials Allowed: The Fab Lab provides one general The bandsaw blade can cut or Kiln-dried lumber blade (3/8" x 4 TPI). amputate fingers and limbs if used incorrectly. Plywood Melamine Bandsaw blades need at least 3 teeth To limit your risk: MDF contacting the material while cutting to ensures a long life and quality cuts. Always lower the blade Foam guard just above the Plastics workpiece before cutting. Using too thin of a material will dull Use push sticks and push the blade prematurely. blocks when necessary. Materials Prohibited: For complex cuts, use a jig Pressure-treated lumber Using a blade with too many teeth to ensure safety and Green lumber accuracy. (such as a metal-cutting bandsaw Concrete, glass, metals, blade on wood) will dull the tool and etc. burn your material.  Bandsaw: Basic Operation Check your PPE - tie up loose sleeves and hair. Put on hearing protection and safety glasses. Rip Operations Check for entanglement hazards. Inspect the machine for damage or loose parts. When ripping or resawing lumber, Set the blade guard 1/8th of an inch above the adjust the fence to the width of your piece to be cut. Check to ensure that all the safety guards are in cut. place and working correctly. Use a push stick or block to push the Have all cut lines clearly marked before operating the Band Saw. workpiece against the fence. Hold the material away from the blade before you turn on the Band Saw. Hold the material firmly on the table while cutting Do not pinch the blade by pushing on the Band Saw. against the fence behind the blade. Keep your fingers away from the cut line and blade. 2 inches minimum. Use push sticks or push blocks as necessary. Turn on the saw. Begin your cut. MATERIAL & HARDWARE IN THE WOODSHOP The Fab Lab provides a limited selection of plywood for purchase. Makers may bring materials from outside sources, but all materials must be vetted by Fab Lab staff. Fab Lab provides a variety of hardware and fasteners in the hardware section of the woodshop. Makers must provide their own hardware and fasteners if not available in hardware selection. Makers can request hardware using the appropriate request form for class and club projects only. Hardware requests are not guaranteed to be filled. Fab Lab provides 80-, 120-, 180-, 220- and 320- grit sandpaper. The Fab Lab does not provide spray paint and finishes; however, leftover spray paint and finishes may be available for use.