Table of Contents contents Page Introduction 1 Objectives 2 Background 2 Apparatus and tools 3 Requirements 5 Procedures 6 Conclusion 10 References 10 1
Introduction Carpentry work is one of the most important careers in our nowadays life. A carpenter invest wood he gets from trees in forming useful stuffs that we deal with daily, such as: beds, tables, closets, doors etc In carpentry we deal with different types of machines and tools, and many operations are included in a carpenter work, such as: marking, mortising, filing, tonguing and assembling. There are several types of wood we use in carpentry works, these types differ in strength, price, quality, colors and weight. And before I move on my project s report I think it is important to talk briefly about these types. (Summarized in table 1) Wood type Description Application Examples Soft wood Hard wood Plywood Hard board Block board Laminated plastic (Formica) Soft and light in weight and color. It is long and straight. 1. Planes and ships wood components. 2.Outside doors. It is hard and 1. Constructions. The Civil dark. Engineering 2. Home Furniture. Center Provided large sizes (3 layers with crossing fiber). It is cheep and available with flexible size. It is produced by mixing and pressuring wood to form sheet. It is cheep with flexible size. It combines two types of wood. It is a thin plastic film and it is highly costly. 1. Low stress applications. 2. Outside door. Used in low stress applications. It is used with heavy duty applications. 1. Insulation. 2. Decoration. Cypress Cedar Pine Oak Beech Mahogany (Table 1) Note: Some nods are some times found on wood pieces, these nods were bough in the origin and wherever they appear in wood pieces they are weakness areas. 2
Objectives: In our project we aimed to make a stool chair, which will be used in university s studios. We will use beech wood for that purpose because of its strength as we know it is a hard wood. Background of our project: Making a stool chair took us two lab lectures (about 6 hours). We worked in the carpentry department of the workshops of the Engineering department in the Jordanian University. Under the supervision of Mr. Mohamed Abulayla, I and my partner used several pieces of beech wood in making the legs of the stool and its battens, using manual and electric tools, which was available in the lab, and then we assembled the pieces using the glue. Apparatus and A tools: H M 531 The tools we used can be classified into 2 sections: 1.The manual tools. 2. The electric machines. Table 2 contains the manual tools and there use. # Name Description Use 1 Carpentry The working area. A vice: is used to fix wooden piece bench with two A vice consists of: while working on it to prevent it *fixed jaw from slipping. vices *Movable jaw Vice Shoes: to protect the surface of *2 vise shoes wooden pieces we are dealing with from scrabble while fixing it. 2 Clamps It is used to fix wooden pieces together. 3 Bench flat Its blade is sloped with 30 Used to clean or smooth small pieces planner degrees angle of wood. 4 Chisel Used for mortising wood manually. 5 The sharpening While using it, oil must be Used to sharp the chisel and the stone placed on it to less the friction blade of the planner. 3
and to make the operation easier. 6 The Screw There are two types of it: Used to fix and loose screws. driver *Straight *Cross 7 Hand back saw Used to saw small pieces of wood. 8 Nail Hammer Used to knock the nail or to extract it. 9 Mallet Used to knock on the chisel while mortising. 10 Steel ruler Divided from (1-60)cm and (1-24)inch 11 Nail extracting player 12 Right angle (try square) 13 Adjustable parallel line tracer 14 Electric Bench drill 15 Electric portable drill machine It leaves traces on the wood. 16 Wooden file It has two types: *Rough file *Smooth file Used to measure and to draw straight lines. Used to extract nails. Used to draw horizontal, vertical and parallel lines on the wood and it can be used to measure 45 and 90 degrees angles. Used to mark straight parallel lines on the wood. Used to make holes in wood or metal with consideration of the twist drill. Used to make holes in wall wood or metal with consideration of the twist drill. Used to remove an extra layer from the wood. 17 Adjustable Used to saw the small pieces of wood angle saw at the exact angle. 18 Screw Used for fixing. 19 Nail Used for fixing. 20 Emery Paper Used for smoothing wood surfaces. 21 Grease Used to grease tool, instruments and machine. 22 Glue Used to glue the pieces of wood together (Table 2) About the electric machines they are: 4
1. Band saw machine: It is used for vertical and horizontal cut, and to make curves and circles and to make tongues. 2. Setting and girding machine: It is used to sharpen saws. 3. Carpentry Compact: Definition: It is one machine containing several types of machines. Circular saw machine: Used for Vertical and horizontal cut. Spindle molding machine: Used to make decorations in wood and make tongues and (farez). Surface planner: To level and smooth the surfaces of wood. Mortising machine: It is used to make holes (Mortises) it the wooden piece in an exact measurement. Requirements: 1- Four wooden pieces (45*45*655) mm for making the legs of the stool. 2- Four wooden pieces (45*20*245) mm for making the lower battens. 3- Four wooden pieces (45*20*185) mm for making the upper battens. Note that all the pieces are beech wood. 5
Procedures: Many operations are done while making a stool chair: Marking, Mortising, Tonguing (which contained 2 operations Filing and Sawing) and finally the Assembling. (Note that there are other procedures in the carpentry work but we haven t done them because of the lack of time.) In mentioning the procedures of our project I will come through three steps: 1- Making the legs of the stool. 2- Making the battens of the stool. 3- Assembling the battens and the legs and forming the stool body. 1- Making the legs: The only thing we need to do to prepare the legs it to mortise them enough space to let the battens A H in. M And 531 to do that we will start Marking the wooden pieces (45*45*655) and then take them to the carpentry The compact Civil to use Engineering the Mortising machine. Center (1-A): Marking (The legs) We used in this marking operation the Adjustable Parallel lines Tracer, The try angle, A ruler, and a pencil off course. In marking the legs, we marked the measurements on one leg and then we transferred these marks to another leg (2 legs at once) and that is for accuracy. From the bottom of a wooden piece we start, measuring a vertical distance of 18.5 cm and drew a horizontal line at that point. From that line we measured another vertical distance of 4.5 cm and drew a horizontal line at that point. Then, from the upper side of the wooden piece we measure a vertical distance downward of 4.5 cm and drew a horizontal line. After that we used the try angle to transfer these marks to the other side of the wooden piece. Then we align the leg we have marked next to another one and transfer the marks using the ruler and the try angle. And we repeated that procedure to mark all the legs aligning a marked one and an unmarked one at once. 6
