TOOLS & MACHINES - A

[[ sh ][ HAND TOOLS & EQUIPMENT ]]

Planes

Planes are used to smooth the faces and edges of timber and to reduce pieces of timber to the sizes and shapes required.

The illustration on the right shows the main parts of a typical plane. The plane iron (or blade) is screwed to the cap iron and then held in place on the frog with the lever cap.

The depth of cut is adjusted by turning the adjustment nut clockwise to increase the depth and anti-clockwise to decrease the depth of cut.

The lateral adjustment lever is used to adjust the cutting iron so that the edge is parallel to the sole of the plane.

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The smoothing plane is mainly used for fine finishing work.

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The jack plane is a general purpose plane which can be used to remove waste quickly or for finishing work.

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The try plane is used for straightening long edges.

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Chisels

The firmer chisel is a general purpose cutting tool used mainly for the heavier applications of bench work.

The bevel edge chisel is usually used for fine work such as paring and cutting dovetails where the bevelled edge allows the chisel to fit the shape of the joint.

The mortice chisel is much thicker and stronger than other chisels so it can be used as a lever in cutting mortices. Wide mortice chisels are often used for very heavy work.

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Sharpening Methods

The diagrams which follow illustrate the methods of sharpening plane irons and chisels. When a cutting edge becomes dull it can usually be sharpened by rubbing on an oil stone to produce a fine bevel at 30° to the face of the blade.

A burr will be formed on the cutting edge. This burr must be removed by rubbing on the oil stone with the face of the blade flat on the face of the stone.

When the plane iron or chisel can no longer be effectively sharpened on an oil stone or if it has become gapped, it must be ground on a grinding wheel to an angle of 25° and then sharpened on an oil stone at 30°.

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Sharpening Angle Grinding Angle

Measuring And Marking Tools

Folding rules are used for making accurate measurements and are available in two sizes, 600mm and 1m. Never leave a folding rule open on the bench as it can be easily broken. Measurement should always be made with the rule on edge to avoid parallax errors.

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Steel rules are available in 300mm and 1m lengths. They are also used for making accurate measurements and are handy straightedges.

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The marking gauge is used for marking lines parallel to the faces and edges of dressed or sawn timber. The stock is held firmly against the face side or face edge of the timber and the point scribes a line as the gauge is pushed forward.

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The mortice gauge is similar in construction and usage to the marking gauge except that it has two points. These two points scribe parallel lines as required when marking out a mortice. One point is fixed and the other is adjusted by loosening off the stock set screw and turning the set screw at the end of the stem, then tightening the stock set screw. The distance between the points is set to the width of the mortice chisel to be used.

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The try square is used for drawing lines at right angles to the faces and edges of straight pieces of timber and testing edges and corners for squareness. When using the try square always hold the stock against the face side or face edge.

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The sliding bevel is a marking tool which is used for drawing lines at acute or obtuse angles to the face side or face edges of pieces of timber. It is also used for testing the accuracy of angle cuts.

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Wing dividers or compasses are used for scribing circles and arcs in marking out operations and for transferring measurements and stepping off equal distances on a setout. Wing dividers can also be used as a parallel gauge when scribing an irregular joint.

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Saws

The tenon saw is a versatile tool used for both cross cutting and rip cutting in the whole range of fine bench work. It features a rigid back which stiffens the saw blade and helps to keep the cut straight.

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Hand saws are used for cutting both softwoods and hardwoods and are available in a range of sizes. Small hand saws with fine teeth are called panel saws and are used for accurate cross cutting of small sections and light panels. Large saws with teeth specially shaped for cutting with the grain are called rip saws.

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Coping saws are used for fine cutting of curves and intricate shapes. The blade of a coping saw is usually placed in the frame with the teeth facing backward to cut on the backward stroke. This keeps the blade tight on the cutting stroke. Cutting on the forward stroke springs the frame and slackens the blade which can cause it to break.

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Keyhole saws are used when an internal cut is required. A hole is bored in the sheet or board to allow the saw to enter and start the cut. A portable jigsaw could also be used to perform this work.

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The hole saw features a cylindrical saw blade and pilot drill. Interchangeable blades of different diameters are available. The hole saw cuts a perfectly round hole and is generally suitable for boards or sheets which are thinner than the width of the blade. Thicker material can sometimes be cut from both sides. Hole saws can be used in a portable drill but are most accurate when used in a drill press.

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The teeth of a saw are ‘set’ so that the saw cut is wider than the thickness of the saw blade to prevent jamming. Every second tooth is bent outward and the alternate teeth are bent in the opposite direction. Tenon saws and hand saws are set with a special tool called a sawset.

