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Ministry of Education and Science

Russian Federation

State educational institution

secondary vocational education

"Mariinsky forestry technical school"

250403 Woodworking technology

Discipline SD.01:

Technology and organization of woodworking production

course project

explanatory note

DEVELOPMENT OF A TECHNOLOGICAL PROCESS FOR MANUFACTURING PARTS OF THE DG21-7 DOOR BLOCK

Performer: student gr. TD-41

Pipkin Alexander Leonidovich

Leader: L.V. Pukholenko

Initial data

Table 1. Specification of raw materials

Content

• Initial data
• Introduction
• 1. General part
• 2.1 Project justification
• 2.5 Waste balance
• 2.13 Calculation of workshop area
• 3. Energy part
• 4. Labor protection
• Conclusion
• Literature

Introduction

There are three types of deaf people interior doors: smooth doors, with a molded outer panel, as well as paneled doors. From the outside, blind doors can be finished with panels made from sliced ​​roots of oak, walnut, elm and other tree species. For external finishing of deaf doors, carved wood panels, combinations of veneer of various types of wood with various patterns and different grain directions are also used.

themselves door leafs can be made from solid wood, usually conifers, with honeycomb filling. This design gives the leaf a certain resistance and prevents deformation during the service life of the door. Honeycomb-filled sheets are lighter than solid or chipboard-filled sheets. This reduces the load on the door hinges. For other doors, heavier hinges should be used.

As always, doors made entirely of wood are in the greatest demand. However, the use of other materials allows not only to reduce the cost door structures, but also offset some of the shortcomings natural material- tree. For example, MDF has a higher hydrophobicity compared to wood. Recently, this material is often used in the manufacture of doors, also because of its increased density.

Improved performance, quite long term services, great potential for creating special designs and a variety of color solutions give these doors the right to occupy their own niche among interior doors.

In doing so, it should be borne in mind that interesting design, the elegance and subtlety of the exterior finish cannot compensate for the strength, durability and other high performance of interior doors.

For the manufacture of quality door environmentally friendly natural materials- solid wood or natural veneer. A good door should have smooth surface, perfectly smooth, perfectly polished, warm and pleasant to the touch.

Modern doors must be equipped exclusively with L-platbands and L-frames, which can be adjusted during installation to the thickness of the wall without the need for adjustment, and attached without the help of nails and a hammer. The reason why the manufacturer does not have such components lies again in the field of cost savings. The box must have a seal. If the door meets the above requirements, it means that this door made by a serious manufacturer, subject to all technological processes. It is safe to say that such a door will serve you for a long time.

1. General part

1.1 Characteristics of products. Technical requirements, GOST for products

Door block DG21-7 with a blind leaf. Type G doors are made with one- and two-leaf panels, with small-hollow (rack) filling of the panels, with and without a threshold, with and without overlap, with and without lining, with and without boxes.

Doors manufactured in accordance with this standard are referred to as doors of normal moisture resistance.

Doors must be manufactured in accordance with the requirements of GOST 475 and this standard according to working drawings approved in the prescribed manner.

Doors are lined with materials in accordance with GOST 475 in the part related to doors of normal moisture resistance.

A box without a threshold is embroidered at the bottom with a mounting board fastened with nails or spiked joints to the ends of the vertical bars.

Frameless doors of type G must be equipped with sealing gaskets in accordance with GOST 10174 or others that provide the necessary tightness of the porches.

Figure 1 Door unit DG21-7

2. Settlement and technological part

2.1 Project justification

Wooden door blocks are used in the construction industry as they are a necessary part of buildings. This type of product will always be in demand by the population and enterprises, so the production of door blocks is economically profitable.

In this course project, modern equipment was selected: TsME - 3B for transverse sawing of lumber, TsDK 4 machine for longitudinal sawing, four-sided PROFIMAT-185, planer PF-430, thicknesser SR8-20M, trimming machine Bi6-800. On these machines, operations are performed to obtain finishing blanks. To obtain parts, it is proposed to perform the operations of the technological process on a 6T-4S tenoning machine, the WT3200 panel saw is designed for piece and batch cutting board materials.

The selected equipment has a number of advantages: high performance, easy to operate, compactness and versatility, low weight of the machines will make it easy to move equipment, also providing high quality material processing, but more demanding on the level of training of maintenance personnel. The selection of technological equipment is carried out according to the technological process.

The installation of modern equipment will make it possible to manufacture high quality products with high labor productivity and optimal consumption of raw materials.

door panel wood natural

2.2 Product parts list

Table 1. Specification of parts of the door block DG 21-7

Name of parts and assembly units		Material	Dimensions, mm
door frame
Bar vertical		Saw - terial
Bar horizontal		Saw-terial
Door leaf		Saw-terial
Aggregate bars		Saw-terial
Facing

2.3 Calculation of raw materials and materials

In the course project, I calculate the required amount of raw materials and materials for the production of the DG 21-7 door block. When calculating the amount of lumber, I am guided by the guidelines for completing coursework and theses. I set the consumption rates for sawn timber per unit of production in the following units of measurement: wood - cubic meters.

I enter all the calculations made in table 2. I take the dimensions cleanly from the specification of parts.

I find the volume of a complete set of parts in purity by multiplying the dimensions and quantity of each part. I take the dimensions in the blank with allowances, which I took in the guidelines for calculating term papers and theses. Standard thicknesses were also determined in the guidelines. The volume of a set of blanks was determined in the same way as the volume of a set of clean parts. The coefficients taking into account technological waste and the coefficients of useful output during cutting were taken into study guide Hasdan M.M., Ratner M.L. "Sawmill and woodworking production".

