Formulae and Tables - Wood / textbooks for vocational training (GTZ, 122 p.) 10. Setting-up of Tools 10.1. Setting-up of Hand Tools 10.2. Setting-up of Machine Tools

Formulae and Tables - Wood / textbooks for vocational training (GTZ, 122 p.)

10. Setting-up of Tools

10.1. Setting-up of Hand Tools

Setting-up of hand saws

Operation Representation	Aids/tools		Remarks
cleaning of the saw blade	petroleum thinner		Remove glue residues, resin residues and similar
clamping of the saw blade 1 saw blade, 2 hand vice	hand vice		Clamp the saw blade horizontally, closely below the tooth gullet line.
checking of the top line 1 saw blade, 2 glass plate	small glass plate or similar		Differently long teeth lead to running-off centre of the saw; the saw blade is jolting during sawing.
dressing of the saw blade 1 saw blade, 2 gauge made of wood (dimensions in cm), 3 flat file	clamped flat file		File a uniform tooth line.
checking of the tooth form 1 saw blade, 2 plate template	sheet-metal template for tooth - forms		Find out which teeth are to be corrected.
corrective filing of such teeth which deviate in form and size 1 saw blade, 2 saw file	saw file	Hold the file horizontally and at right angles to the saw blade.
reclamping of the saw blade for saw setting with the saw set 1 saw blade, 2 stop bar, 3 hand vice	hand vice and stop bar	The teeth uniformly project 1/3 of their height beyond the stop bar.
saw setting with the saw set (1) schematic representation (2) representation showing the principle of operation 1 saw blade, 2 stop bar, 3 hand vice, 4 saw set	saw set	At first set every other tooth to one side and then - after resetting the bar and the saw blade - the rest of the teeth uniformly to the other side. The clearance of the saw blade in the saw set slot is ³ 0.1 mm; amount of deflection: 1/2 saw blade thickness to each side.
saw setting with saw set pliers	saw set pliers	Set the setting height and amount of deflection (setting width) on the saw set pliers. Mount without rule.
checking of the setting width (1) Schematic representation (2) Representation showing the principle of operation 1 saw blade, 2 saw setting gauge, 3 setting width	saw setting gauge	Move the saw-setting gauge with the recessed edge past the teeth in the blade plane.
correction of incorrectly set teeth	saw set or saw set pliers	Reset or further deflect the teeth concerned by the amount necessary.
equalizing 1 saw blade, 2 saw setting gauge, 3 setting width	flat file or hone	Slightly “equalize” on the tooth line and at the tooth profile before sharpening to compensate the different resetting ability of the saw teeth.
sharpening (filing) of the saw blade 1 saw blade, 2 hand vice, 3 sharpening file, 4 direction of pushing, 5 direction of filing	sharpening file	Clamp the saw blade into the hand vice; tooth gullet line at the most 5 mm above the jaws. Hold the file exactly horizontally and at right angles to the saw blade; the same number of file strokes in every tooth space. File against the direction of the cut, move the file with uniform pressure. The tooth is sharp, when the tooth crest is not bright any more, but appears dull. File cutting face and flank uniformly.

Mistakes made when setting-up hand saws

Kinds of mistake Representation	Effects of the mistake
missing or too small tooth set 1 saw blade, 2 workpiece	the saw is jamming or drifting
too large tooth set 1 saw blade, 2 workpiece	unclean cut and bad guidance of the saw
one-sided tooth set 1 saw blade, 2 workpiece	the saw deviates from the true course
tooth set too deep (whole tooth height deflected) 1 saw blade, 2 workpiece	danger or cracking at the tooth gullet; insufficient stability of the saw blade
filing into the direction of the cut 1 saw blade, 2 hand vice, 3 sharpening file, 4 filing burr, 5 direction of pushing, 6 direction of filing	the burr forming at the primary cutting edge acts in the direction of the flank and reduces the cutting effect
canting on the sharpening file 1 saw blade, 2 sharpening file	chip removal at the flank or cutting face too great; differences in the tooth height and wedge angle occur; cutting capacity is reduced, as only a part of the teeth is working; the saw is hacking
deviation of the file position from the horizontal 1 saw blade, 2 hand vice, 3 sharpening file	chamfering of the flank, change of the tooth height, reduction of the cutting effect
file position not at right angles to the saw blade 1 saw blade, 2 sharpening file	chamfering of the flank, change of the tooth height, reduction of the cutting effect

