Woodwork Career Alliance Skill Standards
57
Considerations: Pre-Operation Checklist is a prerequisite for ANY operation. Material is fed in a smooth, continuous motion. Appropriate stance is utilized for optimum balance and part control. Hands remain firmly on router throughout entire cut. Router bit pointed away from body after completion of a cut.
Appropriate direction of feed is used to prevent loss of router control (no climb cutting unless explicitly specified).
Clears machine and cleans work area after operation.
Machined surfaces exhibit a uniform smoothness between 15-25 knife cuts per inch (KCPI). Variations accepted for accommodation of difficult grain patterns and materials with defects.
Disconnect procedure is in place and followed by everyone.
Required OSHA approved personal protective equipment is worn.
Entrance and exit are clean and straight.
Section 004: Shaping
Portable Router
Routers are widely used for shaping the surfaces and edges of stock, and for creating joinery. The portable router is a versatile tool capable of making internal cutouts, trimming overlays, and doing specialized contouring on wood and composite materials.
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Portable Router
004
58
Shaping
Pre-Operation
Checklist Level 1:
Performance standard:
Given machine, demonstrate ability to verify proper conditioning prior to use.
Verifies sole plate is installed correctly and tight. Verifies depth adjustment bolt is securely tightened. Verifies depth collar functions smoothly. Verifies switch is off before plugging in tool.
Level 2:
Performance standard:
Given a router and a cutting tool, demonstrate ability to install and adjust bit and depth gauge prior to use.
Verifies collet and collet seat are clean and in good condition. Assures cutting tool shank is straight and true. Installs cutting tool properly. Meets Level 1 performance standard.
Level 3:
Performance standard:
Given machine in unknown condition, demonstrate ability to set up and calibrate for operation by checking spindle alignment, brush condition, and inspecting motor bearings and wiring.
Inspects motor brushes to confirm they are intact and functioning.
Meets Level 1 and Level 2 performance standards.
Inspects power cord for breaks or tears. Verifies spindle has no run-out. Tests motor bearings for any indication of wear.
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Portable Router
004
59
Shaping
Edge Profile
Level 1:
Performance standard:
Given material and machine set up and ready to operate, use a 0.25” (1/4”) [6 mm] carbide quarter round bit with live bearing, route quarter round profile on 1 edge and 1 end of solid wood board.
Dimension tolerance of 0.0156” (1/64”) [0.4 mm] is held for the entire length of the profile.
Level 2:
Performance standard:
Given material, set up equipment with 0.25” (1/4”) [6 mm] carbide quarter round bit with live bearing, route quarter round profile on 1 edge and 1 end of solid wood board.
Installs correct cutter tool securely.
Level 3:
Performance standard:
Given material, set up equipment with 0.25” (1/4”) [6 mm] carbide quarter round bit with live bearing, stop route quarter round profile 3” [76 mm] from 1 edge and 1 end of solid wood board.
Sets motion stops to leave 3” [76 mm] of one end of the board free of profile.
No shoulder present in finished piece. Machined surfaces exhibit uniform cut marks with minimal burn or defects.
Verifies face plate is free from obstructions, and calibrated to 90° with cutter. Verifies live bearing is clean and properly lubricated. Meets Level 1 performance standards.
Verifies motion stop clamps do not impede operation of tool. Dimension tolerance is ±0.0156” (1/64”) [0.4 mm] at profile termination. Meets Level 1 and Level 2 performance standards.
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Portable Router
004
60
Shaping
Rabbet
Level 1:
Performance standard:
Given material and machine set up and ready to operate, use a 0.5” (1/2”) [13 mm] straight shank carbide bit, route a 1/2 x 1/2 [13mm] rabbet in edge of a 24” [610 mm] board.
Dimension tolerance of 0.0156” (1/64”) [0.4 mm] is held for the entire length of the rabbet.
