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4.1 Spindle Shaper

Considerations

  • Pre-Operation Checklist is a prerequisite for ANY operation.
  • Stock is supported at out-feed.
  • Push stick is used when required.
  • Stock is fed in smooth continuous motion past tooling with proper feed rate while controlling stock movement and waste removal.
  • Proper stance and hand position are demonstrated.
  • Material is fed against the cutter rotation when hand feeding.
  • Grain direction is correctly identified and appropriately considered for feed to minimize tear-out.
  • Demonstrate appropriate feed rate to control stock movement and waste removal relative to the size and type of material being shaped.
  • Stock is held securely against the fence, miter gauge, or fixture as appropriate.
  • Material is pushed completely past the tooling before releasing it.
  • Clears machine and cleans work area after operation.
  • Required OSHA approved personal protective equipment is worn.
  • Lock-out/Tag-out procedure is in place and followed.
  • Process is completed in a timely manner.

Pre-Operation Checklist

Level 1

Performance Standard -
  • Verifies tool is properly guarded
  • Demonstrates knowledge of and proper use of all machine specific controls
  • Ensures paths of in-feed and out-feed have no obstructions to material and operator
  • Verifies jigs and/or fixtures are secure and operating effectively
  • 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 -
  • Verifies cutting tools are secure and free of defects
  • Installs cutting tool properly and verifies cutter rotation
  • Sets spindle rotation correctly
  • Sets spindle speed correctly
  • Verifies feed table is free of defects and clean
  • Verifies spindle height and/or angle are set to specified dimension(s)
  • Installs and properly adjusts required jigs and fixtures.
  • Adjusts In-feed and out-feed fences to yield correct profile with smooth entry into and exit from part
  • Sets In-feed and out-feed fences with appropriate clearance to cutter head
  • Meets Level 1 performance standard

4.1.1 - Rabbet

Level 1

Given material and machine set up and ready to operate, shape a 12.7 x 12.7 mm (1/2 x 1/2") rabbet in edge of a 530 mm (21") board.
Performance Standard -
  • Loads material with appropriate edge and face towards cutter head and table surface
  • Dimension tolerance of ±0.4 mm (1/64") [0.0156"] is held for the entire length of the rabbet
  • Shaped surfaces exhibit a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks

Level 2

Given material, set up equipment with cutting tool, shape a 12.7 x 12.7 mm (1/2 x 1/2") rabbet in edge of a 530 mm (21") board.
Performance Standard -
  • Meets Level 1 performance standard

4.1.2 - Edge Shaping a Profile

Level 1

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.
Performance Standard -
  • 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 is ±0.4 mm (1/64") [0.0156"] 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

Level 2

Given material, set up the machine to cut a target edge profile, shape the edge of the material to the specified profile.
Performance Standard -
  • Meets Level 1 performance standard

4.1.3 - Edge Shaping a Profile with ground-to-pattern insert tooling

Level 1 - N/A

Level 2

Given machine and material, set up and properly install insert tooling on the machine, shape the edge to a specified dimension or profile.
Performance Standard -
  • Balances and installs tooling properly
  • Shaped surfaces exhibit a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks
  • Dimension tolerance is ±0.4 mm (1/64") [0.0156"] 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
  • Uses machine manual to effect adjustments and maintenance
  • Recognizes machine-based defects and the adjustment/maintenance solutions

4.1.4 - End Shaping

Level 1

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.
Performance Standard -
  • Loads material with appropriate edge and face towards cutter head and table surface
  • Feeds material in the proper direction for cutter head rotation
  • Shaped surface exhibits a uniform smoothness,15-25 knife cuts per inch (KCPI), with no burning or hesitation marks
  • Shaped surface is free of snipe and tear out
  • Profile is consistent along entire shaped surface, with no visible variation

Level 2

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.
Performance Standard -
  • Verify material hold-downs are effective, and do not impede operation
  • Verify Jig operates smoothly across feed table and fences
  • Verify Jig tracks square to the cutting tool
  • Meets Level 1 performance standard

4.1.5 - Edge Shaping Using Automatic Stock Feeder (Power Feed)

Level 1

Given material, the machine set up ready to cut, and a target edge profile, shape the edge of the material to the specified profile.
Performance Standard -
  • 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
  • Shaped surfaces exhibit minimal snipe at the entry and exit points
  • Dimension tolerance of ±0.4 mm (1/64") [0.0156"] is held for the entire length of the detail

Level 2

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.
Performance Standard -
  • Adjusts stock feeder position and speed settings for control of part
  • Meets Level 1 performance standard

4.1.6 - Edge Shaping Using Automatic Stock Feeder (Power Feed) and an Outboard Fence

Level 1

Given material, the machine set up ready to cut, and a target edge profile, shape the edge of the material to the specified profile.
Performance Standard -
  • 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
  • Shaped surfaces exhibit minimal snipe at the entry and exit points
  • Dimension tolerance of ±0.4 mm (1/64") [0.0156"] is held for the entire length of the detail

Level 2

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 using an outboard fence to ensure uniform widths.
Performance Standard -
  • Installs outboard fence
  • Adjusts stock feeder position and speed settings for control of part
  • Meets Level 1 performance standard

4.1.7 - Edge Shaping Curved Parts

Level 1

Given material, jig and machine set up and ready to cut, shape the edge of curved material to a specified profile.
Performance Standard -
  • 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 is ±0.4 mm (1/64") [0.0156"] 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

Level 2

Given material and jig, set up and ready to cut, set up machine and shape the edge of curved material to a specified profile.
Performance Standard -
  • Securely fastens part to jig
  • Inspects and prepares template edges for smooth operation of tool
  • A dimension tolerance of ±0.8 mm (1/32") [0.03125"] (accounting for the collar offset) is held for the entire perimeter of the template
  • Meets Level 1 performance standard

4.1.8 [tent] - [under discussions] Stopped cuts or milling (title TBD)