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Ministry of Education and Science

Russian Federation

State educational institution

secondary vocational education

"Mariinsky Forestry Technical College"

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 DOOR BLOCK DG21-7

Performer: student gr. TD-41

Pipkin Alexander Leonidovich

Head: L.V. Pucholenko

Initial data

Table 1. Specification of raw materials

Content

• Initial data
• Introduction
• 1. General part
• 2.1 Project rationale
• 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 external panel, as well as paneled doors. On the outside, solid doors can be finished with panels made from sections of the roots of oak, walnut, elm and other tree species. For the external decoration of blind doors, carved wood panels and combinations of veneers of various types of wood with various patterns and different directions of fibers are also used.

Sami door leaves can be made from solid wood, usually coniferous species, with cellular content. This design gives the canvas a certain resistance and prevents deformation during the service life of the door. Panels with honeycomb filling are lighter than solid panels or panels with chipboard filling. This reduces the load on door hinges. For other doors, heavier hinges should be used.

As always, doors made entirely of wood are in greatest demand. However, the use of other materials allows not only to reduce the cost door designs, but also eliminate some disadvantages natural material- wood. For example, MDF has a higher hydrophobicity compared to wood. IN Lately this material is often used in the manufacture of doors also due to its increased density.

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

It should be borne in mind that interesting design, grace and subtlety exterior finish cannot compensate for the strength, durability and other high performance qualities 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 should be equipped exclusively with L-platbands and an L-frame, which can be adjusted during installation according to the thickness of the wall, without requiring adjustment, and attached without the help of nails or a hammer. The reason why the manufacturer does not have such components lies, again, in the area of ​​saving product costs. The box must have a seal. If the door meets the above requirements, this 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 Product characteristics. Technical requirements, GOST for products

Door block DG21-7 with a blank leaf. Doors of type G are made with single- and double-leaf leaves, with fine-hollow (slatted) filling of the leaves, with and without a threshold, with overlay and without overlay, with facings and without facings, with frames and without frames.

Doors manufactured according to this standard are classified 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 and secured with nails or tenon 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 ensure the necessary tightness of the doorways.

Figure 1 Door block DG21-7

2. Calculation and technological part

2.1 Project rationale

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 among the population and enterprises, so the production of door blocks is economically beneficial.

In this course project selected modern equipment: TsME - 3B for cross-cutting lumber, CDK 4 machine for longitudinal sawing, four-sided PROFIMAT-185, jointer RF-430, surface planer CP8-20M, cross-cutting machine Bi6-800. These machines perform operations to obtain finishing workpieces. To obtain parts, it is proposed to perform technological process operations on a 6T-4S tenon-cutting machine; the WT3200 format-cutting machine is designed for piece and batch cutting of slab materials.

The selected equipment has a number of advantages: high performance, easy to operate, compact and versatile, the low weight of the machines will allow you to easily move the equipment, also providing high quality processing of materials, but more demanding on the level of training of the operating personnel. The selection of technological equipment is carried out according to the technological process.

Installation of modern equipment will allow us to produce high quality products with high labor productivity and optimal consumption of raw materials.

door panel wood natural

2.2 Specification of parts for the product

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

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

2.3 Calculation of raw materials and materials

In a course project I expect required amount raw materials and materials for the production of door block DG 21-7. When calculating the amount of lumber, I am guided by methodological instructions for completing coursework and theses. I set consumption rates for lumber 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 pure dimensions from the parts specification.

I find the net volume of a set of parts by multiplying the size and quantity of each part. I take the dimensions in the workpiece with the allowances that I took in the guidelines for calculating coursework and dissertations. Standard thicknesses also defined in the guidelines. The volume of the set of blanks was determined in the same way as the volume of the set of clean parts. The coefficients taking into account technological waste and the coefficients of useful output during cutting were taken into account textbook Hasdan M.M., Ratner M.L. "Sawmill and woodworking production."