Level 2:
Performance standard:
Given material, set up equipment with 0.5” (1/2”) [13 mm] straight shank carbide bit, route a 1/2 x 1/2 [13mm] rabbet in edge of a 24” [610 mm] board using an edge guide.
Installs correct cutter tool securely.
Level 3:
Performance standard:
Given material, set up equipment with 0.5” (1/2”) [13 mm] straight shank carbide bit, route a 1/2 x 1/2 [13mm] rabbet in edge of a 24” [610 mm] board. Set motion stops to leave 0.5” (1/2”) [13 mm] of both ends of the board free of the rabbet.
Assures motion stop clamps do not impede operation of tool.
Machined surfaces exhibit uniform cut marks with minimal burn or defects.
Verifies face plate is free from obstructions, and calibrated to 90° with cutter. Installs and adjusts edge guide properly. Meets Level 1 performance standard.
Dimension tolerance of ±0.0156” (1/64”) [0.4 mm] is maintained at rabbet termination. Meets Level 1 and Level 2 performance standards.
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Portable Router
61
004
Shaping
Dado/Plough/Groove
Level 1:
Performance standard:
Given material and machine and straight edge guide set up and ready to operate, use a 0.5” (1/2”) [13 mm] straight shank carbide bit, route a 1/2 x 1/2 [13 mm] dado inset 1” [25.4 mm] from edge of a 24” [610 mm] board.
Dado is parallel to edge of board.
Level 2:
Performance standard:
Given material, set up equipment with a 0.5” (1/2”) [13 mm] straight shank carbide bit and straight edge guide, route a 1/2 x 1/2 [13 mm] dado inset 1” [25 mm] from edge of a 24” [610 mm] board.
Installs correct cutter tool securely.
Installs and adjusts edge guide properly.
Verifies face plate is free from obstructions, and calibrated to 90° with cutter.
Meets Level 1 performance standard.
Level 3:
Performance standard:
Given material, construct edge guide and set up equipment with a 0.5” (1/2”) [13 mm] straight shank carbide bit, route a 1/2 x 1/2 [13 mm] dado inset 1” [25.4 mm] from edge of a 24” [610 mm] board.
Edge guide is constructed with ample length to allow a straight exit from the board.
Dimension tolerance of ±0.0156” (1/64”) [0.4 mm] is held for the entire length of the dado. Machined surfaces exhibit uniform cut marks with minimal burn or defects.
Meets Level 1 and Level 2 performance standards.
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Portable Router
62
004
Shaping
Template Cutout
Level 1:
Performance standard:
Given material and machine set up and ready to operate, use a 0.5” (1/2”) [13 mm] straight shank carbide bit and template collar, set template and route a pre- determined cutout in board.
Falloff is properly supported with cleating prior to the operation.
Level 2:
Performance standard:
Given material, set up equipment with a 0.5” (1/2”) [13 mm] straight shank carbide bit and template collar, set template and route a pre-determined cutout in board.
Installs correct cutter tool and collar securely.
Level 3:
Performance standard:
Given material, set up equipment with a 0.5” (1/2”) [13 mm] straight shank carbide bit and template collar, construct template and route a pre-determined cutout in board.
Dimension tolerance of ±0.03125” (1/32”) [0.8 mm] (accounting for the collar offset) is held for the entire perimeter of the template.
Dimension tolerance of ±0.03125” (1/32”) [0.8 mm] (minus the collar offset) is held for the entire perimeter of the cutout. Machined surfaces exhibit uniform cut marks with minimal burn or defects.
Verifies sole plate is free from obstructions, and calibrated to 90° with cutters.
Secures templates appropriately to materials so as not to impede operation of tool. Meets Level 1 performance standard.
Template edges are inspected and prepared for smooth operation of tool. Meets Level 1 and Level 2 performance standards.
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Woodwork Career Alliance Skill Standards
63
Considerations: Pre-Operation Checklist is a prerequisite for ANY operation. Position hands so part can be run from start to finish without lifting hands while avoiding tooling. Utilize positive stance and positioning for optimum balance, part control and to minimize body exposure in event of material kick-back.