Other Tools

Claw hammers are general purpose hammers which feature a specially shaped claw which is used mainly for pulling nails. The size of a hammer is given by the weight of the head. The type illustrated is a standard claw hammer with a replaceable wooden handle. Other types have steel or reinforced fibreglass handles. A hammer should never be used on a chisel in the workshop.

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The wooden mallet is used in conjunction with chisels to remove the waste material in most woodwork jointing operations. The mallet is preferred to a hammer because it is less likely to damage the handle of the chisel.

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The warrington hammer is similar to the cross pein hammer used in metalwork but is generally smaller in size and weight. It is usually used for fine nailing work.

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Screw drivers are used for turning screws when inserting or removing them from the work. The illustrations below show general purpose screwdrivers for both Phillips and Slotted head screws.

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The ratchet screwdriver shown below is also available for Phillips head screws. These screwdrivers have a mechanism that enables the screw to be driven or withdrawn in a continuous, alternating motion without altering the grip on the handle.

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Care must always be taken to select a screwdriver that fits snugly into the slot of the screw.

The nail punch is used in conjunction with a hammer to punch nail heads just below the surface of the timber in preparation for stopping (filling).

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The spokeshave is used to smooth round edges. It has a blade and cap iron similar to a plane and works on the same principle. Spokeshaves with a round sole are used on concave edges.

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The half round file is often used in shaping operations such as freeform work and smoothing curved edges. The flat face of the file is used on flat or convex surfaces and the rounded side is used to shape concave surfaces. Half round files used in woodworking are sometimes called cabinet files.

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A rasp is similar to a file. It has coarse teeth and is used for rough shaping wood. The main difference between a file and a rasp is the way the teeth are formed. The teeth of the rasp are punched into its surface, whereas the teeth on a file are cut into its surface.

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Pincers are generally used for pulling small nails which bend when being driven in with a hammer. Pincers are sometimes used for cutting thin wire or small nails.

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The quick action clamp illustrated below on the left is a general purpose clamp used for holding parts together when fixing or gluing. These clamps are often called quick release clamps.

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The G clamp shown on the right has similar uses to the quick action type. Its main disadvantage is that it is slow to operate compared to the quick release clamp, while its main advantage is that a more positive pressure is possible with the screw type.

The sash cramp (or tee bar cramp) shown below is used for holding large jobs such as frames and carcases when gluing. Considerable pressure can be applied to the job using one or more sash cramps.

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The pipe cramp is a general purpose gluing clamp. Their main advantage is that the length is limited only by the length of interchangeable pipe available.

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Twist drills are capable of cutting a variety of materials. A high speed drill will cut most metals including mild steel, as well as wood.

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Dowel bits are designed to cut a clean, reasonably flat bottom hole in softwood.

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Single flute drills cut wood faster than twist drills which have two flutes.

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Countersink bits are used to enable countersunk screws to be sunk flush with the surface of the work.

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Spade bits rely on high speed to cut efficiently. They are used for rough drilling in both softwood and hardwood.

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Auger bits are used for drilling deep holes and have a draw thread to assist entry. They should be used at very slow speed. Softwood auger bits have spurs on the tip to provide a clean cut.

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Auger Bit (hardwood) Auger Bit (softwood)

Reflect and Respond

Before leaving this page, think of what you've just been reading, and test yourself with these questions.

[[ mc /f /r ][ What plane would be best suited to starting a job on a rough piece of wood? ][ Jack plane ][ * Smoothing plane ][ Try plane ][ The jack plane would be best suited to quickly remove the waste from the rough piece of wood. ]]

[[ mc /f /r ][ What chisel would I use to cut dovetail joints? ][ Bevel edge chisel ][ * Firmer chisel ][ * Mortice chisel ][ The bevel edge chisel's design allows it to fit the shape of the joint. ]]

[[ tr /f ][ What angle of bevel do you want to sharpen a dull chisel to? (Just need a number) ][ 30 ][ A 30° angle. ]]

[[ mm /f ][ Select the measuring device that is best suited for each measurement: ][ Marking 20cm on a straight piece of timber ~ Steel rule ][ Marking a line at a right angle to the edge of a 2x4 ~ Try square ][ Marking a line at any angle other than 90° to the edge of a 2x4 ~ Sliding bevel ][ Marking an arc to create a curved edge on a piece of timber ~ Compass ][ Steel rule is for marking in a straight line, try squares are for marking at right angles, sliding bevels can do any other angle, and compasses can be used to mark circles or arcs. ]]