NOTE: It might be a source of a problem if we marking the four legs at once, Because if there was an error in the ruler or the try angle we used, This error will be obvious in the legs of our stool. After that we measured from the right side of the wooden piece a 1.3 cm horizontal distance and mark the wit a dot using a pencil. And from that dot we measure a 1.2 cm horizontal distance and marked that too. Then we mark these distances to the adjacent side, these distances should be measured from the side we marked before. After that came with the adjustable parallel line tracer, fixed it on a side of the leg, Put the first pin on the first dot and adjusted the second pin on the next dot. (We have to keep these adjusts because we will use the four the whole four legs.) We moved the tool along the area enclosed with the 2 horizontal marks at the bottom and top of the leg and we also move it along the upper surface of the wooden piece. And we do the same thing on the other marked side. We marked the traces with a pencil. We did the same thing for the 4 wooden pieces. And with that we finish marking (the legs). (1-B): Mortising We took the marked wooden pieces to the mortising machine which was presetted to our project by the supervisors. The depth f the mortise depended on the spindle used in that machine. Then we place the legs (one at once) on the movable base positioning the marked areas in front of the mortising pin. Pushing the leg towards the pin taking a radius each time we made a mortise on the legs of our stool. And so we finished making the legs and that took us 3 hours. 2- Making the battens: 7
We will have 8 battens in our stool; the upper 4 are smaller and are made of wooden pieces (45*45*185), and the lower ones are larger and are made of wooden pieces (45*45*245). This operation will contain the following procedures: A. Marking B. Tonguing; Which contains to more procedures: *Sawing *Filing (2-A): Marking In this operation we will use the Try angle, Bevel square, Tracer and a ruler. First of all we mark the width of the tongue which equals 30 cm from each side, and that will be for the whole battens. Then we will mark the height (the vertical distance from the upper side), which equals 1.2 cm. We used the tracer to mark that distances on the 8 battens and then marked it with a pencil. After that we marked the inner angle of the tongue by transferring it from a pre made sample to our wooden piece using the Bevel Square. (2-B): Tonguing A tongue is a jut in piece of wood to be place in a mortise on another piece of wood. Tonguing contains two operations as I mentioned before: 1- Sawing 2- Filing (2-B-1) There were two sawing operations in making the tongues, 1- The horizontal sawing to determine the height of the tongue. 2- The vertical sawing to get the tongue. In the horizontal sawing we might use the manual hand back saw or the circular saw in the carpentry compact. To do it manually using the hand back saw, 1- We fix the batten by the vice on the carpentry bench in a vertical position 2- We saw on the mark (that defines the height of the tongue) till we get to the depth we need (the distance that specifies the width of the tongue) 8
To do it by using the circular saw Machine, it is presetted to get the wanted height for the tongue (1.2 cm) and move it into the saw till we get the wanted width (30 cm). In our project we used the second method because we didn t have the time. After that we did the vertical sawing by taking our battens to the adjustable angle saws which were adjusted before the lab class. There were 2 for the right side angle and 2 for the left side angle. And we sawed vertically till we get rid of the lower piece of wood which lies under the tongue. On the battens sketch we noticed that there were 45 angles on the outer sides of the tongue, and we executed that by use the Adjustable angle cross out saw. And by that we formed the tongues but it still needs some few operations to be ready for using in our stool. (2-B-2): Filing We used a file neither too smooth nor too rough, and we used the straight side of it. To make the round edges on the tongues and the small angle on its upper edges, first we had to fix the batten by the vice on the bench and the start filing by taking the wood file back and forth estimating the wanted angle and the radius of the round. Sometimes the place on the tongue where the wooden piece separated from is not clean and so the battens won t be assembled well, and so we had to clean it by fix it with the vice and sawing the dirty area using the hand back saw. NOTES: The angles on the upper edges of the tongues are to be made for the lower battens only. We mark the plane side of the batten near the straight edges with an x mark. (will be needed later). 3- Assembling: 9
Assembling is the last step of our project, and it contains getting the whole parts together. In this operation we will Glue, Knock and clamp. (3-A): Gluing We glued the tongues and placed them in the mortises on the legs. We assembled each two legs together first and then we joined the four legs together. Note that you have to place x sign of the battens to the lower, the inside of our stool. (3-B): Knocking Using the mallet we knocked at the joints to let them assembled well. Remember that you don t knock directly on the stool, we got an unneeded wooden piece and placed it on the places we wanted to knock on and then we knocked on it. We remove the excess glue by using water and a sponge. (3-C): Clamping After fixing the stool together we use the clamps to keep it fixed till the glue gets dry. We do that by placing small wooden pieces on the clamps jaws (to protect our stool) and then strengthen the clamps on it. Conclusion: Finally we got our stool done, but it wasn t so ready is still needed some few operations. And now I know so many things about carpentry and its tools and how to use them. I learned about type of wood, the safety that must be taken while working and I m happy for getting this experience. References: Manual work shop technology. The supervisors instructions. 10