Material is fed against the cutter rotation. Grain direction is correctly identified and appropriately considered for feed to minimize tear-out.
Required OSHA approved personal protective equipment is worn.
Demonstrate appropriate feed rate to control stock movement and waste removal relative to the size and type of material being shaped.
Section 004: Shaping
Spindle Shaper
Clears machine and cleans work area after operation.
Lock-out/Tag-out procedure is in place and followed.
Shaping is the process of making contoured surfaces and edges for decorative purposes or for joinery. This relatively simple machine can do a wide variety of operations depending on the kinds of cutters available. While shapers have a reputation for being notoriously dangerous machines, proper setup and careful use can reduce these dangers considerably.
Š 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Spindle Shaper
004
64
Shaping
Pre-Operation
Checklist Level 1:
Performance standard:
Given machine, demonstrate ability to verify proper guarding and dust collection operation.
Verifies tool is properly guarded. Ensures paths of in-feed and out-feed have no obstructions to material and operator. Verifies hold-downs are positioned correctly at in-feed and out-feed for clearance to feed material. Verifies dust collection is positioned for effective chip removal.
Level 2:
Performance standard:
Given machine with cutting tools installed, install fences and set cutter dimensions to a specification.
Verifies cutting tools are secure and free of defects.
In-feed and out-feed fences are set with appropriate clearance to cutter head.
Verifies feed table is free of defects and clean.
Meets Level 1 performance standard.
Verifies spindle height and/or angle are set to specified dimension(s). In-feed and out-feed fences are adjusted to yield correct profile with smooth entry into and exit from part.
Level 3:
Performance standard:
Given machine in unknown condition, demonstrate ability to set up and calibrate the machine for operation.
Confirms in-feed and out-feed fences for coplanar state, target 0.0156” (1/64”) [0.4 mm] maximum deviation.
Meets Level 1 and Level 2 performance standards.
Installs cutting tools and verifies cutter rotation. Installs auxiliary hood guard for maximum protection and chip removal.
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Spindle Shaper
004
65
Shaping
Rabbet
Level 1:
Performance standard:
Given material and machine set up and ready to operate, shape a 1/2 x 1/2 [13 mm] rabbet in edge of a 24” [610 mm] board.
Dimension tolerance of ±0.0156” (1/64”) [0.4 mm] is held for the entire length of the rabbet.
Level 2:
Performance standard:
Given material, set up equipment with cutting tool, shape a 1/2 x 1/2 [13 mm] rabbet in edge of a 24” [610 mm] board.
Installs cutter correctly.
Level 3:
Performance standard:
Given material, set up equipment cutting tool, shape a 1/2 x 1/2 [13 mm] rabbet in edge of a 24” [610 mm] board. Set motion stops to leave 0.5” (1/2”) [13 mm] of both ends of the board free of the rabbet.
Installs motion stop clamps so they do not impede feeding of material.
Shaped surfaces exhibit a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks.
Installs/adjusts fence properly. Meets Level 1 performance standard.
Meets Level 1 and Level 2 performance standards.
Dimension tolerance of ±0.0156” (1/64”) [0.4 mm] is maintained at rabbet termination.
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Spindle Shaper
004
66
Shaping
Edge Shaping
Level 1:
Performance standard:
Given material, the machine set up and ready to cut, and a target edge profile, shape the edge of the material to the specified profile.
Shaped surfaces exhibit a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks.
Level 2:
Performance standard:
Given material, set up the machine to cut a target edge profile, shape the edge of the material to the specified profile.
Balances and installs cutting tool properly.
Dimension tolerance is ±0.0156” (1/64”) [0.4 mm] along entire length of material.
Shaped surfaces are free of snipe. Shaped surfaces exhibit minimal tear-out. Shaped surface meets target profile. Profile is consistent along entire shaped surface, with no visible variation.