Setting-up of plane irons and chisels

Operation representation	Tools/aids	Remarks
cleaning of the plane iron and the flap or chisel	petroleum or similar	Remove resin and glue residues.
Checking of observance of safety regulations		Use safety goggles or safety glass. Spacing between tool support and abrasive tool must be correct. Mounting flange diameter must be correct. Observe maximum permissible peripheral speed of the abrasive tool. Do test run of the abrasive tool.
Checking of the cutting edge 1 cutting edge not at right angles, 2 jagged cutting edge, 3 dull cutting edge (bright edge), 4 cambered (round) land		Sharpen only when it is not possible any more to get a good cutting edge by dressing.
clamping of the plane iron 1 sharpening wheel, 2 plane iron	plane iron and ripping chisel sharpening machine	Firmly clamp the plane iron into the carriage, grind against the direction of rotation of the wheel.
setting of the angle of support of the tool support 1 sharpening wheel, 2 plane iron, 3 support for plane iron	plane iron and ripping chisel sharpening machine	plane iron rest is sufficient; setting e is to be made in such a way that the correct wedge angle (27°) is reached. Cool the plane iron.
reduction of the land width 1 sharpening wheel, 2 plane iron	plane iron and ripping chisel sharpening machine	This is necessary, if the wedge angle is too small. Cool the plane iron.
increase in the land with 1 sharpening wheel, 2 plane iron	plane iron and ripping chisel sharpening machine	This is necessary, if the wedge angle is too great. Cool the plane iron.
sharpening of the ripping chisel (straight flank) 1 ripping chisel, 2 cup wheel	sharpening machine and cup wheel	Clamping fixture is necessary. The straight flank produces a completely wedge-shaped cutting edge. It penetrates better into the wood.
sharpening of turning tools (like ripping chisel with straight edge)	sharpening machine and cup wheel	Clamping fixture is not absolutely necessary; tool support is sufficient, because due to the greather wedge angle of the tool cutting edge (see 7.4.) the angle of inclination of the tool to the sharpening wheel is considerably flatter than for the ripping chisel.
honing of plane irons and ripping chisels (1) Schematic representation (2) Representation of principle operation 1 wooden strip, 2 inserted hone, 3 plane iron	hone	Clamp the hone in position, firmly put on the land of the tool, hone with circular movements over the whole surface of the hone. Hone alternately the land and the minor surface of the tool, until the sharpening bun falls off by itself.
Honing of turning tools 1 turning tool, 2 shaped stone	hone	Turning tools are honed by means of round, half-round or shaped stones. Move the stone on the tool.
Setting-up of the plane iron flap 1 plane iron, 2 flap	sharpening file, hone	File the front edge of the flap until it is at right angles to the central axis of the flap, has a width of 1 mm over the whole of its length, firmly rests on the minor surface of the tool after tightening the screw, has a uniform spacing to the cutting edge of 0.5... 1.0 mm; polish the bun edge brightly with a very fine hone.

Setting-up of the scraper

Operation representation	Tools/aids	Remarks
filing of the scraper 1 pack of scrapers, 2 work supporting block, 3 hand vice, 4 flat file	vice, 2 hard wood blocks, flat finishing file	Clamp packs of several pieces between 2 hard wood blocks in the vice, align the edges in one plane, file the edges to be rectangularly even, longitudinal direction must be exactly straight, slightly round the comers.
Honing of scrapers 1 pack of the scrapers, 2 work supporting block, 3 hand vice, 4 hone	coarse hone	Regrind the pack of filed scrapers by circular movement until the surface is completely smooth.
1 scraper, 2 hone	fine-grain hone	Hone the narrow and broad sides until the burr is completely removed and the edges are sharp-edged.
scraping off of the scraper 1 scraper, 2 scraper steel, 3 supporting block	scraper steel	Place the scraper steel evenly on the scraper. Scrape off the surfaces under pressure from the centre outwards.
scraping of the cutting burr 1 scraper, 2 scraper steel, 3 supporting block	scraper steel	Scrape the edge of the scraper with the scraper steel under moderate pressure. This produces a cutting bun. The burr can be enlarged by scraping several times.
resharpening of the scraper	scraper steel	A dull burr can be scraped off with the scraper steel and renewed several times, before filing becomes necessary again (round edges).

