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GOU KO POO "KITiS"
Topic: "TECHNOLOGICAL PROCESS OF MANUFACTURING A SHIELD DOOR UNIT" Lecturer Astapenko V.A,
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Joinery and carpentry work is carried out in the construction of all types of buildings and structures: residential and public, industrial and auxiliary, agricultural, etc. Suffice it to say that during the construction of a brick five-story residential building, the cost of joinery and carpentry works is up to 25% of the estimated cost of the object.
I. Introduction.
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Wood is a natural polymer with a set of positive properties that allow it to be used so widely and in a variety of ways in a wide variety of areas. Wood has high physical and mechanical characteristics, is well and simply processed, has a small volume weight, high aesthetic qualities and natural decorative effect, low thermal conductivity, high strength with a small mass, well resists shock and vibration loads; with proper design, manufacture and operation is reliable and durable. Wood is relatively easily and simply connected with fasteners, firmly and reliably glued together; keeps beautiful for a long time appearance; is, as a rule, an environmentally friendly material; protective and decorative compositions are well applied to it.
1. Material and its properties
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Tree- perennial with a clearly defined trunk, side branches and apical shoot. In a growing tree, three main parts are distinguished: the root - the underground part, acts as a foundation and holds the tree in an upright position, sucks water from the soil with nutrients dissolved in it and delivers it to the trunk. the trunk, starting from the neck of the root and ending at the top, serves as a support for the crown, conducts the water and nutrients received from the root to the crown and, conversely, the nutrients produced by the crown during the period of sap flow to the roots; retains moisture and nutrients in winter; crown - the upper part of a tree, formed by a combination of branches and leaves. The main life processes of the plant take place in the crown, its form is hereditary, however, under different growing conditions and with the age of the tree, it can change.
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Door shield block Filler (slats, plywood strips, paper honeycombs). Veneer. Fiberboard. Frame.
The door block consists of a door frame and door leaf hung on a vertical bar of the box on the hinges. By purpose, the doors are divided into internal, including entrance doors with staircases in apartments and other premises, for sanitary facilities, outdoor (entrances to buildings), vestibules and special (soundproof, fireproof, smokeproof, etc.).
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The door block is made using a manual, electrified tool with the manufacture of blanks on woodworking machines. For the manufacture of the door block, the following tools will be required: For marking: 1) Tape measure - used for linear measurements, as well as rough marking of long lumber.
Rice. 3) roulette. 2) Thickness gauge - use for drawing risks parallel to one of the sides of the bar, details.
thickness gauge. 3) Square - designed to check the squareness of elements of building structures.
Rice. 5) square.
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Treatment:
For cutting lumber into blanks, machines for longitudinal and transverse cutting of wood are used. After cutting, the blanks are planed to a clean size. The desired profile is attached on a milling machine.
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4. Sampling grooves for spikes
Drilling and grooving machines are designed for grooving and drilling holes in parts
5. Sawing out spikes and sampling of eyes is done on a tenoning machine
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Press clamps are designed to assemble door elements with the ability to adjust the pressure force
Assembly is carried out in hydraulic clamps
For the manufacture of door blocks, you will need a set of wood cutters
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Technological sequence of manufacturing a panel door block
The process of manufacturing a solid-filled door shield is as follows: after assembling the frame, plywood or a hard fibreboard, previously smeared with glue, is applied to it and attached to the frame with small carnations 20-25 mm long. After fixing the cladding, the frame is turned over and the entire internal space is filled with slats with a thickness corresponding to the thickness of the frame. When laying the rails, make sure that they are tightly pressed against each other (without gluing), their surface should be even, and the joints of the rails should be spaced apart. After filling the frame with slats, it is covered on top with a second sheet. facing material(previously smeared with glue) and attach it with small carnations from four corners. In the manufacture of a shield with a sparse filling with a frame, the latter is filled not entirely, but at intervals.
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Scheme of the manufacturing process for the door block DG21-9
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Workplace and caring for him
The carpenter's workplace must be properly organized, which ensures normal working conditions and high labor productivity. A cabinet is placed near the workbench, which is placed on the floor or mounted on the wall. Tools are stored in a cabinet on the shelves. Auxiliary materials and drawings. Tools are arranged in a certain order, stacking after work strictly in their place. Saws are recommended to hang on the walls, each separately. The cutting tool must always be sharp and dry. The workplace should have the tool needed at the time. The workplace should be well lit. Fire prevention measures must be strictly observed. After work, shavings and sawdust are removed from the workplace and taken out of the workshop. Turn off all heating devices.
