Stationary Power ToolsSection 4Unit 15

Introduction

• Def: A tool driven by a motor, hydraulics, air, manually operated lever, or engine that is too large or heavy to be held in the operators hands.

• Common machines are:– Table saw– Vertical Band Saw– Horizontal Band Saw– Radial arm saw– Power Miter Box Saw – Grinder– Drill press– Chop saw

Safety Principles

• Plan the location of each machine.• Firmly anchor each machine to the floor or a

bench.• Insure electrical supply meets NEC.• Mark work zone around each machine.• Keep all guards and shields in place and in

proper working order.• Follow manufacturer's recommendations for

installation, use, adjustment and repair.• Keep cutting devices properly adjusted and

sharp.

Safety Precautions

• Wear appropriate PPE for each machine.• Insure clothing is not loose or baggy.• Always walk in shop--never run.• Limit the number of people in the work zone to one (1) unless

additional help is needed to hold the work.• Insure machine is in good working order.• Insure power to the machine is off when making adjustments.• Do not walk away until machine has stopped rotating.• Clean machine with vacuum, pressurized air or a brush--never

use your hands.• Don’t overload the machine

Stationary Power Tool Safety-cont.

• An important safety and tool longevity factor is the rotating speed of the cutter and the feed rate.

• The recommended speed of rotation, revolutions per minute, is determined by the diameter of the tool and the material.

Cutting Speed and Feed Rate

• Drilling speed factors include the rotational speed of the drill (sfpm) and the rate that it passes through the material (ipr).

Material sfpm ipr Feed

x 10 E-3

Low alloy steel 50 - 60 3 - 7

Stainless steels (soft) 70 - 90 2 - 6

Stainless Steel (hard) 50 - 60 3 - 7

High Strength Steels 30 - 40 1 - 4

Aluminum 175 - 400 2 - 7

Copper 100 - 250 1 - 5

Cast Iron 75 - 150 1 - 5

Low Carbon Steel 80 - 100 3 - 10

Thermoplastics 100 - 150 2 - 15

Thermosetting Plastics 100 - 150 3 - 8

Cutting Speed Example

• Determine the rpm for a 3/8 inch drill for mild steel.

– Mild steel sfpm = 90

€

rev

min=

90 sf

min

1 rev

2 π r x 1 ft

12 in

⎛

⎝ ⎜

⎞

⎠ ⎟ sf

=90

0.049= 1834.4

rev

min

Feed Rate

The feed rate is the rate (in/min) the tools progresses through the material.

Determine the feed rate (in/min) for a 3/8 inch drill cutting mild steel.

€

( / )Feed rate in rev = 10factor x -3

= 5 10x -3

= 0.005 /in rev

( / )Feed rate in min = 0.005 / 1834.4 /in rev x rev min

= 9.172 / in min

Common Principles of Operation

• Measure twice cut once• Trial cut

Common Operations

• Most stationary tools are used to cut and/or shape wood and metal.

• Five Basic cuts Cross Miter Bevel Rip Compound

Common Operations-cont.

• Additional cuts– Dado

– Rabbet

– Plunge

Stationary Power Machines

Band Saw

• Uses a continuous toothed blade running over two wheels.– Variety of blade sizes and points.

– Blade width determines the minimum radius of cut.

– Minimum points determined by three tooth rule.

• Cuts straight or curved lines.• Can be used for freehand sawing.• Size determined by the diameter of the

wheels.

Band Saw-cont.

• Blade guides must be adjusted correctly.– Top and bottom

• Bearing support must be adjusted correctly.– Top and bottom

• Must use appropriate blade for the work.– Regular tooth– Hook tooth– Skip tooth

• Must use appropriate set for the work.– Raker set– Alternate set

Completing Standard Cuts-Bandsaw

Cut Completion

Cross Hold material in hands or use the miter gauge set at 0o.

Miter Use miter gauge set for the desired angle.

Bevel Tilt the table

Rip Use rip fence or hold material in hands

Compound Tilt fence and set miter gauge to the desired angles.

Band Saw Safety

• Use appropriate PPE.