Table 2. Calculation of raw materials and supplies

Name

Part material

Net dimensions, mm

Clean volume of the part set m 3

Dimensions in the workpiece, mm

Standard thickness, mm

Set volume blanks

Coefficient taking into account technological waste

Volume of technological waste blanks m 2

Efficient yield when cutting

Lumber consumption m2

Door frame Vertical block Bar horizontal

Door leaf filler Facing

2.4 Summary specification of raw materials for the program

Table 3

2.5 Waste balance

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

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

Waste must be stored sorted by type and type, and it is absolutely necessary to store bulk waste separately from lump waste. Bulk wood in open warehouses is placed in conical or prismatic piles 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 lesoma-terials

Annual consumption for the program, m 3, m 2

Cutting waste

Waste from processing workpieces, taking into account technological waste

Total waste, m 3, m 2

In the blank

Clean

Sawdust and dust

Sawdust and dust

Taking into account losses

coniferous materials

2.6 Justification for choosing equipment

The course project proposes to install new generation machines to increase the productivity of the workshop. Modern machines are easy to use, compact and versatile, the low weight of the machines makes it easy to rearrange the machines, and also ensures high quality processing of materials.

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

Advantages of this machine: high productivity, improved 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 high cutting height. The unique design of the machine ensures greater rigidity and vibration resistance of the machine. The main table has large dimensions, which is convenient when processing these parts.

Table 6. Technical characteristics of the TsDK-4 machine

The PF-430 universal machine is designed to create a base surface. It has a large length of tables and the ability to automatically raise and lower the machine tables; their reliable fixation allows you to remove the required layer of material in a high-quality manner and uniformly along the entire length of the workpiece.

Table 7 Technical characteristics of the PF-430 machine

Name	Indicators
Processing width, mm
Naib. thickness with him. layer, mm
Total length of tables, mm
Knife size, mm
Front table lifting height, mm
Lifting height of the rear table, mm
Knife shaft diameter, mm
Rotation speed, rpm/world
Installed power, kW
Dimensions, m
Weight, kg

The thicknesser machine is designed for planar one-sided planing of wood products to a given size in thickness. Processing is carried out with a knife shaft along the upper surface of the workpiece. The machine has a simple and reliable design chain driven feed mechanism.

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

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

This machine is designed for the operation of cutting blanks.

Table 9 Technical characteristics of the Bi6-800 machine

Tenon cutting machine is designed for milling tenons and eyes of parts frame structures made of wood with preliminary trimming.

This machine has high precision and cleanliness of processing.

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

Table 10 Technical characteristics of the GT-4S machine

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

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

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

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

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

Table 12. Technical characteristics of the WT-3200 machine

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
Movable carriage size

2.7 Drawing up and calculating 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 production rate, processing time per part and per product.

