Working with Wood and Wood Materials

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1 Working with Wood and Wood Materials Excerpt from the Bosch Encyclopedia of Power Tools. Written & Published by ROBERT BOSCH GmbH and Robert Bosch Tool Corporation. The grain direction of the fibers determines the way tools are used, their shape, advance feed and cutting speed. The processing of wood and wood materials has to reflect the heterogeneity of these materials. The grain direction of the fibers determines the way tools are used, their shape, advance feed and cutting speed. This is the main difference between woodworking and working with other materials. A possible exception is wood materials with homogenous characteristics due to their composition and manufacturing process. Chipless Processing Wood can be permanently shaped by chipless processing under certain conditions. Depending on the working task one has to observe the suitable type of wood the degree of deformation (bending) to suit the material involved the relevant preparation Suitable wood types Light to medium heavy timbers can be more easily formed than heavy timbers. Wood cuts with parallel long running fibers facilitate deformation. Degree of deformation With reasonable effort only two-dimensional shaping is possible. In addition to the wood type, the possible degree of deformation depends mainly on the thickness of the shaped work piece. The thinner the material, the easier the bending. Lengthwise wood shaping (with grain) is possible but difficult; however, the risk of breakage is reduced. Shaping across the wood fibers is easier; however, the risk of breakage is higher. With suitable preparation one can improve the shaping ability even further. Preparations Suitable preparation can substantially improve the potential deformation of wood. Essentially, the following measures are possible: watering steaming laminating Watering: Wetting or thorough watering makes the wood cells absorb water which makes them more elastic and tighter bending radii possible. The deformation achieved in this fashion is elastic and the material returns to the original state when the bending force is removed. In order to make the deformation permanent one has to maintain the bending force until the wood has dried to its original moisture value. Even then there will be a certain spring-back effect. If need be the wood has to be bent even tighter than the desired final state requires. Steaming: Steam treatment can achieve the same effect as watering, however, in less time. Additional heating enhances formability.

2 Laminating: Thick work pieces cannot be bent at all or only very little before they break. If, in contrast, the work piece is made of thin wood strips (lamina) one can achieve higher degrees of deformation. The thickness of the individual lamina is adjusted to the bending radius (smaller bending radii require thinner lamina) and, after glue has been applied, they are fixed in a suitable device or mould until the glue has set. When the work piece is removed, it maintains its lasting shape. The layered construction allows the manufacturing of complex shapes with very high mechanical strength. The layered structure itself can be highly decorative. Chip-Producing Shaping The low hardness of wood in comparison to metal allows high cutting speeds and therefore fast work progress. Wood is, especially in grain direction, long-chipping. These factors require special measures for the removal of large quantities of long chips. For this reason one should only use metal processing tools in special cases (drill bits) and only if the demands on quality are low. The materials of the cutting edges are selected in accordance with the required surface quality and endurance. Depending on the type of wood to be processed, one would use HSS application tools for the first case and carbidetipped application tools for the second case. Typical machining methods involving power tools are: drilling sawing routing planing sanding and grinding wood turning Drilling Drilled holes in wood materials are mainly used for connections with screws, dowels and other special joining elements. For most applications the drilled hole has to be precisely positioned and a specific hole diameter has to be maintained. This precludes the use of spiral bits for metalworking. The hard annual rings in solid wood would deflect the drill bit and the hole position cannot be kept. In the relatively loose texture of particle boards, however, the drill bit will not find proper guidance. The edges of drilled holes tend to be torn by the tool geometry which is optimized for the processing of metals. Precise drilling in wood requires drill bits which are equipped with centering and edge limitation features. The setting of dowels often requires deep and large diameter holes. The feeding power for some working positions can no longer be supplied by the tool user. In these cases one has to use drill bits with brad points equipped with an advance feed thread. The brad point pulls the bit into the material almost by itself and the operator has to supply little feeding power. Large and very large holes in boards and panels are better cut with hole saws. Hole saws are equipped with a cup shaped cutting edge and cut a deep round groove in the material. Work progress is fast, the torque demand on the power tool is very high. Sawing Saws are used to cut wood into sections. The following power tools are used for this purpose: stroke-type saws rotary saws circulating saws Each type of saw has characteristics which have to be suitable for specific jobs. Saws are fitted to process different types of material by selecting a suitable application tool. Stroke-type saws: Work on the principle of manual sawing by reciprocating motion. The stroke length largely defines the application range. If the stock is more than twice as thick as the stroke length, the sawdust can no longer be sufficiently removed from the saw cut and both the work progress and the quality of the cut will suffer substantially. The use of stroke type saws (typical example: jigsaw) is therefore limited to rather low cutting depths. The easy manageability of stroke type saws and the narrow saw blades allow curved cuts, whereas they are less suitable for accurate, straight cuts.