• Insure blade is suitable for job.

• Check blade tension.

• Check blade guides and support wheel.

• Move upper blade guide until it is within 1/8 inch of work.

• Clear table of all materials and tools.

• Slowly push the stock into the teeth of the blade.

• Complete cut.

• Try to keep body parts off of the line of cut.

• Insure blade has stopped before leaving machine.

Table Saw

• A rotating blade extends through a slot in a table.

• Saw size determined by blade size.• Exposure of the blade above the

table (depth of cut) is set with a hand wheel on the front of the saw.

• Maximum blade exposure is 1/4 inch or the depth of one tooth above the work.

• Blade angle set by a hand wheel on the side of the saw.

• Saw should have splitter mounted or arm mounted blade guard.

• Fence is used for ripping.• A large table is needed to cut

plywood.• Table will have a slot for the

miter gauge and rails for the rip fence.

Table Saw-cont.

A wide variety of blades sizes and teeth configurations are available for different cuts and finishes.

Blades are classified by the type of teeth.

a. Cross cutb. Ripping

c. Combination

d. Plywood

Most blades are available with carbide teeth.

Table Saw-cont.

• Special purpose blades are also available. Examples:– Dado

– Molding heads

Completing Cuts-Table Saw

Cut Completion

Cross Miter gauge set at 0o.

Miter Use miter gauge set for the desired angle.

Bevel Tilt the blade

Rip Set the rip fence the desired width.

Compound Tilt blade and miter gauge to the desired angles.

Table Saw Safety

• Wear appropriate PPE

• Use two people to saw large pieces

• Use a push stick when ripping pieces 3.0 inches wide or less.

• Always stand and keep hands to one side of the blade.

• Select the correct type of blade.

• Adjust blade height and angle.

• When ripping move miter gauge off the saw table.

• When using the miter gauge move ripping fence to far right or

remove from table.

Table Saw Safety-cont.

• Push work into blade with slow steady movement.

• When ripping, focus your attention on the along the edge of the work at the rip fence.

• Never use the miter gauge and the rip fence at the same time unless a space block is used.

Radial Arm Saw

• Radial arm saw is a portable circular saw attached to a arm so that it can slide and rotate.– Arm can move up and down, and rotate

left and right.

• Most complicated saw.• Most versatile saw.• Most hazardous saw.• Saw can pivot at three locations

– Arm

– Carriage

– Motor

• Each pivot has a lock and a clamp.

Completing Cuts

Cut Completion

Cross Set and lock arm at 0o.

MiterPivot arm to the desired angle.

Lock the arm pivot.

BevelTilt the motor in the carriage to the desired angle. Lock the motor pivot.

Rip

Pull the carriage out. Pivot the carriage 90o with the blade to the outside.

Lock the carriage pivot.

Set the desired distance between the blade and the fence and lock the carriage.

Set anti-kickback

CompoundPivot the arm to the desired angle for the miter and pivot the motor for the bevel. Lock the arm and the motor.

Radial Arm Saw Safety

• Wear appropriate PPE.• Disconnect power before

adjusting.• Always cut by pulling out.

• Always have guards in place.• Carriage must always be

locked or controlled by operator.

Radial Arm Saw Safety-cont.

• Always stand to one side when pulling carriage out.– Figure 15-14 incorrect

• Never start the saw when the blade is touching the wood.• Insure blade has stopped before removing boards or scrap.

Cutoff Saws

• Also called power miter box saw or compound miter box saw saw when used for wood.

• Commonly called a chop saw when used to cut metal.

Power Miter Box Saw (PMBS)

• A PMB saw uses a blade similar to portable circular saw.

• Size of saw is determined by size of blade.

• Usually includes the ability to cut miters up to 45o in one or both directions.

• Some have the capability to cut bevels.

• Laser popular for aligning the cut.• Some manufacturers increase

capacity by adding a sliding mechanism.

• Spring loaded to the up position.