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

Table 13. Routing 1

Namedetails: Vertical box block

Numberonproduct: 2

Breedwood: coniferous

DimensionsdetailsVworkpiece,mm: D 2091 Sh 80 T 51

DimensionsdetailsVcleanliness,mm: 2071 74 45

VolumeVworkpiece,m 3 0,00689

VolumeVcleanliness,m 3 0,00853

the name of the operation

Dimensions after processing, mm

Name

Control method

Production rate

Duration, min

equipment

tool

adaptations

For detail

Per product

Cut across the grain

disk

Knives, cutter

Calipers

Trimming to length

Circular saw

Ruler, tape measure

Cutting tenons and lugs

Calipers

Table 14. Technological map 2

Namedetails: Bar horizontal box

Numberonproduct: 2

Breedwood: coniferous

DimensionsdetailsVworkpiece,mm: D 690 Sh 80T 51

DimensionsdetailsVcleanliness,mm: 670 74 45

VolumeVworkpiece,m 3 0,00223

VolumeVcleanliness,m 3 0,00281

the name of the operation

Dimensions after processing, mm

Name

Control method

Production rate

Duration, min

equipment

tool

Adaptations

For detail

Per product

Cut across the grain

disk

Processing on 4 sides with quarter cutting

Knives, cutter

Trimming to length

Circular saw

Calipers

Cutting tenons and lugs

Ruler, tape measure

Table 15. Technological map 3

Namedetails: Filler bars

Numberonproduct: 12

Breedwood: coniferous

DimensionsdetailsVworkpiece,mm: D 2020 Sh 56T 38

DimensionsdetailsVcleanliness,mm: 2000 50 32

VolumeVworkpiece,m 3 0,0032

VolumeVcleanliness,m 3 0,00429

the name of the operation

Dimensions after processing, mm

Name

Control method

Production rate

Duration, min

equipment

tool

adaptations

For detail

Per product

Cut across the grain

disk

Creation base surface

Pusher

Visually

Processing to cross-sectional size

Calipers

Trimming to length

Circular saw

Ruler, tape measure

Table 16. Technological map 4

Namedetails: Facing

Numberonproduct: 2

Breedwood: Fiberboard

DimensionsdetailsVworkpiece,mm: D 2000 Sh 600T 4

DimensionsdetailsVcleanliness,mm: 2000 600 4

VolumeVworkpiece,m 3 0,0048

VolumeVcleanliness,m 3 0,0048

Shift capacity P cm, pcs CP8-20M is determined by the formula p.310

Psm = Tsm* U*n* Kr*Km/ L z *m, (4)

T cm - shift duration 480 minutes;

U - feed speed m/mi;

n - number of sides being processed;

Kis - utilization factor 0.5;

L z - length of the workpiece, m.

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

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

calculated using the formula p.296

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

where Psm is the shift productivity of the machine;

U - feed speed m/min;

K p-working time coefficient 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 =480*10*0.2*0.85*1/0.050*1.5*2=5440 pcs.

Replacement capacity of four-sided machine PROFIMAN-18S P, see pcs. calculated using the formula p.310

P cm = T cm *U * n* K r *K m / L z * m, (5)

where Psm is the shift productivity of the machine;

T cm - shift duration 480 min;

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

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

m - number of facing sides 2 pcs.

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

Replacement capacity of single-sided tenoning machine GT-4S P, see pcs. calculated using the formula p.310

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

where Psm is the shift productivity of the machine;

T cm - shift duration 480 min;

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

Z-number of machined ends of the part;

Keys - computer time utilization factor 0.7-0.8.

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

The shift productivity of the WT-3200 format cutting machine is calculated using the formula p.22

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

where Psm is the shift productivity of the machine;

Tcm - shift duration, min;

Kl - machine utilization factor (0.8 - 0.9);

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

m is the number of blanks obtained from one sheet;

Tc - duration of the cutting cycle for one bookmark.

m =S l / S z K p. in, (8)

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

Sз - workpiece area;

Kp. c is the useful output coefficient.

m = 6|1.2*1.087=4.6 pcs

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

2.9 Process flow diagram. Calculation of the required amount of equipment

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

Table 17. Process diagram

Continuation of table 17

The annual operating time of workplace equipment is calculated using the formula p.444

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

where Tf is the annual equipment operating fund;

Dr - number of days in a year;

K ob - coefficient of equipment downtime due to technical reasons 0.93 - 0.95;

t - shift duration, hours;

i - number of shifts.

Tf = 250 *1*8 *0.9 = 1800 hours.

The time required T pr, h. for processing all workpieces to complete the annual task is determined

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

where Tpr is the time for the program in hours;

Qr - annual program, pcs.:

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

n - number of blanks, pcs.

Tpr = 9000*8*2/ 1339=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

fз=Ncalc. /Nprin. *100%, (11)

fз=0.47/1*100=47

2.10 Statement 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; Feeding speed 8-40 m/min; Weight 900 kg. Dimensions 1.9*1.4*1.4 m
4-sided machine			Engine power 20 kW; Feed speed 6; 12 m/min. Dimensions 3*1.2*1.5 m
Joining machine			Power 3 kW; Knife rotation frequency. shaft 6000 rev. /min Weight 800 kg.
Thicknessing machine			Power 7.87 kW; Feed speed 8; 4 m/min; Weight 150 kg.
Trimming			Power 3 kW Cutter rotation speed 2840 rpm. /min Dimensions 1.5*1.3*1.6 m
Tenoner			Engine power 10.2 kW; Feed speed is manual; Dimensions 1.7*1.5*1.3 m
Format cutting machine			Dimensions 3.3*3.2*0.9 m Scoring saw motor power 0.75 kW Main motor power Saws 4kW

2.11 Description of the technological process

Lumber is delivered to the woodworking shop by road or truck and manually stacked. 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 its final moisture content, it is sent for further processing. The technological process consists of two streams: processing of bar parts and cutting of fiberboard into blanks.