Table 2. Calculation of raw materials and materials

Name

Part material

Clear dimensions, mm

The volume of the complete set of parts in cleanliness m 3

Dimensions in the workpiece, mm

Standard thickness, mm

Kit volume blanks

Factor taking into account technological waste

The volume of blanks of technological waste m 2

Cutting efficiency

Lumber consumption m 2

door frame Bar vertical Bar horizontal

Door leaf placeholder Facing

2.4 Summary specification of raw materials, materials for the program

Table 3

2.5 Waste balance

In some cases, lumpy waste can be transferred for processing as technological raw materials to other enterprises. However, it is unprofitable to export lumpy waste (especially large ones) outside the enterprise, even for short distances, due to the great difficulty of storage and handling operations.

Pure spruce sawdust and woodworking shavings are considered the best raw materials for the manufacture of wood flour, used as a filler in the production of phenolic plastics, linoleum, explosives and piezothermoplastics. Wood-based boards are made from sifted sawdust by extrusion pressing. In this case, up to 50% of sawdust is used along with chips.

Waste must be stored sorted by type and type, and it is absolutely necessary to store loose waste separately from lumpy waste. Loose wood in open warehouses is placed in riots of conical or prismatic shape up to 5 m high on a concrete, asphalt or wooden base

Table 4 Balance of processed wood and calculation of the amount of waste

Name forest-materials

Annual consumption for the program, m 3, m 2

Cutting waste

Wastes during the processing of blanks, taking into account technological waste

Total waste, m 3, m 2

In the blank

Clean

Sawdust and dust

Sawdust and dust

Including losses

coniferous

2.6 Rationale for equipment selection

In the course project, it is proposed to install new generation machines to increase the productivity of the workshop. Modern machines are easy to operate, compact and versatile, the low weight of the machines will make it easy to rearrange the machines, they also provide high quality material processing.

For cross cutting, a CME-3B trimming machine is used, the material is clamped automatically by the upper stop before lifting the saw; clamping design reduces the formation of chips on the surface of the workpiece.

The advantages of this machine: high productivity, increased safety conditions, modern design.

Table 5 Technical characteristics of the TsME-3B machine

For longitudinal cutting, the TsDK-4-2 machine is used, this is a machine tool with a cast table and a large cutting height. The unique design of the machine provides greater rigidity and vibration resistance of the machine. It has a large main table, which is convenient when processing these parts.

Table 6. Technical characteristics of the TsDK-4 machine

The universal machine PF-430 is designed to create a basic surface. It has a large length of tables and the possibility of automatic lifting - lowering of the machine tables, their reliable fixation allows you to remove the desired layer of material qualitatively and evenly throughout the entire length of the workpiece.

Table 7 Specifications of PF-430

Name	Indicators
Processing width, mm
Naib. thicknesses with him. layer, mm
Total length of tables, mm
Knife size, mm
Lifting height of the front table, mm
Rear table lifting height, mm
Blade shaft diameter, mm
Rotation frequency, about, / world
Installed power, kW
Dimensions, m
Weight, kg

Thickness thicknesser is designed for planar one-sided planing of wood products to a given size in thickness. Processing is carried out by a knife shaft along the upper face of the workpiece. The machine has a simple and robust design chain driven feeder.

Table 8. Technical characteristics of the machine SR8-20M

Name	Indicators
Naib. thicknesses with him. layer, mm
Workpiece thickness, mm
Number of knives, pcs
Feed speed, m/min
Blade shaft diameter, mm
Number of knives of the knife shaft, mm
Rotation frequency, about, / world
Installed power, kW
Dimensions, m
Weight, kg
Processing width, mm

This machine is designed for cutting workpieces.

Table 9 Bi6-800 Machine Specifications

The tenon cutting machine is designed for milling tenons and eyelets of parts frame structures from wood with preliminary trimming.

This machine has high precision and cleanliness.

Easy to set up and maintain the machine, unlimited workpiece length.

Table 10 Specification of GT-4S Machine

The four-sided planer is designed to produce high quality products with precise geometric dimensions.

Table 11. Technical characteristics of the machine PROFIMAT-18S

Name	Indicators
Workpiece width, mm
Workpiece thickness, mm
Minimum workpiece length, mm
Tool dimensions, mm
Number of working spindles, pcs.
Spindle speed, rev. /min
Feed speed m/min.
Number of electric motors, pcs.
Installed power, kW

The machine format - cutting WT-3200 is designed for piece and batch cutting of plate materials.

The machine of the middle class is used in the processing of full-size fiberboard sheets in furniture production.

Table 12. Specifications of WT-3200

Name	Indicators
Dimensions, m
Weight, kg.
Scoring saw motor power
Main saw motor power
Maximum cutting length
Main saw diameter
Scoring saw diameter
Main table size
Moving carriage size

2.7 Compilation and calculation of technological maps

When compiling and calculating technological maps, I use a table that includes: names of operations, dimensions after processing (length, width, thickness of the workpiece), name of equipment, fixtures, tools, control method. In it, I calculate the rate of production, the duration of processing per part and per product.

In this course project, four technological maps were compiled and calculated.