[[ mm /f ][ Select the saw that is best suited for each cut: ][ Cutting a curve into the end of a piece of timber ~ Coping saw ][ Making a lengthwise cut through the centre, but not out at either side, of a piece of timber ~ Keyhole saw ][ Cutting out a round hole in a piece of board ~ Hole saw ][ Coping saws are for cutting curves or shapes, keyhole saws are for internal cuts, and a hole saw can cut out round holes. ]]

[[ tr /f ][ What tool would you use in conjunction with a chisel in most jointing operations? (2 words) ][ wooden mallet ][ The mallet is preferred over a hammer because it is less likely to damage the chisel. ]]

[[ tr /f ][ What tool is used with a hammer to prepare nails in timber for stopping? (2 words) ][ nail punch ][ The nail punch punches nail heads to just below the surface of the timber. ]]

[[ tr /f ][ What tool should be used for large gluing jobs? (2 words) ][ sash cramp ][ The sash cramp can apply considerable pressure. ]]

[[ mc /f /r ][ Which of these drill bits would be most suited for drilling a hole into a piece of copper pipe? ][ Twist drill ][ * Countersink bits ][ * Auger bits ][ * Single flute drill ][ A high speed twist drill will cut most metals. ]]

[[ sh ][ PORTABLE POWER TOOLS ]]

Drills

Portable drills are available in a wide range of types and sizes with a number of different features including dual and variable speeds, forward and reverse, torque settings and impact or hammer function.

The drill bit is held in a chuck which is connected by a shaft and gear arrangement to an electric motor.

Most portable electric drills are equipped with a switch lock. Generally, students are advised to use the switch lock only when the drill is fixed in a drill stand.

Basic drills are light and compact, usually featuring variable speed and reverse. Chuck size is usually 6.5mm or 10mm.

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Cordless drills feature a rechargeable battery and are usually equipped with a 10mm or 13mm chuck.

Other features may include dual or variable speeds, multiple torque settings, forward and reverse.

These features combine to make most cordless drills suitable for both drilling and screwdriving operations.

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Impact drills often have extra features such as a two speed gearbox, variable speed reversible, usually with a 13mm geared chuck.

The model illustrated on the left also has an adjustable depth guide fitted.

The impact or hammer mode is engaged by pressing the button provided and is used for applications such as drilling into masonry or brickwork.

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Sanders

Orbital sanders are generally used for fine finishing work. The flat pad to which the abrasive paper is attached moves in a small orbit or circular motion at a very high speed.

The orbital action is caused by an eccentric attachment fitted between the pad and the drive shaft from the motor. The model illustrated on the right has a dust collection bag fitted.

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Random orbital sanders are often called eccentric sanders because they combine the circular motion of a disc sander with the eccentric motion of an orbital sander.

The combination of the circular motion and the orbital motion provides a fast but smooth sanding action which is suitable for fine finishing work.

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Belt sanders are used mainly for rough sanding work as they tend to cut much more quickly than other types of portable sanders. A belt of abrasive material rotates around two drums which act like pulleys.

One of these drums is driven by an electric motor and the other runs free. Portable belt sanders feature an adjustment which is used to align the drums so that the belt runs true.

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Jigsaw

The jigsaw is a versatile power tool which can be used for a variety of cutting operations on wood and most sheet materials.

It can be used for straight cutting but is most useful for cutting shapes which involve tight curves.

The model illustrated on the right features an adjustable foot plate which can be rotated up to 45° for bevel cuts. The foot plate should always rest wholly on the workpiece while cutting.

When cutting out internal shapes, a hole should be drilled through the material first, to allow entry of the jigsaw blade.

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Safety Precautions

Reflect and Respond

Before leaving this page, think of what you've just been reading, and test yourself with these questions.

[[ mm /f ][ Match the features to the drill: ][ Basic drill ~ Variable speed and reverse ][ Cordless drill ~ Variable speed, multiple torque settings, forward and reverse ][ Impact drill ~ Two speed gearbox, variable speed reversible, and hammer mode ][ Basic drill has variable speed and reverse, cordless drill often also have torque settings, and the hammer drill has a gearbox and hammer mode. ]]

[[mc /f /r ][ Which sander would you use to start a project with a rough piece of timber? ][ Belt sander ][ * Orbital sander ][ * Random orbital sander ][ * Galaxy sander ][ Belt sanders cut much quicker than other sanders. ]]

[[ sh ][ THE WOOD LATHE ]]

The wood lathe is one of the oldest machines used for shaping articles from wood. Archaeological evidence shows that the early Egyptians, about 1400 BC, had developed a machine which operated in a manner similar to the modern wood lathe.