Setting-up of drilling tools

Operation representation	Tools/aids	Remarks
cleaning of drills	petroleum or similar	Remove impurities (resin residues etc.).
sharpening of the centre point 1 drilling tool, 2 centre point, 3 sharpening file	sharpening file, hone	File and hone the centre point uniformly from all sides until all file traces are removed.
no filing of the infeed thread 1 drilling tool, 2 infeed thread
sharpening of entering taps 1 drilling tool, 2 entering tap, 3 sharpening file	sharpening file, hone	File the entering taps only from inside, then hone until all file traces are removed.
sharpening of lips 1 drilling tool, 2 lip, 3 sharpening file	sharpening file, hone	File lips from below, do not interrupt the connection between the lips and the infeed thread, hone carefully.
sharpening of twist drills with roof-shaped point 1 twist drill with roof-shaped point, 2 sharpening wheel, 3 swivel range	plane iron and ripping chisel sharpening machine, grinding gauge	Take the body of the drill with thumb and forefinger of the right hand. The left hand holds the drill at the shank and carries out an upward and downward movement of the drill between the horizontal and an imaginary line 15° below the horizontal. In doing so, continuously check by means of the grinding gauge the point angle, the shape of the cutting edges under the same angle, the concentricity of the point, the position of the chisel edge and the wedge angle.
checking of sharpening 1 checking of the drill point angle, 2 checking of the position of the chisel edge, 3 checking of the wedge angle

10.2. Setting-up of Machine Tools

Setting-up of circular saw blades and band saw blades

Operation Representation	Tools/aids	Remarks
cleaning of the saw blade	petroleum, thinner
setting of the saw blades	setting pliers, set gauge, setting dial gauge	Use setting pliers. Because of its greater accuracy the setting dial gauge is more suitable than the set gauge for checking the setting width.
clamping of the circular saw blade into the sharpening machine	sharpening machine	Saw blade bore hole must fit exactly on the centring taper; put grinding wheel head into highest position, set tooth height greater than necessary.
setting of the saw blade thickness 1 saw blade, 2 adjustable stop, 3 sharpening wheel	sharpening machine	Middle of the saw blade exactly under the middle of the axis of the abrasive tool.
setting of the rake angle	sharpening machine	In case of band saw blades set according to the scale of rake angles of the sharpening machine - choose it a little greater at first.
setting of the saw pitch 1 feed finger, 2 path of the feed finger, 3 upper third of the saw tooth	sharpening machine, measuring tape	Measure the pitch at the saw blade and set it on the saw pitch scale of the machine.
fine setting of the tooth feed 1 sharpening wheel, 2 feed finger	sharpening machine	Switch on the machine, set the tooth feed so that the abrasive tool coming down slightly attacks the cutting face.
setting of the moment of shear	sharpening machine	The feed must start to act at the moment when the abrasive tool reaches the tooth gullet.
sharpening	sharpening machine, hone	At least 4 sharpening passes are necessary; material removed per pass 0.05...0.1 mm; in the last pass only minimum metal removal (0.01... 0.03 mm); carefully remove the sharpening burr with a fine hone.
setting of the tooth height 1 sharpening wheel, 2 flank of the saw tooth	sharpening machine	Fine setting: Abrasive tool must run parallel to the flank.
checking of the top line	glass plate or tooth crest dial gauge	Check band saw blades like hand saws (see par. 10.1.), check circular saw blades with tooth crest dial gauge.
checking of cutting edge angles 1 rake angle gauge, 2 wedge angle gauge	bevel steel square, plate template, wedge angle gauge or similar	Check either with plate template as is done in the case of hand saws or with wedge or rake angle gauge or with bevel steel square.

Mistakes made when sharpening the saw blades

Sharpening mistake	Cause of mistake		Effect of mistake	Elimination of mistake
uneven flank	feed is acting too early (flank becomes hollow) or too late (flank will get lugs)		chip diasposal rendered more difficult, warming-up and drifting of the saw blades	Set the moment of shear correctly.
tooth gullet radius too great	saw pitch set to small		low stability of the saw teeth, drifting of the saw blade	Increase the travel of the feed pawl.
tooth gullet radius too small	profile of the sharpening wheel rounded too little, wheel too thin		drifting of the saw blade at higher feed	Choose proper sharpening wheel, reduce the travel of the feed pawl.
tooth height too great or too small	machine wrongly set		changed tool geometry, shorter cutting life of the cutting edge, drifting of the saw blade	Correct the fine setting of the tooth height.
tooth height not uniform	axis of the sharpening wheel not exactly above the middle of the saw blade		load on the saw teeth not uniform, quicker dulling, worse cutting quality	Check the guidance of the saw blade and correct it.
discolouration of teeth crests	too much material removed by grinding or peripheral speed of the sharpening wheel too high or sharpening wheel too hard	loss of strength of the teeth crests, quicker dulling, drifting of the saw blade		Correct the sharpening wheel’s action and the tooth feed, choose another sharpening wheel.
saw pitch not uniform	tooth feed wrongly set, the sharpening wheel coming down too late attacks the cutting face too heavily	load on the saw teeth not uniform, drifting of the saw blade, worse cutting quality		Reset the sharpening wheel action on the cutting face.
wedge angle altered	tooth height setting too great (wedge angle becomes smaller) or too small (wedge angle becomes greater)	altered tool geometry, worse cutting conditions, higher load on the saw teeth		Correct the fine setting of the tooth height setting.
remaining of a sharpening burr	great abrasion, dull or excessively coarse-grained sharpening wheel	quicker dulling of the cutting edges		Make last sharpening pass with only little abrasion.