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The carpenter's workplace is equipped with a workbench with a set of tools. The workbench must match the height of the worker.
Rice. Crafting table general form. 1-understand. 2-caliper with screws. 3-workbench cover. 4 holes. 5 mushroom. 6-tray. 7 holes for wooden fingers. 7-stop articulated. 9-terminal box. 10-screw
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Industrial safety.
Modern woodworking equipment is equipped with high-speed cutting tools, feed mechanisms and other devices. When working on woodworking machines, you need to know and strictly follow the following general safety rules: - you can only work on a fully functional machine. the cutting tool of the moving part must be securely fixed and protected. Before the start of each shift, you need to check the serviceability of the devices. - Do not operate the machine with defective safety devices removed. - it is forbidden to brake cutting tools and other moving parts with random objects. - levers, pedals and handles to stop the machines must operate smoothly and must be at the shortest distance from the workplace. - when working on the machine, you need to be careful not to talk to strangers. - it is impossible to remove waste, clean and lubricate the machine during its operation (to do this, it must be stopped and disconnected from the electric network). - at each workplace there should be a box or cabinet for storing tools, testing devices and fixtures. - do not put keys, rulers and other tools on the machine. - there should not be anything superfluous in the workplace; the passages near the machines should be free, the floor should be even. - at the end of his work (shift), the machine must be cleaned and lubricated, the identification of deficiencies should be reported to the shift foreman to the shift machine operator.
Production of door blocks
The door leafs of the panel and frame structure are manufactured mainly at specialized woodworking enterprises, but at the same time, at some construction sites, in order to quickly provide them with carpentry, door leafs are made on site using non-standard equipment.
Approximate scheme technological process for the manufacture of door blocks with frame doors (Fig. 87), it is envisaged that cutting lumber into blanks will be carried out on circular saws, and milling - on planer and four-sided longitudinal milling machines.
Nests in vertical bars are selected on a chain slotting machine. A stud cutter is used to cut the studs. The selection of profiles, the selection of darkness and other similar operations are performed on a milling machine.
Preliminary assembly of products with fitting of parts is carried out at the workplace, and the final assembly - in the assembly machine. Along the perimeter of the door, they are processed on a format machine.
In the absence of the above machines, door parts are processed on combined machines with electrified or hand tools.
Consider the procedure for processing a vertical bar of a frame (paneled) door, which has a clean size of 44x94x2000 mm. The allowance for milling and jointing on both sides for softwood blanks should be 5.5 mm, and for trimming on both sides along the length of the parts - 40 mm. Thus, the dimensions of the bar in the workpiece are (44 + 6) and (94 + 6) and (2000 + 40) or 50 x 100 x 2040 mm. Based on these dimensions, they take a board 50 mm thick and mark the length and width of the bar, after which it is cut out with an electric saw or a bow saw.
After sawing out, the bar is treated on four sides with an electric planer or planer and jointer. When planing, it is necessary to ensure that the bar is rectangular in shape and does not have curvature and distortions. On a planed bar with a square, with a thickness gauge, nests for spikes are marked, for which the bar is placed with the edge up on the table and, using a square, is applied with a pencil on the edge of the line.
The bars are marked according to the scheme shown in Fig. 88. Stepping back from the end of the bar by 20 mm, draw line 1 with a pencil; having measured 32 mm, apply line 2; at a distance of 140 cm from the second line - line 3. After that, having measured the necessary distances, lines 4, 5, 6, 7 and 8 are applied. Then lines 12, 13 are applied at the ends of the bar at a distance of 12 mm from each rib.
The intersections of the transverse and longitudinal lines form nests 9 on the edge. The nests are selected with a chisel, making sure that the chisel does not go beyond the markup. This operation can be performed with an electric slotter, then cleaning the surfaces of the nests with a chisel. It is necessary to monitor the accuracy of nest sampling. If the nest is larger, the spike will not fit tightly; if the nest is smaller, the spike will not fit into it.