The material being machined is held in the lathe while it is rotated at a suitable speed. Cutting tools are fed into the rotating wood and waste material is removed providing the operator with the means of creating the desired shape.

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The photograph above illustrates a typical wood lathe and its component parts. The headstock spindle is driven by a vee belt connected to an electric motor. The motor may be directly below the headstock as in this example or fitted to the left side of the headstock. Step cone pulleys provide a range of turning speeds suitable for all turning operations.

Turning speed should be varied according to the diameter of the material being used. Generally, the RPM should be reduced for larger diameter work.

Lathe Tools

Wood turning tools can be divided into two groups; scraping tools and cutting tools. For most normal turning operations the gouge, skew chisel and parting chisel could be described as cutting tools and the round nose, square nose and spear point as scraping tools.

However, most tools are quite versatile, e.g. a round nose tool may be used as a cutting tool when turning the inside of a wooden bowl. The round nose tool is less likely to ‘dig in’ than the gouge in this type of wood turning. The illustrations below show a typical set of wood turning tools.

The gouge is used for quick removal of waste and for most rough turning operations.

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The skew chisel is used for cutting and finishing straight and convex surfaces.

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The round nose chisel can be used as a scraping tool for finishing shapes and for cutting grooves and concave surfaces.

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The parting chisel is used mostly for cutting square grooves and shoulders. Because its sides are relieved it can be fed into the work with little side friction.

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The spear point chisel can be used to advantage in scraping beads and shapes where a square nosed chisel would be difficult to operate because of the shape of the cutting edge in relation to the shape of the surface being turned.

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The square nose chisel is usually used for finishing square grooves and shoulders.

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Centres

The wood stock for all spindle turning operations is held between the headstock and the tailstock of the lathe by means of centres. These centres are tapered and fit the tapers in the headstock and tailstock perfectly providing a non-slip friction fit.

The spur centre is fitted into the headstock spindle. The spurs are tapped into the end of the wood stock to grip the work, enabling the lathe spindle to rotate the job.

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The live centre or revolving cone centre is fitted into the tailstock to support the end of the job. Its greatest advantage over other types of tailstock centres is that lubrication is not required because the cone centre rotates with the work.

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A cup centre adaptor which can be fitted over the cone centre is also shown in the illustration above.

The plain centre is used in the tailstock to support the wood stock in a similar manner to the live centre except that it does not rotate with the work.

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Tailstock centres that do not rotate are often called dead centres.

The wood stock rotates on the conical surface of the plain centre causing friction and heat, which must be minimised by lubricating with a suitable grease.

The cup centre is also a dead centre that can be fitted in the tailstock to support the work during spindle turning operations.

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This type of centre provides extra bearing surface on the cup face and usually requires less adjustment than the plain centre during turning operations. The cup centre must also be properly lubricated because it remains stationary while the woodstock rotates causing friction and heat.

Face Plates

The illustrations which follow show three common methods of attaching material to the headstock of the wood lathe for turning articles such as bowls, lamp bases and knobs which cannot be successfully turned between centres.

The screw point face plate is suitable for turning small articles only, such as cupboard knobs and screw hole buttons.

This type of face plate features a large fixed screw as illustrated on the right. The wood stock is centred with a small pilot hole then threaded onto the screw.

For safety reasons, larger articles should never be turned using a screw point face plate. The extra pressure exerted may cause the wood fibres to fracture around the screw with the danger of the job flying off the lathe.

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The standard face plate is suitable for larger articles such as bowls.

The wood stock is attached to the face plate with screws, usually three or four depending on the design of the face plate.

Care must be taken to use the correct length screws to ensure that the lathe tool does not come into contact with the screws when the centre is being turned out.

It is also very important that the surface of the wood stock fitted to the face plate is perfectly flat, otherwise movement may cause the screws to become loose.

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The face plate chuck or bowl turning chuck enables quick mounting and demounting of the wood stock.

The type illustrated on the right locks into the back of the wood stock. The chuck is expanded to fit tightly into a recess which is first drilled with a special cutter.

Other types of face plate chucks are available, such as the multi-grip chuck. This versatile chuck can grip the wood stock by expansion but also converts to contraction mode so it can grip the wood stock externally like a conventional chuck.

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Spindle Turning

The illustration on the right shows a typical spindle turning operation with the wood stock mounted between centres and rotating toward the operator.

The following procedure should be used to mount the wood stock in preparation for spindle turning.

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For cutting operations the height of the tool rest should be adjusted so that the cutting edge of the tool is slightly above centre and for scraping operations the cutting edge of the tool should be on centre.