Table 13 Routing 1

Namedetails: Bar vertical boxes

Numberonproduct: 2

Breedwood: coniferous

DimensionsdetailsVworkpiece,mm: D 2091 W 80 T 51

DimensionsdetailsVcleanlinessmm: 2071 74 45

VolumeVworkpiece,m 3 0,00689

VolumeVcleanlinessm 3 0,00853

the name of the operation

Dimensions after processing, mm

Name

Control method

Production rate

Duration, min

equipment

tool

adaptations

Per detail

per item

Cut across the grain

disk

Knives, cutter

Calipers

Trimming to length

Saw round

ruler, tape measure

Cutting spikes and eyelets

Calipers

Table 14. Technological map 2

Namedetails: Bar horizontal boxes

Numberonproduct: 2

Breedwood: coniferous

DimensionsdetailsVworkpiece,mm: D 690 W 80T 51

DimensionsdetailsVcleanlinessmm: 670 74 45

VolumeVworkpiece,m 3 0,00223

VolumeVcleanlinessm 3 0,00281

the name of the operation

Dimensions after processing, mm

Name

Control method

Production rate

Duration, min

equipment

tool

Adaptations

Per detail

per item

Cut across the grain

disk

Processing from 4 sides with a quarter cut

Knives, cutter

Trimming to length

Saw round

Calipers

Cutting spikes and eyelets

ruler, tape measure

Table 15. Technological map 3

Namedetails: Bars fillers

Numberonproduct: 12

Breedwood: coniferous

DimensionsdetailsVworkpiece,mm: D 2020 W 56T 38

DimensionsdetailsVcleanlinessmm: 2000 50 32

VolumeVworkpiece,m 3 0,0032

VolumeVcleanlinessm 3 0,00429

the name of the operation

Dimensions after processing, mm

Name

Control method

Production rate

Duration, min

equipment

tool

adaptations

Per detail

per item

Cut across the grain

disk

Creation base surface

Pusher

Visually

Machining to cross-sectional dimension

Calipers

Trimming to length

Saw round

ruler, tape measure

Table 16. Technological map 4

Namedetails: Facing

Numberonproduct: 2

Breedwood: fiberboard

DimensionsdetailsVworkpiece,mm: D 2000 W 600T 4

DimensionsdetailsVcleanlinessmm: 2000 600 4

VolumeVworkpiece,m 3 0,0048

VolumeVcleanlinessm 3 0,0048

Shift productivity P cm, pcs SR8-20M is determined by the formula p.310

Psm \u003d Tsm * U * n * Kr * Km / L s * m, (4)

T cm-shift duration 480 min.;

U - feed rate m / mi;

n is the number of processed sides;

Kis - utilization factor 0.5;

L z - workpiece length, m.

Psm-480*0.95*0.8*6.8*2/2.020*2=1228 pcs,

Shift capacity P cm, pcs. trimming machine Bi 6-800

calculated according to the formula p.296

P cm \u003d T cm * U * n * K d * K m / L xk * m, (5)

where Psm - replaceable productivity of the machine;

U - feed rate m / min;

K p-coefficient of working time 0.9-0.8;

Km-coefficient of machine time 0.7-0.8;

L xk - stroke length of the carriage L xk =1.5 bookmarks;

P cm \u003d 480 * 10 * 0.2 * 0.85 * 1 / 0.050 * 1.5 * 2 \u003d 5440 pcs.

Replaceable performance of the four-sided machine PROFIMAN-18S P, see pcs. calculated according to the formula p.310

P cm \u003d T cm * U * n * K r * K m / L s * m, (5)

where Psm - replaceable productivity of the machine;

T cm - shift duration 480 min;

U - feed rate m / min; K p-coefficient of working time 0.9-0.8; Km-coefficient of machine time 0.7-0.8;

n is the number of workpieces stacked simultaneously on the machine table;

m - the number of sides to be trimmed 2pcs.

P cm \u003d 480 * 12 * 0.9 * 0.8 * 1 / 2.091 * 1 \u003d 1983 pcs.

Replaceable performance of the one-sided tenoning machine GT-4S P, see pcs. calculated according to the formula p.310

P cm \u003d T cm * U * Kis / S * Z, (6)

where Psm - replaceable productivity of the machine;

T cm - shift duration 480 min;

U - feed rate m / min; S - the second stroke of the carriage;

Z-number of machined ends of the part;

Kis - coefficient of use of machine time 0.7-0.8.

Psm = 480 * 0.72 * 6 / 1.2 * 2 = 1165 pcs.

The shift productivity of the WT-3200 panel saw is calculated using the formula p.22

P cm \u003d T cm K l n m / T c, (7)

where Psm - replaceable productivity of the machine;

Tcm - shift duration, min;

Kl - machine utilization factor (0.8 - 0.9);

n - the number of sheets in the bookmark (for fiberboard 4 mm thick - 12 pcs);

m is the number of blanks obtained from one sheet;

TC - the duration of the cutting cycle of one bookmark.

m \u003d S l / S s K p. in, (8)

where Sl is the area of ​​the original format;

Sz - workpiece area;

Kp. c - coefficient of useful output.

m = 6|1.2*1.087=4.6 pcs

Psm = 480 * 0.8*10*4|2 = 7680 pcs

2.9 Scheme of the technological process. Calculation of the required amount of equipment

The calculation of the amount of equipment is calculated in Table 17.

Table 17. Process flow diagram

Table 17 continued

The annual fund of working hours of workplace equipment is calculated according to the formula p.444

T f = Dr*i t K vol., (8)

where Tf is the annual fund of equipment operation;

Dr - number of days in a year;

To about - coefficient of equipment downtime in operation due to technical reasons 0.93 - 0.95;

t is the duration of the shift, hours;

i - number of shifts.

Tf \u003d 250 * 1 * 8 * 0.9 \u003d 1800 hours.

The time required T pr, hours for the processing of all blanks to complete the annual task is determined

T pr \u003d Qr * p / Psm., (9)

where Tpr - time for the program in, hours;

Qr - annual program, pcs.:

P h - the duration of the machine, pcs. /h

n is the number of blanks, pcs.

Tpr \u003d 9000 * 8 * 2 / 1339 \u003d 107

The number of required machines is determined

N=Tpr/Tf (10)

where N is the number of required machines, pcs.