Setting-up of stripe irons

Operation Representation	Tools/aids	Remarks
cleaning of the stripe iron and the clamping surface	solution	Cleaning also serves for preventing grinding inaccuracies.
clamping of stripe irons for sharpening 1 stripe iron, 2 clamping plate, 3 detent of stripe iron	sharpening machine	Clamp the stripe irons on the grinding beam so that the cutting edges project about 2 mm beyond the grinding beam and the sharpening wheel can run a few centimetres beyond the end of the stripe iron. When clamping is made in a vice, clamp from the middle of the stripe iron outwards.
infeed grinding	sharpening machine	Infeed the sharpening wheel according to the desired degree of keenness by 0.01...0.03 mm each.
abrasive machining	sharpening machine	Grind in one pass; infeed according to the degree of dulling 0.1...0.4 mm.
flat grinding	sharpening machine	Cup wheel is without tilt angle.
finish grinding	sharpening machine	Grind with moderate pressure. In the last pass the sharpening wheel must come clear. Always grind against the land.
hollow grinding (1) view in the running direction of the cup wheel (2) view at right angles to the running direction of the cup wheel 1 stripe iron, 2 cup wheel, 3 tilt angle	sharpening machine	Tilt the cup wheel by 2...3º in the running direction of the grinding wheel head; multiple honing is possible.
honing 1 machine iron, 2 hone with rough and fine sides	sharpening machine	Remove the grinding burr and fine traces of grinding. Hone only at the cutting face and always in longitudinal direction of the cutting edge. Hone must firmly be placed in position.

Setting-up of milling cutters

Operation Representation	Tools/aids	Remarks
mounting of the cutter on the grinding arbor; centring	sharpening machine	Centring is made by means of centring rings.
aligning of the cutting edges for sharpening	sharpening machine	Align always according to the shortest cutting edge which is determined by means of the dial gauge.
grinding of the tool face 1 milling cutter, 2 sharpening wheel	sharpening machine	Grind relief-turned cutters only at the tool face. Regrind cutters with straight flank (straight relief grind) at the tool face only slightly (infeed axially).
radial infeeding 1 sharpening wheel, 2 material removed in grinding, 3 infeed, 4 milling cutter	sharpening machine	Relief-turned cutters must be fed to the sharpening wheel radially, i.e. they must be turned around the axis during feeding.
checking of the cutting rake	sharpening machine, protractor	In order to ensure always the same cutting rake, the chip removal over the whole tool face is not uniform (chip removal increasing towards the periphery).
grinding of the flank	sharpening machine	Sharpen cutters with straight flank (see par. 9.4.) at the tool face and flank (with the exception of grooving and tonguing cutters which are sharpened only at the tool face).
axial infeeding 1 milling cutter, 2 sharpening wheel, 3 infeed	sharpening machine	Sharpen cutters with straight flank mainly at the flank, in-feed axially.
sharpening	sharpening machine	Grind all cutting edges uniformly.
dressing of the sharpening wheel	sharpening machine, silicon carbide stone	In case of considerable dulling of the cutting edges dress the sharpening wheel once more before finish grinding. To do this, hold the silicon carbide stone by freehand at an angle of 10...15° against the rotating sharpening wheel.
finish grinding	sharpening machine	In the final pass feed the sharpening wheel only slightly so that the sharpening burr can easily be removed.
removing of the sharpening burr	sharpening machine, hone	Carefully hone the cutting edges to remove the sharpening burr.
checking for true running	sharpening machine dial gauge	All cutting edges must lie on the same cutting circle (run-out £ 0.02 mm).
regrinding	sharpening machine	Regrind projecting cutting edges individually to lie on the cutting circle.