Sets spindle rotation correctly. Sets spindle speed correctly. Meets Level 1 performance standard.
Level 3:
Performance standard:
Given machine and material, set up and properly install a vertical and horizontal featherboard assembly on the machine, used to shape the edge to a specified dimension.
Dimension tolerance of featherboards 0.03125” (1/32”) [0.8 mm] less than thickness and width of board. Verifies featherboards do not impede smooth feed of material. Meets Level 1 and Level 2 performance standards.
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Spindle Shaper
004
67
Shaping
End Shaping
Level 1:
Performance standard:
Given material, the appropriate jig, the machine set up ready to cut, and a target end profile, shape the end of the material to the specified profile.
Feeds material in the proper direction for cutter head rotation.
Dimension tolerance is ±0.0156” (1/64”) [0.4 mm] along entire length of material.
Shaped surfaces exhibit a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks.
Shaped surfaces are free of snipe.
Level 2:
Performance standard:
Given material, the appropriate jig, set up the machine to cut a target end profile, shape the end of the material to the specified profile.
Balances and installs cutting tool properly.
Level 3:
Performance standard:
Given material and machine, construct the appropriate jig, set up the machine to cut a target end profile, shape the end of the material to the specified profile.
Jig tracks square to the cutting tool.
Profile is consistent along entire shaped surface, with no visible variation.
Sets spindle rotation correctly. Sets spindle speed correctly. Meets Level 1 performance standard.
Jig operates smoothly across feed table and fences. Material hold-downs do not impede operation of machine. Meets Level 1 and Level 2 performance standards.
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Spindle Shaper
68
004
Shaping
Edge Shaping Using Automatic Stock Feeder
Level 1:
Performance standard:
Given material and a target edge profile, shape the edge of the material to the specified profile.
Loads material with appropriate edge and face towards cutter head and table surface. Shaped surfaces exhibit a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks.
Dimension tolerance of ±0.0156” (1/64”) [0.4 mm] is held for the entire length of the detail.
Shaped surfaces exhibit minimal snipe at the entry and exit points.
Level 2:
Performance standard:
Given material and a target edge profile, set up both the shaper and the feeder to shape the edge of the material to the specified profile.
Verifies automatic stock feeding as the correct method for part being machined. Correctly installs cutting tools in balance and to tolerance.
or multiple passes if required for amount of stock to be removed. Meets Level 1 performance standard.
Sets spindle rotation speed relative to size and profile of knives, type of stock and tooling. Adjusts stock feeder position and speed settings for control of part. Sets cutter height and/or fence for partial cut
Level 3:
N/A
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED
Spindle Shaper
004
69
Shaping
Edge Shaping Curved Parts
Level 1:
Performance standard:
Given material, jig and machine set up and ready to cut, shape the edge of curved material to a specified profile.
Feeds material in the proper direction for cutter head rotation. Shaped surfaces exhibit a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks.
Shaped surfaces are free of snipe. Profile is consistent along entire shaped surface, with no visible variation.
Dimension tolerance is ±0.0156” (1/64”) [0.4 mm] along entire length of material.
Level 2:
Performance standard:
Given material and jig, set up and ready to cut, set up machine and shape the edge of curved material to a specified profile.
Balances and installs cutting tool properly. Sets spindle rotation correctly. Sets spindle speed correctly. Verifies spindle bearing is operating smoothly. Securely fastens jig to part. Meets Level 1 performance standard.
Level 3:
Performance standard:
Given machine and material, fabricate jig to utilize in edge shaping process.
A dimension tolerance of ±0.03125” (1/32”) [0.8 mm] (accounting for the collar offset) is held for the entire perimeter of the template. Inspects and prepares template edges for smooth operation of tool. Meets Level 1 and Level 2 performance standards.
© 2009 Woodwork Career Alliance ALL RIGHTS RESERVED