N=859/1800=0.47

Load percentage is determined

fz=Ncalc. /Nprin. *100%, (11)

fz=0.47/1*100=47

2.10 List of technological equipment

Table 18

Machine name		Quantity	Options
			Power 3 kW; Dimensions 5.1*1.8*1.9m Weight 780 kg.
			Power 13 kW; Feed speed 8-40 m/min; Weight 900 kg. Dimensions 1.9*1.4*1.4 m
Machine 4-sided			Engine power 20 kW; Feed rate 6; 12 m/min. Dimensions 3*1.2*1.5 m
Planer			Power 3 kW; The frequency of rotation of the knife. shaft 6000 rpm /min Weight 800 kg.
Thicknessing machine			Power 7.87 kW; Feed rate 8; 4 m/min; Weight 150 kg.
Miter			Power 3 kW Cutter speed 2840 rpm /min Dimensions 1.5*1.3*1.6 m
tenon-cutting			Engine power 10.2 kW; Feed rate manual; Dimensions 1.7*1.5*1.3 m
The machine is format - cutting			Dimensions 3.3*3.2*0.9 m Scoring saw motor power 0.75 kW Main motor power Saws 4kW

2.11 Process description

Lumber is delivered to the woodworking shop by road, trucks and stacked manually in piles. Also, in the summer, lumber can be laid on a specially designated area for atmospheric drying, which is not equipped with special equipment.

After drying the lumber to the final moisture content, it is sent for further processing. The technological process consists of two streams: processing of bar parts and cutting fiberboard into blanks.

The processing of bar parts begins with the transverse sawing of boards to a certain length on a CME-3B machine.

The material is fed onto the table, pressed against the thrust planes (table, bar or guide ruler) and sawn to a predetermined length with a saw. The machine is operated by two workers.

Next, the boards are fed to a circular saw for longitudinal sawing TsDK-4, which is served by two workers. One worker turns on the machine, the other, being behind the machine, takes the sawn blanks. Boards with defective edges on machines with a closed floor are first sawed off the edge, focusing on the risk applied on the casing of the clamping device against the saw. For repeated cuts, the boards are fed onto the saw, pressing them with their edge to the guide ruler.

The resulting box blanks are transported using a trolley to a four-sided planer PROFIMAT-18S, where processing is performed from 4 sides according to a given profile with a quarter selection. Processing is carried out by knife shafts located in the direction of the workpiece being processed. Workpieces are fed into the machine piece by piece without inter-face gaps.

Then the workpieces are brought to the Gt - 4S machine, where the workpieces are trimmed to a predetermined length, and then the spikes and eyelets are cut at the ends of the workpiece using a milling cutter.

The resulting workpieces, fillers of the door leaf and workpieces with unevenness, are manually fed to the PF-430 planer to create a base surface. The workpiece is placed with a concave surface down on the machine table. pressed with both hands to the guide ruler, served on the knives. Further, when the workpiece is moved, the processed part of the workpiece is pressed against the plane of the rear table, the processing is carried out by a knife shaft. The machine is serviced by two workers or one.

The planed blanks on the trolley are moved to the thickness gauge. machine SR8-20 M. The machine is serviced by two workers. The workpiece is placed with the reverse surface on the work table and moves towards the rollers. When the rollers capture the front part of the workpiece, the machine operator puts the next workpiece on the table, resting it with its end against the end of the previous one. During operation, it is necessary to periodically check the thickness of the part.

Processed workpieces are transported by trolley to trimming machine Bi 6-800, where the workpiece is trimmed to a predetermined length.

The second stream carries out processing of slab blanks.

The first operation of the technological process is the cutting of board materials into blanks on the WT-3200 machine, cutting is carried out with a circular saw.

2.12 Determination of the required number of workers

Table 19

Name of equipment	Quantity
		Main	Auxiliary

In total, 13 people work in the workshop in 1 shift.

2.13 Calculation of workshop area

Table 20. Calculation of the workshop area

	Name of equipment and workplaces	Machine model	Number of pieces of equipment and jobs	Norm of production area per unit of equipment, m 2	Required area, m 2
	Cross cutting machine
	Longitudinal cutting machine
	Machine 4-sided
	Planer
	Thicknessing machine
	Miter
	tenon-cutting
	The machine is format - cutting

Total area m2=182.7

The production area by direct calculation is determined by:

F pr \u003d F 1 / 0.6, (10)

where F1 - area of ​​workplaces, m2

F1=182/0.6=304.5 m2

The area of ​​household and auxiliary premises calculated:

F y \u003d 0.2 F pr, (11)

Fu=0.2 304.5=60.9 m2

The required workshop area is calculated:

F total \u003d F pr F y, (12)

Ftot=304.5+60.9=365.4 m2

The length of the building is determined by:

L= F o B , (13)

L=365.4/12=30.45 m

3. Energy part

3.1 Calculation of power consumption

Table 23

Name equipment	Type, model		Total mouth power,	General conn. power, kWt	Coeff. use electric motor	Required powerful,	Network losses, %	Power on high voltage lines.	Number of working hours per year	Annual consumption electric power, kW
Miter
cut-off
Machine 4-sided
Planer
Thicknessing machine
Tenoning machine
Trimming machine
The machine is format - cutting

3.2 Calculation of electricity consumption for lighting

Table 24

4. Labor protection

4.1 Safety when working on the equipment

The equipment should not be placed above work areas, driveways, uninsulated power lines, in areas of high temperature, gas contamination and dustiness. Mobile equipment is installed in places where it does not create danger and unfavorable conditions for workers, fire safety, and evacuation of people.

The placement of production equipment in the organization of technological processes of woodworking should ensure safety and convenience for its maintenance, repair and the possibility of evacuating workers.

Format - cutting machine. When working on this machine, the saw must be well prepared, correctly installed, secured and protected by an automatically operating device; you must not stand near the saw against the direction of rotation of the saw blade.

If the workpieces are leveled on the carriage, it is pulled away from the saw and secured with a pawl or hook so that it does not come close to the saw again. The material supply carriage is provided with shields that secure the front part of the saw, which goes beyond the stop.

Exceed the dimensions specified in the technical specification. When feeding a stack of veneer, do not move your hands close to the feed rollers.

Circular saws for cross cutting

When working on these machines, the saw must be well prepared, correctly installed, secured and protected by an automatically operating device; one should not stand near the saw against the direction of rotation of the saw blade. Workpieces can only be fed when the saw is in its original position; before feeding the workpieces to the saw, their ends can be aligned at a distance of at least 0.5 m from the front teeth of the saw.