Then, a groove is selected in the bar with a groove, and a profile is selected with a planer (moulding). After the manufacture of all the bars and panels, the door is pre-assembled.
After pre-assembly and adjustment, the door is disassembled, the spikes and eyes are lubricated with glue, and then reassembled and crimped in the assembly machine. Additionally, pins are placed on the glue in the corners.
The bars of the box are also assembled with glue and fastened in the corners with dowels. The correct assembly of the boxes is checked from corner to corner with a ruler and square.
The assembled door leafs must have an allowance for processing with a jointer, an electric plane 2 ... 3 mm per side along the perimeter.
Door locks are recommended to be cut in at a height of 1000 mm from the bottom of the leaf manually or with a mechanized tool. Nests are marked using a square or a template by P. E. Kuskov (Fig. 89), made of wood and plywood. The top plank of the template is made from a milled board with a thickness of 10 ... 12 mm, and the side ones are made of plywood. Side planks are nailed to the top with nails.
P 
When marking the nest for the lock, template 2 is put on the edge of the Door so that its horizontal axis 1 is at a distance of 1000 mm from the bottom of the door, after which the nest and the position of the keyhole 3 are marked with a pencil. Then the nest is selected with a chisel and the keyhole is drilled. The socket for the lock can be selected on a horizontal drilling machine or with an electric drill and an electric slotter in several steps.
In the box, you need to choose a place for the striker plate with a chisel. It is outlined by applying the bar to the bar of the box and tracing the outline with a pencil.
Locks cut into vertical bars of frame doors, but above or below the middle horizontal bar. It is not allowed to embed locks against middle bars, as this violates the strength of the tenon joint.
Then the door leaf is adjusted to the frame, cleaning individual places if necessary.
The assembled box is placed on a special table or workbench, and the door is carefully fitted to the quarters of the box so that it lies flush with the edge of the box. After fitting, the door must have a gap of 2 mm between the trim and a quarter of the frame, which is necessary for the normal operation of the door.
In double-leaf doors, before fitting into the box, the folds are pre-selected along the alignment of the doors on a milling machine or hand tool, then the doors are folded in the alignment places (folds) and driven in in the usual way. The gap at the points of alignment should be 2 mm. After fitting, they put on glue, screws, flashings and hang the doors on the hinges. Nests for hinges are selected at the workplace using the Pavlikhin template.
Each canvas is hung on two or three loops, and the bouts of the upper and lower loops must be on the same vertical axis. The hinges are positioned as shown in Fig. 90.
Entrance doors to buildings are hung on hinges PN 1-150, PN2-150, PNE-130, PNZ-150 (GOST 5088-78), internal doors - on hinges PN4, having a size of 98 mm.
After fitting and hanging the door, the entire block is checked, sags are cleaned in the necessary places. The door should not spring when opening and closing; on the hinges, it should rotate freely. Warping, distortions of more than 2 mm in any direction, unfinished places and roughness are not allowed in the door block. Finished block embroidered with packing strips and sent for painting and glazing.
By production of a door cloth the method of hot pressing is applied. The distinguishing feature of this method is its high performance. Due to the high temperature, the adhesive quickly cures between the parts of the door leaf. One of distinctive features modern production is the use of honeycomb core - the most promising material for the manufacture of ultralight and durable structures. By placing a honeycomb core between the skins, the rigidity of the structure increases sharply by more than 100 times.
Honeycomb core is one of the most economical modern structural materials currently available. Significant strength with low weight, environmental friendliness, good heat and sound insulation, the ability to withstand shock loads, high processability of processing are the main factors that ensure high quality products.
Honeycombs, depending on the size of the cell, the density of the cardboard, differ in their physical and mechanical properties. For doors, honeycombs are mainly used with a cell of 45 mm, 35 mm and less, and a compressive strength in the stretched state of at least 0.5 kg/cm 2 (GOST 23233-78).
Innovative honeycomb technology is now used in wooden structures such as doors, furniture boards, interior elements, shipping pallets, as well as in aircraft and sports equipment.
Particular attention in the manufacture of door panels by hot pressing with the use of honeycomb core is given to such technological parameters as temperature, time, pressure. Strict adherence to them allows you to get quality products.