Processing of timber parts begins with cross-cutting boards to a certain length on a TsME-3B machine.

The material is fed onto the table, pressed against thrust planes (table, block or guide ruler) and cut to a given length using 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 operated by two workers. One worker turns on the machine, the other, standing behind the machine, accepts the sawn workpieces. Boards with defective edges on machines with a closed hollow, first saw off the edge, focusing on the mark marked on the casing of the clamping device against the saw. When making repeated cuts, the boards are fed to the saw, pressing their edge against the guide ruler.

The resulting box blanks are transported using a trolley to the four-sided planer PROFIMAT-18S, where processing is carried out on 4 sides according to a given profile with a quarter cut. Processing is carried out using knife shafts located in the direction of the workpiece being processed. The workpieces are fed into the machine one piece at a time without any gaps between the ends.

Then the workpieces are brought to the Gt - 4S machine, where the workpieces are finished trimmed to a given length, and then tenons are cut and the ends of the workpiece are lugged using a cutter.

The resulting blanks, door leaf fillers and blanks that have unevenness, are manually fed to the PF-430 jointing machine to create a base surface. The workpiece is placed with its concave surface down on the machine table. presses both hands against the guide ruler and feeds it onto the knives. Subsequently, when moving the workpiece, the processed part of the workpiece is pressed against the plane of the back table, processing is carried out with a knife shaft. The machine is serviced by two workers or one.

The formed workpieces are moved on a trolley to the surface planer. machine CP8-20 M. The machine is serviced by two workers. The workpiece is placed with its reverse surface on the work table and advanced towards the rollers. When the rollers grab the front part of the workpiece, the machine operator places the next workpiece on the table, resting its end against the end of the previous one. During operation, it is necessary to periodically check the thickness of the part.

The processed workpieces are transported to the cross-cutting machine Bi 6-800, where the workpiece is trimmed to a given length.

The second thread processes slab blanks.

The first operation of the technological process is cutting slab materials into blanks on a WT-3200 machine; cutting is done with a circular saw.

2.12 Determining the required number of workers

Table 19

Name of equipment	Quantity
		Basic	Auxiliary

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

2.13 Calculation of workshop area

Table 20. Calculation of workshop area

	Name of equipment and workplaces	Machine model	Number of equipment units and workplaces	Standard production area per unit of equipment, m2	Required area, m 2
	Cross cutting machine
	Slitting machine
	4-sided machine
	Joining machine
	Thicknessing machine
	Trimming
	Tenoner
	Format cutting machine

Total area m2=182.7

The production area is determined by direct calculation:

F pr =F 1 /0.6, (10)

where F1 is the area of ​​workplaces, m2

F1=182/0.6=304.5 m2

Area of ​​household and auxiliary premises calculated:

F y =0.2 F pr, (11)

Fу=0.2 304.5=60.9 m2

The required workshop area is calculated:

F total = F pr F y, (12)

Ftotal=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		General mouth power,	General connection power, kWt	Coeff. use electric motor	Required powerful,	Network losses, %	Power on high voltage lines.	Number of working hours per year	Annual consumption electrical power, kW
Trimming
cut-off
4-sided machine
Joining machine
Thicknessing machine
Tenon cutting machine
Cross-cutting machine
Format cutting machine

3.2 Calculation of electricity consumption for lighting

Table 24

4. Labor protection

4.1 Safety precautions when working on equipment

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

The placement of production equipment when organizing woodworking technological processes 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 saw blade.

If the workpieces are aligned on the carriage, it is pulled away from the saw and secured with a pawl or hook so that it does not get closer to the saw again. The carriage for feeding material is provided with shields that secure the front part of the saw, which extends beyond the stop.

Exceed the dimensions specified in the technical specifications. When feeding a pack 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; you must not stand near the saw against the direction of rotation of the saw blade. Workpieces can be fed only 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 feeding manually, the part of the saw located above the table must be protected by a reliable consul, which automatically lowers onto 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.

Jointer

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

Thicknesser

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, or worn surfaces.