Circular saws for longitudinal cutting

When manually fed, the part of the saw located above the table must be protected by a reliable consul, which automatically descends on the material being cut of any thickness and covers all the teeth: the lower part of the saw is protected by two brushes placed at a distance of no more than 100 mm. one from the other and protruding beyond the line of the tops of the teeth by at least 100 mm.

Planer

On machines with manual feed, the feed shaft is closed with an automatically operating fan, which, during the milling process, opens only that part of the knife shaft along which the workpiece comes.

Planer

When working on this machine, safety stops must be installed in all machines, regardless of the presence of sectional feed rollers. Corrugated rollers should not have cracks, knocked out ribs, worn surfaces.

4.2 Shop fire safety

By degree fire safety the workshop belongs to category B. When operating electrical networks, it is necessary to monitor the condition of the wires in order to prevent sparking, heating or short circuits. Lubricate the bearings of electric motors regularly, and clean the electric motors themselves from dust, chips and sawdust. Conveyors, machine tools, fans, cabins, pipelines must be reliably grounded.

Fire-fighting equipment (shovels, buckets, fire extinguishers, boxes of sand, barrels of water) in all workshops and warehouses are stored in specially designated places for them, overalls are hung in cabinets in special rooms. It is not allowed to leave oiled cleaning material and matches in the pockets of overalls. Special places are allocated for smoking (outside the finishing shops), where there should be urns and barrels of water.

The shop of the enterprise is provided with water for fire-fighting purposes. Fire-fighting plumbing must be designed for high or low pressure. In high-pressure water pipelines, the pressure of water necessary to extinguish a fire is created directly from the hydrant using specially installed stationary pumps. Stationary fire pumps are equipped with devices that ensure that the pumps are started no later than 5 minutes after a fire signal is given.

To eliminate a fire, timely notification of its occurrence is of great importance, therefore, fire alarm systems are installed at enterprises.

Conclusion

In the course project, the amount of raw materials and materials, taking into account technological waste, is calculated, which is necessary for the manufacture of a door block of the DG21-7 brand. Also, modern equipment with high quality indicators was selected and its required quantity was calculated. A technological process has been developed for the area for manufacturing door block parts.

Literature

1. Magazine “Furniture Factory” No. 3, 2004

2. Komarovsky V.S. “Workshop on furniture production technology”. M.: Timber industry, 1989, p.119

3. Mamontov A.S., Strezhnev Yu.F. “Design of technological processes for the manufacture of woodworking products”. 2006, p.584

4. Guidelines for the implementation of course and graduation projects

5. Hasdan M.M., Ratner M.L. “Sawmill and woodworking production”. M.: Timber industry, 1981, p.184

6. Shumega S.S. “Technology of carpentry and furniture production”. M.: Timber industry, 1988, p.285

7. 7. Shcherbakov A.S., Nikitin L.I., Bobkov N.G. “Labor protection in the forestry and woodworking industry”. M.: Timber industry, 1990, p.429

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1.

1.1 Introduction

1.2 Design and purpose

1.3 The grafical part

1.4 Routing

1.5 Properties and characteristics of the materials used

1.6 Applied equipment, mechanical and hand tools

1.7 Labor protection, safety measures when working on machines

1.8 Used Books

1. The technological process of manufacturing a door block

1.1 Introduction

Interior doors are part of the interior, so their choice must be approached very responsibly. In this article, we will talk about the variety of interior doors, their characteristics, production technology, price difference and much more, which will help potential buyers make their choice.

Wooden doors are often installed in houses and apartments. If you also opted for them, then you need to approach the purchase very seriously. A wooden door is the very item that will either serve for many years and delight with its beauty and quality, or quickly warp, crack and become completely unusable for its intended purpose. Therefore, even when buying expensive interior wooden doors created by designers, you need to pay attention not only to their appearance, but also to whether the technology was followed during their manufacture.

The production of interior wooden doors is a very complex technological process that must meet certain requirements. Only with exact observance of the technology, high-quality and reliable interior wooden doors, entrance wooden doors can be obtained, which will serve for a long time and will not lose their performance. Properly treated wood is a durable, frost-resistant, soundproof material. From it not only do wooden doors, but also build houses. A wooden house turns out to be so warm, reliable and beautiful that, despite the appearance of a huge number of more modern and less expensive building materials, wood has not lost its relevance, they continue to build from it.

The production of interior wooden doors requires very precise compliance with all technological stages. The solid wood is first dried. If the drying of the wood was carried out poorly, then the wooden doors from this array will be short-lived, they will quickly change shape and become unusable. But made of high-quality dried wood, on good equipment in compliance with all the subtleties of the technological process, wooden doors, pine, whether inexpensive or valuable wood served as a material for them, will be very durable and functional.

After drying, the wood is glued. The composition of the adhesive depends on the type of door to be made - wooden exterior doors, paneled wooden doors or Finnish wooden doors. Different types of doors use different adhesives and require different temperature conditions during gluing.

And, finally, wooden doors are polished, impregnated with various protective compounds, primed and painted. After the wooden doors are sanded, they are stained, sanded again, covered with a waterproof primer, and then painted and varnished.

Often, interior wooden doors are not painted, but simply covered with a transparent varnish so that the structure of the wood can be seen. But the entrance wooden doors should be more resistant to various influences from the outside, so they are usually coated with special paints for outdoor work. A wooden door that will be constantly exposed to the outdoors is usually not only finished with clear varnish, but requires a more durable and resistant coating. If it is sometimes varnished, then only high-strength and at least four times.

Wooden exterior doors, paneled wooden doors, Finnish wooden doors and any other wooden doors are varnished only with polyurethane varnish, because it can stretch with the surface of the wood. If wooden doors even slightly crack during operation, then the polyurethane varnish will stretch along with microcracks and make them completely invisible to the eyes.