Face Plate Turning

The position of the tool rest is very important in face plate turning. The illustrations which follow show the two basic positions. Other positions may be necessary depending on the shape of the article being turned. The illustration below shows the tool rest position when the face of the wood stock is being turned.

The tool rest should be as close as possible to the work and just below centre so the cutting edge of the tool is on centre.

When turning the face of the job the movement of the tool should be from the centre toward the operator as shown by the arrow in the illustration.

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The illustration on the right shows the tool rest position when the edge of the job is being turned.

The tool rest should be positioned as close as possible to the work and its height adjusted so the cutting edge of the tool is slightly above centre.

Positioning the cutting edge just above centre helps to prevent ‘digging in’ when turning the edge of large diameter work.

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Safety

Students should use the wood lathe only when:

Personal Safety

Operating Safety

Reflect and Respond

Before leaving this page, think of what you've just been reading, and test yourself with these questions.

[[ mc /f ][ Using a wood lathe to carve into 2 posts, one with a 10 cm diameter and the other with a 15 cm diameter, which should be worked on at a lower RPM? ][ The 15 cm post ][ * The 10 cm post ][ * They should be the same ][ * A wood lathe doesn't have variable RPM ][ The larger the diameter of wood being worked, the lower the RPMs should be. ]]

[[ mm /f ][ Match the lathe tool to the work desired: ][ Gouge ~ Quick removal of waste ][ Skew chisel ~ Cutting and finishing straight and convex surfaces ][ Parting chisel ~ Cutting square grooves and shoulders ][ Square nose chisel ~ Finishing square grooves and shoulders ][ The gouge is for waste removal, skew chisel for straight surfaces, parting chisel for cutting shoulders, and square nose chisel for finishing shoulders. ]]

[[ mm /f ][ Match the centres with their operating descriptions: ][ Spur centre ~ Rotating centre that grips the work with tapped spurs ][ Live centre ~ Rotating centre that is fitted into the tailstock ][ Plain centre ~ Non-rotating centre that is fitted into the tailstock ][ Cup centre ~ Non-rotating centre fitted into the tailstock that provides extra bearing surface ][ The plain and cup centres are non-rotating with the cup centre providing extra bearing, while the spur centre has tapped spurs for grip and the live centre is much like the plain except it rotates. ]]

[[ so /f ][ Put these steps in order they should be performed to mount the wood stock: ][ Mark the diagonals of the square ends ][ Punch both centre points ][ Cut the diagonals of one end ][ Seat the spur centre ][ Plane off the corners of the wood stock ][ Mount the wood stock][ Wind the tailstock centre in ][ Rotate the wood stock by hand adjusting the tailstock ][ Position the tool rest parallel to the wood stock ][ Mark the diagonals > Punch the centre points > Cut the diagonals > Seat the spur centre > Plane off corners > Mount the wood > Wind the tailstock > Adjust the tailstock > Position the tool rest. ]]

[[ mc /f /r ][ Select the personal protective equipment required to remain safe while using a wood lathe: ][ Face shield ][ * Goggles ][ * Sunglasses ][ * Hardhat ][ A face shield is required to protect your eyes and race from flying wood chips or tools. ]]

[[ sh ][ THE BUFFING MACHINE ]]

The photograph below illustrates a typical buffing machine used for polishing mainly plastic materials in school workshops. The machine spindle is fitted with tapered screws to which the polishing buffs or mops are attached.

The right hand tapered screw has a right hand thread and the left hand tapered screw has a left hand thread. When the machine is running the spindle is rotating towards the operator.

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The direction of the rotation causes the mop to actually tighten on the screws by centrifugal force. If the left hand tapered screw had a right hand thread the left hand mop would tend to loosen and perhaps come right off the spindle when the machine was switched on.

The mops are usually dressed with a very fine abrasive before use. Several types are available, the most common being in the form of a wax which is impregnated with the fine abrasive grit. This abrasive should be applied sparingly with the machine running.

Mops are generally made from calico or other similar material layered to a thickness of 25mm or more.

Operation and Safety

Reflect and Respond

Before leaving this page, think of what you've just been reading, and test yourself with these questions.

[[ mc /f ][ Which best describes the design of the buffing machine displayed above? ][ The right hand screw has a right hand thread and the left hand screw has a left hand thread ][ * Both left and right hand screws have a right hand thread ][ * Both left and right hand screws have a left hand thread ][ *That wasn't a buffing machine displayed above, it was the handlebars of a motorcycle ][ The thread has a matching screw (right hand to right hand) so as to keep tightening while running, instead of coming loose. ]]