Power Miter Box Saw (PMBS) Safety

1. Wear appropriate PPE

2. Insure power is disconnected before adjusting.

3. Hold lumber firmly (or clamp) on the table.

4. Do not force saw.

5. Insure all guards are in place and working properly.

6. Always hold wood firmly against fence. DO NOT SAW FREEHAND.

7. Insure correct blade is installed and in good condition.

8. Check to insure base is locked before starting saw.

9. Wait for the blade to come up to speed before starting cut.

10. Remove all chips, tools, etc. from table top before starting.

11. Keep hands and all other body parts to one side of the blade.

Completing Cuts-PMBS

Cut Completion

Cross Set and saw at 0o.

MiterPivot saw to the desired angle.

Lock the saw in place.

Bevel Not available on most saws.

Rip Not available

Compound Not available.

Chop Saws

• Uses an abrasive wheel or carbide blade to cut metal.

• Abrasive wheel invented to cut high carbon and alloy steel.

• Carbide blade designed for mild steel.

• Poor substitute for a horizontal band saw for cutting mild steel.

• Popular because less expensive to purchase than a horizontal band saw.

• More expensive to use than a horizontal band saw.

Completing Cuts-Chop saw

Cut Completion

Cross Set and saw at 0o.

Miter Not available on most saws.

Bevel Not available on most saws.

Rip Not available

Compound Not available.

Chop Saw Safety

1. Wear appropriate PPE.

2. Insure there are no loose clothing, long hair etc.

3. Check all guards and inure the a working properly.

4. Insure hands and all other body parts are to one side of the blade/ wheel.

5. Use only the recommended RPM and sizes of blades.

6. Disconnect power before change the blade.

7. Clamp all work before cutting.

8. Do not perform operations freehand.

9. Do not attempt to cut short pieces.

10. Long work must be supported at the same height as the table.

11. Do not reach into the cutting area until the blade comes to a full stop.

12. Release trigger switch before returning the saw to the start position.

Horizontal Band Saw

• Has a continuous blade that travels around two wheels.

• Blade aligned for cutting by two sets of guides.

• Most efficient way to cut mild steel.• Size usually categorized by the

widest/largest cut.• Designed to cut angles from 0o to

45o. • Some saws use a coolant system

to extend the life of the blade.

Completing Cuts-Horizontal Band Saw

Cut Completion

Cross Set and saw at 0o.

Miter Set vise at desired angle.

Bevel Not available on most saws.

Rip Not available

Compound Not available.

Horizontal Band Saw Safety

1. Wear ppropriate PPE

2. Support long work at the same height as the saw table

3. Disconnect power before changing blades.

4. Do not push down on the cutting head while while the saw is cutting.

5. Set moveable blade guide as close to the work as possible.

6. Hand start the blade into the work. 1. Especially when cutting a thin edge.

7. Wait until blade stops before removing work.

8. Insure work is clamped securely in vise.

Drill Press

• Machine for producing holes in hard substances.

• The bit is held in a rotating spindle and is fed into the work piece by a gear rack operated by a handle.

• The work is usually clamped in a vise resting on a table.

• The bit may be gripped in a chuck with three jaws.

• Bit may also be held by a tapered shank that fits into a tapered hole in the spindle.

Drill Press-cont.

• Available as bench top or floor mount.

• Speed adjusted by variable speed drive or step pulley.

Drill Press Safety

• Wear appropriate PPE

• Never wear loose clothing or loose jewelry.

• Secure long hair.

• Always center punch hole location when drilling in metal.

• Always used vise or clamp work to table when drilling metal.

• If vise is not clamped to table, rotate it until is is blocked by the

column before drilling.

• Disconnect power before adjusting drill press.

• Before installing bit insure it is sharp and not damaged.

Drill Press Safety-cont.

• Remove chuck key from chuck before drilling.

• Do not exceed the recommended speed of bit.

• Never stop the rotation of the drill chuck and spindle with your

hands or fingers.

• When drilling deep hole raise the drill bit from the hole to

remove cuttings.

• When using cutting oil, apply oil after center punching, and as

needed when drill to prevent bit from overheating.

Additional Stationary Power Tools

• Jointer

• Planner

• Sanders

• Wood lathe

Questions