Of course, everyone wants to buy wooden doors that will last a long time and will not lose their shape and appearance during operation. Wooden doors are not so easy to make, so good doors are rarely obtained in artisanal conditions. It is best to buy doors from well-known manufacturers who have their own large-scale production and have been working on the market for several years. When purchasing doors made by someone unknown, you can be very disappointed when they warp and stop opening.

The cost of wooden doors depends on their quality, on how precisely the technological process was observed during their production. If you decide to install wooden doors in your wooden house, then make sure that you purchase doors made by a reliable manufacturer.

1.2 Design and purpose

The door block consists of:

1. Two vertical strapping bars

2. Two cross bars

3. From the lower and upper transverse bars

4. Inner four vertical straps

5. Inner two cross bars

6. Of the six lower and upper panels

7. From one middle panel.

Specifications:

1. The door block is made of pine wood, should not

be on the details of falling knots, rot, cracks.

2. Make panels from pine wood

3. Assemble the door leaf with PVA glue.

4. Door leaf and door frame should not have

skew more than 1 mm.

5. Connections must be tightly fitted, not

have gaps.

6. The door leaf must be straight

plane, skew no more than 2 mm.

7. Hang the door leaf in the box on the card

8. The door leaf should work without

wiping.

9. The gap in width should be 1.5-2 mm, in height from the bottom 3-5 mm

10. Finish with 3 layers of oil varnish.

1.3 Graphic part

1.4 Product specification

Total: 0.0655

1.4 Worksheet

Equipment

Cross cutting circular saw

Knot knotting machine

Jointing machine.

Press or clamps

4-ex Longitudinal milling

Trimming Sawing.

Chain machine. chiselling

Planer machine.

Tenoning machine.

Milling machine.

Milling machine.

Workplace

Assembly machine.

Tsf-2 grinding

Special machine.

Grinding machine.

Workplace

Workplace

Operations

Cross cutting.

Longitudinal cutting.

Closing knots.

jointing

Gluing

Processing from 4 sides.

Facing to size

Chiselling. nests

Face and edge processing

Spiking

Mold

Mauling processing

pre-assembly

Final. assembly

Perimeter processing.

Selection of nests for hinges

grinding

Box assembly

Blade embedding

Door leaf

vertical bar

Upper horizontal bar

Medium horizontal bars

Bottom horizontal bar

Medium and medium bars

panel

Vertical box bar

horizontal bar boxes

1.5 Properties and characteristics of the materials used

The most common species is Scots pine.

Natural array - solid wood doors are considered the best in our country. And this is true, but with a caveat: if these are high-quality products, from well-dried wood (which sometimes takes several years) and without knots. Especially important is the absence of knots in the door frame. Otherwise, it will deform after a while, and the door will stop closing.

Glued array - today it acts as an alternative to natural array (it is also called type-setting, re-glued). The door made of glued solid wood will not lead, it will not dry out and swell. It can also be installed in bathrooms, which cannot be said about ordinary solid wood doors, no matter what varnish you cover them with.

Doors by design distinguish between frame and panel doors. Frame doors consist of strapping (bars) and filler (panels). Due to the fact that the manufacture of frame doors is laborious and, in addition, sawn timber of a higher grade is required, the consumption of wood is twice as much as on a panel structure door, their use is limited.

Panel doors (see the diagram below) are a frame filled with centers of various designs, lined on both sides with plywood or hardboard 5 with a thickness of 3. ..4 mm. Door leafs 1 have good soundproofing qualities, are durable, dimensionally stable, hygienic and easy to use.

By appointment, there are external and internal doors. and in appearance - deaf and glazed. Doors are made with lining 6 or without it. door blocks can be one- and two-field, right and left.

Panel doors can be with solid, small-hollow and honeycomb filling of the leaf. Doors external and entrance to the apartment are made with a continuous filling of the middle. Door leafs are made with a thickness of 40 mm.

Door blocks for internal doors they are made without a threshold, and external ones can be with or without a threshold.

a - general view, b - cross-sections of the middle porches of the panels of double-panel panel doors, c - sections of the door panels along the edges; 1 - canvas, 2 - flashing, 3 - glass layout, 4 - glass, 5 - cladding, 6 - lining.

Wooden exterior doors for residential and public buildings (see the diagram below), depending on the purpose, are divided into entrance and vestibule (H), service (C), hatches and manholes (L). Type H doors are made of panel or frame doors, and types C and L - with panel sheets. Panel doors can be made with lathed sheathing. Doors of types H and C are made single-leaf, double-leaf, glazed or deaf, with or without a threshold. The lower parts of the H-type door leafs are protected with wooden planks 16 ... 19 mm thick, decorative laminate strips 1.3 ... 2.5 mm thick or superhard fibreboard 3.2 ... 4 mm thick or thin galvanized steel. For glazing, glass with a thickness of 4 ... 5 mm is used.

a - panel doors, b - frame doors, c - cross-sections of panel doors, d - cross-sections of frame doors; 1 - frame bar, 2 - sealing gasket, 3 - hardboard lining, 4 - door leaf, 5 - glass layout, 6 - glass, 7 - protective strip.

The technological process of manufacturing panel door blocks consists of the following main operations: manufacturing frames and filler (the middle of the shield); filling in the frames; cutting of facing material; gluing door panels; processing boards around the perimeter; staging of facings and layouts; manufacturing door frame; hanging the door in the box; door frame finishes.

The frames used as a frame are made from processed bars with a section of 40 ... 60 x 32 ... 34 mm. The bars of the frame in the corners are connected to a spike or fastened end-to-end with paper clips.

For the manufacture of a glazed door, two frames are made: external and internal, and the cross section of the bars of the inner frame must be the same as the cross section of the bars of the outer frame.