Door leaf interior door consists of the following parts:
- frame
- Bars for inserting fittings (hinges, handle, lock)
- sheathing
- honeycomb core
For the manufacture of the frame, chipboard (chipboard GOST 10632-89), MDF (medium density fiberboard GOST 27680-88), or a combination of them, depending on the wishes of the customer, are used. Frame parts are made glued in width and length. Wood is glued along the width to a smooth fugue according to GOST 9330-76, and along the length - to a toothed tenon according to GOST 19414-74.
At the locations of hinges, handles and other devices, longitudinal bars frame increased in width due to additional installation bars. In a chipboard frame - under the lock and under the hinges. When processing a part of the frame of the door leaf, the thickness tolerance is very important and should be reduced to a minimum. In the lower and upper bars of the frame, channels are made in the form of holes or grooves for the release of water vapor from the glue, in order to avoid deformation of the web from hot vapors and moisture.
The honeycomb filler is stretched according to the dimensions of the frame of the door panel, installed in the frame and fastened with brackets to the frame. The thickness of the filler is selected in accordance with the thickness of the frame so that during pressing there is no swelling or dips on the surface of the skins.
The main function of the honeycomb filler is to fill the void between the skins and stiffen the web, prevent deformation of the skins on both sides of the web, and thus obtain a uniformly flat surface.
For the manufacture of skins, TSN-40 is used, HDF laminated with a decorative film. Parts are prepared with an allowance for the size of the frame for subsequent formatting to the final size. Application of hot-curing resin or PVA glue, depending on the model being made, on the frame of the door leaf, with a fixed honeycomb core, carried out on special glue-applying equipment. The most used hot curing resin KF, as it is easy to use, requires more low pressure press, and is also a cheap material. A frame is laid on one skin, a second skin is laid on top and placed in a press. The press is adjusted to a pressure that creates a force on the surface of the pressed product that is slightly greater than the compressive strength of the honeycombs used.
Billets, after their aging and complete cooling, are processed to the desired dimensions on a format-cutting center.
Molded profile products.
The door frame beam, platband and additional element are also made of chipboard, MDF, or a combination of them, again, depending on the type of batch being made, the order being executed. On special equipment, workpieces are processed to the desired geometric shapes and sizes and veneered (wrapped) decorative films. The process of laminating molded products is, in fact, identical to the process of laminating door panels. The only difference is that in the first case, the parts have a complex geometric shape, and in the second they are absolutely flat. And, accordingly, different equipment is used for these purposes.
All operations of the technological process are performed on high-tech machines of imported and domestic production.
In the production of all types of products, several developments have been applied regarding individual operations and the materials used, which are the intellectual property of the enterprise.
Artistic glass processing
Before giving each individuality and originality, our designers develop original design for each model. In this case, the buyer can take a direct part in the creation of the pattern or ornament he needs. We have the ability to make any of your fantasies a reality.
For these purposes, two types of technology are used in the glass manufacturing area. artistic processing glass.
- Matting. This sandblasting blanks right size V special cells or glass treatment with matting paste. There are solid matting, and with a pattern. In the latter case, in order for the pattern to be highlighted on the total glass area, a stencil of the required shape is used.
- Fusing. This is the process of sintering pre-cut glass fragments of a pattern on a substrate. For these purposes, high-temperature furnaces are used. Pattern elements and substrates are cut from special glass in various colors.
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During construction work, overhaul apartments or houses, sometimes you have to deal with the choice, replacement, purchase and installation of door blocks. Installation of door blocks is within the power of even a non-professional builder or repairman. To begin with, before proceeding with the installation of these necessary building elements, consider their main features and varieties.
Classification of door blocks
As a matter of fact, door block- This is a structure consisting of a box and a canvas interconnected with fasteners. Blocks can be divided into the following categories depending on their parameters and characteristics:
- according to the location and size (length and width) of a standard door leaf (external - 200 * 90 mm, interior - 200 * 80 mm, for bathrooms - 200 * 70 mm);
- in the form of a box (four-sided - for external doors, three-sided - for interior doors and bathrooms);
- by the number of canvases (a block with one-two-leaf and one-and-a-half doors);
- according to the material from which they are made (wooden, metal, MDF, glass, combined, etc.).