4.2 Fire safety of the workshop

By degree fire safety the workshop belongs to category B. During operation electrical networks It is necessary to monitor the serviceability of the wires to prevent sparking, heating or short circuits. Lubricate the bearings of electric motors regularly, and clean the electric motors themselves from dust, shavings and sawdust. Conveyors, machines, 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, and workwear is hung in closets in special rooms. It is not allowed to leave oily cleaning material and matches in the pockets of overalls. Special places are allocated for smoking (outside the finishing shops), where there should be trash cans and barrels of water.

The plant's workshop is provided with water for fire-fighting purposes. Fire water supply must be designed for high or low pressure. In water pipes high pressure the water pressure required to extinguish the fire is created directly from the hydrant using specially installed stationary pumps. Stationary fire pumps are equipped with devices that ensure the start of the pumps no later than 5 minutes after the signal about a fire is given.

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

Conclusion

The course project calculates the amount of raw materials and supplies, taking into account technological waste, 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. Designed by technological process 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 manufacturing woodworking products.” 2006, p.584

4. Guidelines for completing coursework and diploma projects

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

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

7. 7. Shcherbakov A.S., Nikitin L.I., Bobkov N.G. “Occupational safety and health in the forestry and woodworking industries.” 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 Equipment used, mechanical and hand tools

1.7 Labor protection, safety precautions when working on machines

1.8 Used Books

1. 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 differences and much more, which will help potential buyers make their choice.

Wooden doors are quite often installed in houses and apartments. If you have also chosen them, then you need to approach the purchase very seriously. A wooden door is the very thing that will either serve for many years and delight with its beauty and quality, or will quickly warp, crack and become completely unsuitable for its intended use. 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 in the process of their manufacture.

The production of interior wooden doors is a very complex technological process that must meet certain requirements. Only with strict adherence to technology can high-quality and reliable interior wooden doors and wooden entrance doors be obtained that will serve for a long time and will not lose their performance qualities. Properly processed wood is a durable, frost-resistant, soundproof material. It is not only used to make wooden doors, but also to build houses. A wooden house turns out to be so warm, reliable and beautiful that, despite the emergence of a huge number of more modern and less expensive building materials, wood has not lost its relevance and people 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 wood was dried poorly, then wooden doors made from this solid wood will not last long, they will quickly change shape and become unusable. But made from high-quality dried wood, using good equipment and observing all the subtleties of the technological process, wooden doors - pine, whether an inexpensive or valuable type of wood served as the material for them, will be very durable and functional.

After drying the wood, it is glued. The composition of the glue depends on what type of door will be made - wooden external doors, paneled wooden doors or Finnish wooden doors. For different types doors use different glues, different ones are also required temperature conditions during gluing.

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

Often, interior wooden doors are not painted, but simply coated with transparent varnish so that the structure of the wood is visible. But wooden entrance doors should be more resistant to various external influences, 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 decorated with clear varnish only, but requires a more durable and resistant coating. If it is sometimes coated with varnish, then only with high-strength varnish and at least four times.

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

Of course, everyone wants to buy wooden doors that will last a long time and will not lose their shape and appearance during use. Wooden doors it’s not so easy to make, so it’s rarely possible to make it in home-made conditions good doors. 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 many years. When purchasing doors made by someone unknown, you can be very disappointed when they become warped and stop opening.

The cost of wooden doors depends on their quality, on whether the technological process during their production was so precisely followed. 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. Internal four vertical strapping bars

5. Internal two cross bars

6. Of six lower and upper panels

7. From one middle panel.

Specifications:

1. The door block should not be made from pine wood.

be on parts of falling knots, rot, cracks.

2. Make panels from pine wood

3. Assemble the door leaf using PVA glue.

4. The 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 a box on cardboards

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 Technological map

Equipment

Circular saw cross cutting

Knot sealing machine

Jointer.

Press or clamps

4-ex Longitudinal milling

Trimming Sawing.

Chain machine. chiselling

Thicknesser machine.

Tenoning machine.

Milling machine.

Milling machine.

Workplace

Assembly machine.

Tsf-2 grinding

Special machine.

Grinding machine.

Workplace

Workplace

Operations

Cross cutting.

Longitudinal cutting.

Sealing knots.

Jointing

Gluing

Processing on 4 sides.

End cutting to size

Chiseling. nests

Face and edge processing

Thorn cutting

Mold

Processing of molding

Pre-assembly

Final. assembly

Perimeter processing.