As a material for the manufacture of core filler, small-sized sawn timber and production waste are used, which are used to manufacture bars and slats for solid and sparse cores, waste plywood and hardboard 3 ... 4 mm thick (for honeycomb filling and filling in the form of a broken strip ). The slats for the centers must be debarked and without sharp wane and rot.

Shields with solid filling are made as follows. After assembling the frame, a lining is applied to it (plywood or a hard fiberboard), previously smeared with glue, and attached to the frame with small nails 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, it is necessary to ensure that they are tightly pressed against one another, and the joints of the rails are spaced apart. After filling the frame with slats, it is covered on top with another sheet of facing material (previously smeared with glue), which is attached with small nails from four corners. In the manufacture of a shield with a sparse filling, the frames are filled not entirely, but at intervals. In panels with honeycomb filling, the cells are made no larger than 40 x 40 mm, since with large cell sizes, the facing material is drawn in.

When using non-calibrated filling rails (of different thicknesses), as well as when using adhesives with a low dry residue, a wavy surface is obtained at the doors. Therefore, the filling rails must have the same thickness, and in the transverse bars of the frame (frame) of the door leaf, grooves are cut or holes 10 mm in diameter are drilled to release the steam generated during the pressing process during the polymerization of the adhesive.

After filling the frame, the door panels are glued together in cold mechanical or hot hydraulic presses. In the first case, the process of gluing boards is 6 ... 12 hours, in the second - up to 15 minutes.

After gluing in hot hydraulic press the shields are kept in the underfoot place for 12 ... 24 hours, then they are transferred for processing along the perimeter and setting of the plates and layouts.

Processing of door panels around the perimeter and setting linings and layouts include filing the shield, cutting a groove for the lining, grinding surfaces, installing glued linings around the perimeter and glass layouts (in glazed doors).

The filing of the door shield and the selection of the groove for the lining is carried out on circular saws and milling machines or on a format trimming machine, then they are placed along the perimeter of the lining and after the appropriate exposure necessary for the adhesive to set, the planes are ground on a three-cylinder grinding machine, then in the glazed doors they put layouts on the glass on the studs.

The details of the box are made as follows. The lumber is cut along the length and width, the resulting blanks are milled (jointed) on jointers, and then processed from four sides on a four-sided longitudinal milling machine with the creation of a quarter, after which spikes are cut in vertical bars and lugs in horizontal bars on tenoning machines. Before cutting the spikes in the bars with defects, close up the knots. After that, in one of the vertical bars, depending on the type of hanging (right and left), nests for hinges are selected and half-loops are placed, and in the other bar of the box, nests are selected for setting the bar under the lock. The box is assembled in an assembly machine (wime) on glue and dowels.

Installing (fitting) the door into the box consists in fitting the canvas to the box, hanging the canvas on previously installed half-loops, cleaning up sags and other irregularities. Before hanging double-leaf doors, the folds are selected along the alignment of the doors on a milling machine, and then the door leaves are folded together and hung in a box. The gap in the alignment points required for the paint layer should be no more than 2 mm. Overlap it by installing flashings on glue and screws. Doors are hung in a box at the workplace, and with a large volume of production on conveyors. When hanging, it is necessary to carefully adjust the doors to the quarter. The hinged door should not spring when opening and closing. The skew of the door after hanging can be no more than 2 mm. It should rotate freely on hinges.

Each door leaf is hung on two or three hinges, and the rods of the upper and lower hinges must be on the same vertical axis.

When installing locks with handles, the axis of the handle must coincide with the axis of the key. The socket for the lock is selected according to the template with an electric drilling machine in several steps. Lock bars and larvae are cut flush with the surface of the door frame bars.

Doors lined with plywood or hardboard are painted oil paints(whitewash) or enamels.

If you don't want to spend a lot on a purchase new door, but you can’t do without replacing it, try to make a door block yourself. It is more convenient to use a tree for this purpose. The whole process can be divided into separate stages, but perhaps you should start with choosing the right design.

Wood is the most convenient material to process

Constituent elements

All door blocks are divided into entrance and interior. Since their purpose is somewhat different, they are installed differently. It concerns the sizes specifications and equipment.

Ordinary door block designed to be filled interior openings, has the following constituent elements:

• a box consisting of two vertical posts and a crossbar;
• door leaf, that is, the leaf itself;
• platbands designed to frame the outer part of the opening and mask the fasteners.

Some interior and necessarily entrance structures, according to GOST, require the presence of one more element - a threshold. It provides complete insulation of the room and joins the canvas at the bottom.

In addition, if the dimensions of the wall do not correspond to the width of the box, auxiliary strips are used - extensions. They hide what could not be closed by the frame and are, as it were, its continuation. Also with their help slopes are made.

Main constituent elements

Types of structures

If we consider the classification of door blocks, first of all, products are distinguished by the number of canvases in the opening:

• Single. In other words, single-sided. They are a familiar door, consisting of one leaf.
• Double. They are also called double-sided or double-sided. They are distinguished by a larger overall width, while the canvas is divided into two parts, which are often the same in size and function in full. The installation of such models is appropriate as an entrance to the house or to the living room.
• One and a half. They differ from double-leaf ones in that one leaf is made less than the minimum door width allowed according to GOST. It remains locked, but opens when needed. The second part of the canvas is a full-fledged movable element.

The main types of structures

Also, door blocks are divided according to the material of manufacture, which are allowed according to GOST:

• Wooden. The most common option. Wooden doors are used for entrance and interior blocks. The cost and characteristics depend on the type of array and design.
• Metal. Basically, we mean entrance doors. Quality products are made of steel with a thickness of 2 mm or more. Thanks to modern technology and additional finishing, rough metal is given an attractive look.
• Plastic. 100% waterproof material. Mostly we are talking about PVC blocks for entrance doors and balconies.
• MDF. Today, this option is becoming increasingly popular. MDF is a natural alternative to wood and is cheaper.

In addition, there is a huge variety of doors according to the type of structure of the canvas and the external design.