3 Rotary saws: Rotary saws (circular saws) use disc-shaped saw blades with saw teeth on the circumference. Because of the rigid, disc-shaped saw blades they are only suitable for straight cuts which can be carried out with high precision and quality. High rotational speeds are possible which result in high cutting speeds and fast work progress. Since the saw teeth leave the material after the cut, the sawdust is effectively removed at all times. Circulating saws: Saws like the (stationary) band saw or the chainsaw work with high cutting speeds and fast penetration. The continuously circulating endless saw blade or saw chain ensures good transportation of sawdust. On stationary band or ribbon saws one can carry out curve cuts with narrow saw ribbons, whereas chainsaws are only suitable for straight cuts on account of their sword-shaped chain guide. Routing Hand-held routing machines are used for groove cutting and for working on edges. The treatment of large surfaces is possible with restrictions. The use of templates and accessories (dovetail jig) allow the series-production of components with high precision. Planing Electric planers are capable of producing edges, rebates and surfaces of high quality. High cutting speeds ensure fast work progress. The position of the fibers has to be observed in order to achieve good work results. Especially on work piece edges precautions have to be taken against tearing. Sanding Surfaces can be smoothed and polished by sanding. Power tools used for sanding are: finishing sanders random orbit sanders angle grinders belt sanders They have different properties which make them suitable for specific applications. Finishing sander: Finishing sanders are equipped with a rigid sanding pad which swings back and forth with high oscillation frequency but rather small eccentric orbital motion. Work progress is rather slow, the finish, however, excellent. The rigid sanding pad enables surfaces to a very high-quality finish. Random orbit sander: Like finishing sanders, random orbit sanders work at high oscillation frequency, but there is an additional superposed rotary motion. For this reason, the sanding plate is round. The combination of oscillation and rotary motion allows high cutting speed of the individual abrasive grain which ensures fast work progress. The surface quality is potentially as good as with the finishing sander. They can be equipped with flexible sanding pads and used to work on convex or concave surfaces. Angle grinder: Angle grinders work exclusively with rotation. The sanding of wood is difficult because of the high rotational speed: work progress is very fast and there is a risk that the material surface will overheat. If at all, angle grinders are only used for rough surface treatment. Belt sander: Belt sanders use an endlessly revolving sanding ribbon which is supported by a rigid sanding plate on the machine side. Belt sanders are particularly suitable for woodworking since their sanding belt travels over the surface in only one direction. The sanding process can be carried out in grain direction and the surface structure of the wood is maintained. The rigid sanding plate allows planer-like processing of surfaces, the high speed circulation of the sanding belt ensures fast work progress. Wood turning The turning of wood is, in principle, like metal turning except that the turning tool (for metalwork: turning steel) is supported by a rail on the turning lathe and guided by hand. Turning is used to produce dynamically balanced work pieces which for better workability are often prepared by wetting

4 them before processing. As a rule, turning lathes are stationary machines, if the demands on quality are not high, they can be driven by power tools. Joining and Fastening Wood and wood materials can be joined together by the following methods: screwing nailing gluing form-fit connections Form-fit connections are the classic wood joints and are still the main wood joining techniques, but in relation to the effort required and quality, they place heavy demands on the craftsman. Screw connections Non-permanent wood joints can be made with the help of wood screws, dry wall screws and machine screws. In this context one has to remember that wood, in contrast to metal, is soft and elastic. Connections using machine screws are therefore not always long-lasting. Threaded rings have to be inserted in the wood before machine screws can be used. If metal fittings and connecting elements are used, only those metals are permitted which do not react with the tannic acid or moisture in the wood. Nailed connections Nailing is regarded as a non-separable connection. Because of the wedge effect of nails, this type of connection cannot be used near edges since the wood may tear. By using suitably shaped nails one can produce long-lasting connections with relatively little effort. Tacks and pins are also on principle nailed joints. With respect to the choice of nail material the same applies as for screw connections. Glued joints Long-lasting connections for wood and wood materials are often established with the help of glued joints for which different adhesives and gluing techniques are used. Large-surface glued joints are used in the production of laminated wood and for veneering. Good quality can only be achieved with stationary glue presses. The adherent surface of joined wood components must be large enough to produce the desired strength. On visible surfaces and if surface coatings are planned one should avoid leaving glue rests which could disturb the external appearance. Wood joints Form-fit connections of wooden components without using glue or mechanical connecting elements have a long tradition and ideally combine functionality with decorative appearance. If correctly implemented, they are the most elaborate joining and fastening methods which require a lot of technical know-how even if machines are used. Work Safety High cutting speeds are based on high tool speeds which in turn necessitate elaborate safety measures. Dusts produced during the sanding of wood and wood materials can linger in the atmosphere for long periods and, especially in form of suspended light, fine dust, is a health hazard. Certain concentrations of fine dust in the air can cause wood-dust explosions triggered off by ignition sources (sparks, cigarettes). Dust extraction systems are therefore mandatory for stationary woodworking operations. If possible, one should also use dust extraction during the hand-held operation of power tools. Suitable system accessories are available from power tool manufacturers for this purpose.

5 Disclaimer Reprint, reproduction and translation, even in excerpts, are only permitted after prior written permission is granted by the publisher and by quoting the source material. Illustrations, descriptions, diagrams, drawings and other specifications are only contained for the purpose of explaining and illustrating the textual content. They cannot be used for constructive or operational purposes. Although this article was prepared with great care, we cannot accept liability for the contents being in accordance with current legal provisions. The contents reflect the latest know-how at the time of print. Subject to change without notice. Insofar as protected trademarks are mentioned in this book, they serve only as examples and are therefore not specifically highlighted. Accordingly, they are not used as an evaluation of any kind. As a matter of principle, the applicable safety regulations and operating instructions must be observed when you operate machine tools, power tools and their system accessories. The examples for use and application given in this article serve only the purpose of explanation. They are not intended as binding instructions for use. No claims for liability can be deduced from the contents of this article.

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