Standard door unit
For the correct installation of the block, it must contain the following set of components (the minimum standard set):
- box;
- canvas;
- set of platbands;
- fasteners;
- set of loops;
- pen;
- mortise lock.
List of materials and tools required for the installation of door blocks
To install the blocks on your own, you will need the following materials and tools:
- mounting foam;
- chisel;
- drill or perforator;
- waterproofing materials (roofing material);
- resin for wood processing;
- jointer;
- hammer;
- building level and plumb;
- wooden wedges;
- wooden plugs for wall masonry;
- additional fasteners (anchor bolts, self-tapping screws, nails, steel ruffs, turboprops, etc.);
- construction adhesive such as "liquid nails";
- pencil or marker for marking;
- construction tape.
Installation of external door blocks
As an example, consider the installation algorithm for an outdoor unit made of wood and consisting of a box and a single-floor canvas. It should be noted that when choosing wooden blocks for their manufacture and installation, one should choose sufficiently dry wood (humidity from 8% to 14% according to GOST).
In the case of the manufacture of wooden door frames, blanks of the following dimensions are mainly used: thickness from 50 to 60 mm, width - 100 mm.
In general, the installation process of outdoor units includes the following steps:
- box assembly;
- fitting the fabric to the edges;
- hinge installation;
- box installation;
- threshold setting;
- installation of platbands;
- tie-in devices (lock, handles, etc.).
Assembling the door frame
The constituent parts (or quarters) of the structure usually have a spike connection between them. It should be glued and have a very tight fit. However, it is necessary to check the joints assembled box by using building level and building plumb.
Fitting the door leaf to the frame. To fit the canvas, its edges are attached to the edges of the box with a jointer, starting from the edge that will be hinged. With a properly made fit, the door leaf fits snugly to the edges of the frame without visible gaps and sinkings.
Hinge installation
The hinge of a cloth is carried out by means of loops in the size of 125-175 mm. Often such loops are also called card loops. The hinges are mounted to the door leaf with self-tapping screws on the hanging side, at a distance of 150-300 mm from the edges of the door leaf (upper and lower). Nests for loops are made using a chisel. Their depth should correspond to the thickness of the loop map, but not more than it, in order to avoid the loops breaking during the operation of the block. The bouts (protruding parts of the hinges) must be positioned during installation in such a way that the axis of the lower and upper installed hinges coincide. In this case, the canvas will not warp and spontaneously open. After attaching the loops to the canvas, they mark their locations on the box itself. Then the canvas is dismantled from the hinges and the hinges are separately installed on the box in the marked places. Door leafs are removed before the completion of plastering and other finishing works.
Door frame installation
It is preferable to mount the outer box before finishing work is completed and before the flooring is done. This will allow you to neatly complete the above work. Before installing the structure in the wall opening (provided that the walls are made of stone or brick), the edges of the quarters of the box in contact with the walls are treated with resin in order to prevent decay, these places are upholstered with roofing material or other waterproofing material.
The box prepared in this way is inserted into the doorway, the ends of which are aligned and prepared for the installation of the block. The ends of the box are mounted into the floor to a depth that is determined by the floor structure, and they are connected with nails to the mounting (spacer) board. This board should be located below the floor level, but also treated with resin and waterproofed. The box itself is mounted in the wall opening using wooden wedges driven between the box and the wall. Then you need to additionally fix the box in the wall opening. This can be done using steel ruffs (a type of nails) or anchor bolts that are driven into pre-prepared wooden sockets in the masonry itself (a punch should be used to insert these nests into the masonry). After that, the cracks and gaps between the wall and the box are filled with mounting foam.
Using construction foam special wooden spacers are installed in the box, on average, 12 hours are taken for the complete drying of the foam, then the excess foam is cut off.
Each vertical quarter of the box is mounted to the opening with steel ruffs or anchor bolts in at least two places. Fasteners should be at a distance of no more than 1.5 m from each other.
After installing the door block frame, final finishing plastering work is carried out.
Do-it-yourself threshold setting.
We attach the lower quarter of the box to the installed and prepared mounting board and to the vertical quarters. The threshold is ready. The door leaf can be hung on the mounted frame.