GOST requirements

In order to avoid problems during installation and operation, standards have been established regarding the size of door blocks. All parameters are divided into three categories:

• Height. It depends on the ceilings in the room and, according to GOST, can vary between 2050-2400 mm. This is especially important for openings in load-bearing walls.
• Width. Here, GOST standards are divided into requirements for interior and exterior doors. For the first, an opening of 700-800 mm is allowed. Sometimes it can be reduced to 600 mm or increased to 1000-1200 mm. should not be less than 800-900 mm. It is allowed to make a maximum opening of 2000 mm for double-floor structures.
• Thickness. This indicator is more important in order to determine the dimensions of the box. It correlates with the size of the partition. wooden blocks usually have a thickness of 90-100 mm.

Schematic representation of the opening parameters required to determine the size of the door unit

In order to ensure correct installation and the normal functioning of the GOST structure, it was established that there must be technological gaps between the wall and the box, the size of which should be within 10-20 mm. And also between the frame and the canvas, here the optimal value is 3 mm.

Production and installation of the box

If you have decided to independent production and installation of the door unit, you should start by determining the design parameters. Since it is easier to work with wood, it is recommended to make wooden doors.

To make a box, it is best to choose the required thickness of the workpiece. They have corresponding cutouts and recesses for the vestibule of the canvas. Such products are sold in almost any construction market. For work, you will need 3 strips 2 meters high at the corresponding GOST.

First, the perimeter of the passage is measured and the parameters of the duct elements are determined, taking into account the clearances for installation. Parts are sawn at an angle of 90 or 45 degrees. In the absence of grooves and sawn spikes for connection, it is best to choose the second option.

Two ways to fasten the door frame from prefabricated parts

Assembly is carried out in a horizontal position. The sawn parts are interconnected using nails or bolts. They need to be hammered on both sides of the fit of the slats. After pre-assembly, the product is transferred directly to the opening.

It is carried out with the help of anchors and studs. It is necessary to set the structure according to the level in observance of the diagonal. Then its position is fixed with wedges and spacers, and holes for fastening are drilled with a drill. You need to tighten the bolts at 3-4 points on each side. Then the position of the box is adjusted and the gaps around the perimeter are filled with mounting foam. Do not touch the structure for the next 2-4 hours until the mass hardens.

The box is assembled in a horizontal position, after which it is mounted in the opening

Making a canvas

The manufacture of a door block includes the creation of a canvas. In principle, you can buy it, but if you want to adjust the dimensions specifically to the opening or create an original design, you will have to try.

According to GOST, the width of the door should be less than the dimensions of the box. Therefore, it is recommended to start making the canvas at the same time as cutting the frame. So you can adjust their sizes.

Wooden doors can be made different ways. To create a structure that is small in weight, but as simple as possible in terms of execution and design, it is better to use pine timber and plywood sheets. First, the frame is made. It consists of bars connected around the perimeter. To do this, the so-called castle is sawn along the edges. The principle of such fastening is based on the entry of sawn spikes into the prepared grooves. In order to give the structure greater rigidity, it is recommended to additionally embed cross bar in the middle of the canvas.

Frame door assembly scheme

Next is the installation of the cladding. Fiberboard sheets are fastened with small nails using glue. To give the product a decorative look, further priming of the base and lining with any available coating is carried out: film, veneer, laminate or simple painting.

The process of making a frame-type canvas

More complex, but beautiful, are paneled doors. They are made from individual elements according to the following principle: first, side posts and crossbars are cut out of a board of suitable thickness. On the inside, with the help of a milling cutter, recesses are made for mounting panels. If you have woodworking skills, try cutting out curly elements.

Panel door assembly scheme

It is permissible to use thinner boards, plywood, MDF, as well as glass for the top decorative insert as panels. Along the edges wooden elements you can slightly grind off the thickness of the notch and make it look like a facet cut.

The assembly is carried out as follows: the panels are driven into the grooves and clamped with frame elements. For better fixation, glazing beads are used. They are attached to nails, having previously sealed the joints with silicone or acrylic.

Panel door manufacturing process

Installation of the finished canvas is carried out using loops. The best option for self-installation. Usually two is enough. The hardware is flush mounted into the wood. The bottom plate with a pin is attached to the box with self-tapping screws, and the top one is at the end of the canvas. Then the door is lifted and hung in the opening so that the hardware halves are connected.

Be sure to lubricate the hinges so that the door moves smoothly and silently, otherwise the hardware will wear out faster.

After hanging the canvas. Additionally, you can complete the door with a latch or. The principle of fastening depends on the chosen model of the product, but there are general provisions. The mechanism itself cuts into the canvas through the end and is inserted inside, fixed with a plate. The pin of the handle and the details of the lock are brought out through the hole. Then clamps are put on top, decorative elements and the handles themselves. The counterpart is attached to the box on the opposite side and closed with a metal plate.

Insert fittings and hanging canvas

opening finishing

The final stage in the manufacture and installation of door blocks is the design of the opening in order to hide defects and create an additional decorative look. The main element in this case are platbands. They frame the opening, and therefore must match the interior as a whole.

To make it, it is not necessary to cut complex shapes with a milling cutter. Molded blanks and profiled boards are used as a frame for the door block. They can be purchased at the construction market.

Finishing the opening

For better use special nails without hats. Installation is carried out in such a way that the nail enters the beam of the block to be lined with minimal damage. It is recommended to connect the elements at an angle of 45 degrees. The cut is made using a miter box to minimize inaccuracies in fitting. Additionally, a couple of nails are hammered on top of the plank, so the sidewalls are fastened to the horizontal crossbar.

Also take care of the proper design of the slopes. They can also be covered with paint, sheathed with panels or covered with extensions. For interior partitions, this question often disappears by itself, since the dimensions of the box completely coincide with the thickness of the wall.

If you install the door block according to all the rules, it will become reliable and stylish design opening.