Secondary Wood Processing Manufacturing Processes 2015
Manufacturing Process Example: Manufacturing of a Sideboard Panel Material for Table Top Solid Wood Doors Hardware
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
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.
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)
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
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
Grading Lumber Mark/Optimize components for Maximum Yield and Beauty Identify and mark any defects in the stock knots checks & shake Wane, etc.
Ways of Cutting Source: http://www.designsponge.com/2011/04/diy-101- building-your-toolbox-saws-part-ii.html
Chop Saw Lumber Breakout -Chopping Used to cut across the face of the board
Lumber Breakout Rough cut to length (Radial Arm Saw, Chop saw, or Pendulum Saw)
Rip Saw Lumber Breakout -Ripping Used to rip along the length of the board
Lumber Breakout Rough cut to width (Table Saw)
Lumber Breakout Rip First Then Chop X X X 4 Usable Parts 3 Waste Parts
Lumber Breakout Chop First Then Rip? X X? X 6-8 Usable Parts 3 Waste Parts
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
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
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
Component Processing -Profiling Profiling To profile an edge/face of a component Moulder
Component Processing -Sanding Sanding To sand the surfaces and edges of components Different Abrasive Papers Brush Sander Wide Belt Sander
Panel construction Wood veneer Edge Composite panel (e.g., MDF, particleboard)
3) Panel Processing Panel Breakout: Large sheets of panel are cut to rough dimension Cutting pattern of a composite panel Panel saw
Component Processing Panel Sawing Horizontal panel saws
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
Veneer Pressing Veneers are pressed onto panel substrate under moderate temperatures and pressures Urea formaldehyde (UF) adhesive is most common Veneer Press
Panel Processing Edge-banding Edges are applied to veneered or laminated panels Some edge-bandersmay incorporate molder heads Edge-bander Edge Bands
Assembly: 4) Assembly Solid wood and panel components have to be assembled Clamping rack Clamping of panels
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
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
Finishing Spray booth Roller Coater, Flat line System
5) Quality Control / Shipping QC: Finished products are checked for defects and packaged for shipping Shipping: Packaging Shipping of furniture
Manufacturing Process Example: Manufacturing of a Sideboard Panel Material for Table Top Solid Wood Doors Hardware