Installation of platbands
After the installation of the box is completed, platbands are installed along its perimeter (except for the bottom, of course) from the outside and inside, provided that this operation allows us to carry out the size (thickness) of the wall opening. Platbands are placed at a distance of 8-15 mm from the edge of the box and connected at 45 ° corners (by the mustache). The correctness of the installation of platbands is checked construction tools(level, plumb). At the floor they are mounted on the base. The platbands are attached to the box with self-tapping screws, nails or building glue. Visible gaps during the installation of platbands are unacceptable.
Installation of door devices (mortise lock, handles)
This The final stage block installation. Handles are placed at a height of 0.8-1.1 m from the floor level and placed in such a way that when the door is operated, the handle does not touch the box.
Mortise locks are usually located at a distance of 0.9-0.95 m from the floor level. Here it is necessary to ensure that the mutual arrangement of the lock and the door handle is ergonomic and convenient. Nest for mortise lock drilled with a drill (perforator), using a drill equal in diameter to the thickness of the socket. After that, they clean the nest with a chisel under the lock. A lock is installed in the prepared nest and fastened with screws or self-tapping screws.
Then they mark out and drill a place for the lock bar in the box itself. The selected place for the lock plate must correspond to the position of the mounted lock. It should be noted that the lock bar should be flush with the edge of the box, and the lock should be flush with the edge of the door itself.
The main requirement when installing various kinds of door devices is the implementation of work without gaps, chips and deformations of the wood.
Installation of interior door blocks
As in the case of an external door block, in general, the installation process of interior blocks made of wood and having a single-floor leaf consists of the following steps:
- box assembly;
- fitting the canvas to the edge of the box;
- hinge installation;
- box installation;
- installation of platbands;
- insertion of door devices (lock, handles, latches, etc.).
It should be noted that the installation of interior door units is usually carried out in the same way as the installation of outdoor units, but after installation floor covering and bypassing the stage of setting the threshold, because its device is expedient only when moving from interior to the outside. Accordingly, the box in this case will be three-sided.
When installing door blocks in bathrooms, all cavities and nests cut out for appliances should be varnished to prevent decay processes in conditions of high humidity. In this case, it is advisable to use fasteners that are resistant to corrosion.
Features of installation of some types of door blocks
The material of the block, at times, has a certain specificity, which makes appropriate adjustments to the standard installation algorithm. So, for example, MDF door blocks have the following installation features:
- The installation of such blocks should be carried out after the completion of finishing work, because. high humidity during these works adversely affects the condition of the MDF.
- Mounting the MDF door frame to the wall opening should be carried out using special fasteners (long nails, self-tapping screws, turbo screws) and construction foam.
- MDF blocks are mainly used as interior ones. However, it is not recommended to use them in rooms with high humidity due to the characteristics of this type of material.
- These blocks are usually delivered already in full ready-made, and the process of their assembly and installation, of course, excludes the fitting of the canvas to the box.
- As a disguise for fasteners, the delivery set of the door block usually also includes decorative elements(panels, end caps, etc.).
The easiest to install are metal blocks, of course, subject to their high-quality manufacturing and assembly. The installation algorithm has the following features:
- there is no fitting of the canvas to the box and preparatory manipulations such as treatment with rot preparations;
- for quiet operation metal doors it is necessary to install rubber seals around the perimeter of the door;
- installation of such doors can be carried out before finishing work;
- the metal box should be fixed to the wall opening with anchor bolts and use mounting foam.
It should be noted that metal doors and door blocks are mainly used as outdoor ones.
It is also worth emphasizing the quality of the purchased door blocks, namely: the best option for external door blocks, for example, in an apartment or house, is to install two door blocks - the first metal and the second - solid wood. As interior blocks, it is optimal to use it completely wooden structures. They are amenable to adjustment and correction. And by itself natural wood provides the widest scope when, with a certain financial opportunity, you can use different breeds wood, including valuable, use carvings, stained glass, etc.
Doors made of MDF are significantly inferior to wooden ones in terms of moisture and wear resistance, but this option doors is quite simple, inexpensive and provides wide opportunities according to the choice of options for the finished door leaf, for example, with decorative inserts, stained glass windows, etc. Naturally, the final choice in the question of which door unit to purchase and install depends on the requirements for it, financial capabilities and preferences of the customer.
