UNIVERSITY of LIMERICK

OLLSCOIL LUIMNIGH

DEPARTMENT OF MANUFACTURING AND

OPERATIONS ENGINEERING (M&OE)

FACULTY OF SCIENCE AND ENGINEERING

END OF SEMESTER ASSESSMENT PAPER

MODULE CODE: WT4603

MODULE TITLE: Wood Processing Safety and Practice

SEMESTER: Autumn Semester 2010-2011

LECTURER: Mr. Joseph Lyster

EXTERNAL EXAMINER: Professor Eddie Norman

DURATION OF EXAM: 2 Hours 30 Minutes

GRADING SCHEME: 35% Examination / 65% Coursework

INSTRUCTIONS TO CANDIDATES:

Students MUST answer TWO questions from SECTION A (2 x 25 Marks)

AND

Students MUST answer ANY 10 questions from SECTION B (10 x 5 Marks)

NOTE FOR SECTION A:

LM094 – (Materials & Architectural Technology) must answer question 1 in Section A and may not answer question 2

LM067 – (Wood Science & Technology) must answer question 2 in Section A and may not answer question 1

SECTION A

1) LM094 - (Materials & Architectural Technology) ONLY. a) Outline your approach to demonstrating the safe and efficient use of wood

processing machines appropriate for use by Junior Certificate Materials

Technology Wood students.

(5 Marks)

b) In a Junior Certificate Materials Technology Wood class, students are required to

use the Chisel Morticer, Pillar Drill and Scroll saw as part of their design project

activity. Outline 4 possible hazards which may arise and discuss the risk

magnitude and possible risk control measures of each.

(20 Marks)

2) LM067 - (Wood Processing & Technology) ONLY.

a) Outline the duties of employers and employees in relation to health and safety

management in a wood machining workshop environment.

(5 Marks)

b) Identify at least 5 potential hazards that may arise while using the following

machines and outline suitable risk control measures for each. In your answer,

make reference to “risk magnitude” and “the hierarchy of risk control”.

i. Bandsaw with blade guard.

ii. Surface Planing Machine with bridge guard.

(20 Marks)

3) Surface Planing Machine.

a) Using notes and sketches explain the terms “clearance angle”, “peripheral

cutting speed” and “cutter pitch”. A 4 knife cutter block is revolving at 4400 rpm

with a feed speed of 24m/min. Calculate the pitch distance and outline an

appropriate use for the processed material.

(15 Marks)

b) The knife clamping mechanism is an important feature of modern cutter block

design. Explain using a neat annotated sketch how modern cutter block designs

utilise forces that are created when in use and also outline the safety aspects of

such cutter block designs.

(10 Marks)

4) Rip Saw.

a) Using notes and sketches explain the terms, namely “hook angle” and

“clearance”.

(10 Marks)

b) Name the circular saw blade tooth configuration parts outlined in figure 1.

Fig1. (4 Marks)

c) A saw blade of Ø750mm is driven at 1300 rpm. Calculate the rim speed of the

saw blade. Also discuss the implications of setting an incorrect peripheral cutting

speed for a saw blade.

(11 Marks)

SECTION B

1. Explain, using a neatly annotated sketch, the purpose of a chip breaker in relation to

circular cutting blocks. (5 Marks)

2. Outline the names of two key legislative health and safety policy documents

pertaining to second level technology education and the work environment.

(5 Marks)

3. Using notes and sketches outline the appropriate method of setting the rip fence for

both ripping and cross cutting of material. (5 Marks)

4. Explain what the CE marking represents. (5 Marks)

5. Given a plank of rough sawn material, outline the procedure for planing the material

all-round. (5 Marks)

6. Indicate using arrows, the internal and external feed direction of the router relating to

the work piece in fig.2. Also describe the consequences of incorrect feed direction

when processing material with a hand router. (5 Marks)

Fig.2 (Re-draw in Answer booklet)

7. Identify and explain one reason why kick back can occur when ripping material.

(5 Marks)

8. Compare and contrast the tungsten carbide (TC) and high speed steel (HSS) cutter

knifes used in circular cutting blocks for surface planing machines. (5 Marks)

9. Discuss the use of PPE as a means of risk control. (5 Marks)

10. Using notes and sketches demonstrate the necessary hand positions and movement of

material when surface planing. (5 Marks)

11. Using notes and sketches outline the purpose of a riving knife when ripping material.

Also outline the position of the riving knife in relation to the saw blade. (5 Marks)

12. Discuss how the collet design contributes to the stability of the cutting bit during the

routing process. (5 Marks)

13. Using notes and sketches discuss two types of start/stop mechanisms related to wood

processing machinery. (5 Marks)

14. Identify and explain any 3 mechanical hazards that may arise from using a circular

sawing machine. (5 Marks)

15. Outline 3 safety considerations that must be taken into account when using the

thicknessing machine.

(5 Marks)