Secondary Wood Processing Manufacturing Processes 2015

Transcription

1 Secondary Wood Processing Manufacturing Processes 2015

2 Manufacturing Process Example: Manufacturing of a Sideboard Panel Material for Table Top Solid Wood Doors Hardware

3 Manufacturing Process Example: Manufacturing of a Sideboard Product Design 1) Lumber Preparation 2) Solid Wood Processing 3) Panel Processing + 4) Assembly / Finishing 5) Quality Control / Shipping

4 The Triangle of Design / Construction FUNCTION / SAFETY DESIGN / CONSTRUCTION ECONOMY QUALITY The product should fulfill a certain function with reliable durability using the most economical manufacturing process. Construction = selecting, dimensioning and combining materials and components into a product.

5 Lumber Preparation Drying Dried lumber becomes more stable and uniform Drying time various depending on the wood species used MC content for furniture should be between 6 and 10% Air drying of lumber can take up to 120 days or more Kiln drying speeds up drying process (e.g., conventional kilns, dehumidification kilns)

6 Lumber Preparation - Drying Application MC% Construction Lumber 19% Windows 12-15% Flooring 7-11% Furniture (fireplace) 10-12% Furniture (central heating) 6-10% Shipbuilding 16-18% Music instruments 5-11% Interior doors 6-10% Digital Moisture Meter

7 Lumber Preparation Breakout/Conditioning Breakout Conditioning: The lumber has to be sorted, graded and cut to rough dimensions (The yield may be between 40 and 55% depending on species and grade required) Machinery used: Chop saw, Gang-saw, etc. Lumber has to be stacked Lumber should be conditioned for approximately 3-7 days before final machining

8 Grading Lumber Mark/Optimize components for Maximum Yield and Beauty Identify and mark any defects in the stock knots checks & shake Wane, etc.

9 Ways of Cutting Source: building-your-toolbox-saws-part-ii.html

10 Chop Saw Lumber Breakout -Chopping Used to cut across the face of the board

11 Lumber Breakout Rough cut to length (Radial Arm Saw, Chop saw, or Pendulum Saw)

12 Rip Saw Lumber Breakout -Ripping Used to rip along the length of the board

13 Lumber Breakout Rough cut to width (Table Saw)

14 Lumber Breakout Rip First Then Chop X X X 4 Usable Parts 3 Waste Parts

15 Lumber Breakout Chop First Then Rip? X X? X 6-8 Usable Parts 3 Waste Parts

16 2) Further Solid Wood Processing Component Processing: Depending on the usage/location, the components may have to be machined further. Further processing steps could include: Sawing Jointing Planing Gluing Profiling, Drilling Sanding

17 Component Processing -Sawing Sawing Cut to final dimension Cut a mitre Cut a groove Cut curved components, etc. Chop Saw to Cut to Final Dimension Mitre Cut Band Saw Curved Components With Bandsaw Groove Cutting

18 Component Processing Drilling Planing -Jointing Drilling Vertical/Horizontal For dowel holes, hardware Planing To S4S Cut to dimension Jointing To remove cup, bow, twist Multi-drill Machine Planer Jointing

19 Component Processing -Profiling Profiling To profile an edge/face of a component Moulder

20 Component Processing -Sanding Sanding To sand the surfaces and edges of components Different Abrasive Papers Brush Sander Wide Belt Sander

21 Panel construction Wood veneer Edge Composite panel (e.g., MDF, particleboard)

22 3) Panel Processing Panel Breakout: Large sheets of panel are cut to rough dimension Cutting pattern of a composite panel Panel saw

23 Component Processing Panel Sawing Horizontal panel saws

24 Veneer Preparation Veneers are dimensioned using the guillotine Cut to length and width Veneers are joined together using a veneer stitcher Veneer Guillotine Veneer Stitcher

25 Veneer Pressing Veneers are pressed onto panel substrate under moderate temperatures and pressures Urea formaldehyde (UF) adhesive is most common Veneer Press

26 Panel Processing Edge-banding Edges are applied to veneered or laminated panels Some edge-bandersmay incorporate molder heads Edge-bander Edge Bands

27 Assembly: 4) Assembly Solid wood and panel components have to be assembled Clamping rack Clamping of panels

28 4) Assembly -Hardware Different hardware is used to connect components with each other for decorative purposes (corner brackets, etc.) for functional purposes (hinges, locks, etc.) Flap Hinge European Cup Hinge

29 Finishing If required the parts or the entire furniture piece are surface treated (lacquered, stained, waxed, varnished, etc.) Finishes may be organic solvent based or water-based Finishes may be applied as sprays or by other coating machines Hand Spray System

30 Finishing Spray booth Roller Coater, Flat line System

31 5) Quality Control / Shipping QC: Finished products are checked for defects and packaged for shipping Shipping: Packaging Shipping of furniture

32 Manufacturing Process Example: Manufacturing of a Sideboard Panel Material for Table Top Solid Wood Doors Hardware