Selection of sockets for hinges

Grinding

Box assembly

Fitting the canvas

Door leaf

Vertical block

Upper horizontal bar

Medium horizontal bars

Bottom horizontal bar

Medium and medium bars

Panel

Vertical box block

Horizontal block boxes

1.5 Properties and characteristics of the materials used

The more common species is Scots pine.

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

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

Doors are divided into frame and panel doors according to their design. Frame doors consist of frames (bars) and filler (panels). Due to the fact that the manufacture of frame doors is labor-intensive and, in addition, high-grade lumber is required, the wood consumption is twice as high as for a panel door, their use is limited.

Panel doors (see diagram below) are a frame filled with the centers of various structures, lined on both sides with plywood or solid fiberboard 5 thick 3. ..4 mm. Door leaves 1 have good sound insulation properties, are durable, dimensional stable, hygienic and easy to use.

Depending on their purpose, there are external and internal doors. and in appearance - deaf and glazed. Doors are made with or without lining 6. Door blocks can be single- or double-leaf, right-handed or left-handed.

Panel doors can be with solid, fine-hollow or honeycomb filling. External doors and entrance doors to the apartment are made with a continuous filling of the middle. Door leaves are made 40 mm thick.

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

a - general view, b - sections of the middle vestibules of the double-leaf panel doors, c - sections of the door leaves along the edges; 1 - canvas, 2 - strip, 3 - glass layout, 4 - glass, 5 - cladding, 6 - lining.

External wooden doors for residential and public buildings (see diagram below), depending on their purpose, are divided into entrance and vestibule (H), service (S), hatches and manholes (L). Doors of type H are made with panel or frame doors, and types C and L are made with panel leaves. Panel doors can be made with slatted cladding. Doors of types H and C are made single-leaf, double-leaf, glazed or solid, with or without a threshold. The lower parts of the door leaves of type H are protected with wooden strips 16 ... 19 mm thick, strips of decorative laminated paper 1.3 ... 2.5 mm thick or ultra-hard 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 - sections of panel doors, d - sections of frame doors; 1 - frame block, 2 - sealing gasket, 3 - cladding made of hard fiber boards, 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 panel); filling out frames; cutting facing material; gluing door panels; processing of panels around the perimeter; installation of covers and layouts; manufacturing door frame; hanging the door into the frame; finishing of the door block.

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

To make a glazed door, two frames are made: an outer and an inner one, and the cross-section of the bars of the inner frame should 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 lumber and production waste are used, which are used for the production of bars and slats for solid and sparse cores, waste plywood and solid fiber board with a thickness of 3 ... 4 mm (for honeycomb filling and filling in the form of a broken strip ). The slats for the centers must be debarked and free from sharp wane and rot.

Shields with continuous filling are made as follows. After assembling the frame, a cladding (plywood or hard fibreboard), previously coated with glue, is applied to it 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 of a thickness corresponding to the thickness of the frame. When laying the slats, you must ensure that they are pressed tightly against one another, and that the joints of the slats are spaced apart. After filling the frame with slats, it is covered on top with another sheet of facing material (previously coated with glue), which is attached with small nails at four corners. When making a shield with sparse filling, the frames are filled not completely, but at intervals. In shields with cellular filling the cells are made no more than 40 x 40 mm in size, since when large sizes cells, the facing material is retracted.

When using uncalibrated infill slats (of unequal thickness), as well as when using adhesives with a low dry residue, the doors end up with a wavy surface. Therefore, the filling slats must have the same thickness, and in the transverse bars of the frame (frame) of the door leaf, grooves are cut or holes with a diameter of 10 mm are drilled to allow the steam generated during the pressing process during glue polymerization to escape.

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 the boards takes 6 ... 12 hours, in the second - up to 15 minutes.

After hot gluing hydraulic press the boards are kept in a place under the footing for 12 ... 24 hours, then transferred for processing around the perimeter and installation of covers and layouts.

Processing of door panels around the perimeter and installation of facings and layouts includes filing the panel, cutting out a groove for the facing, grinding surfaces, installing perimeter facings and layouts on glass (in glazed doors) with glue.

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

The box parts are made as follows. The lumber is cut to length and width, the resulting blanks are milled (planed) into jointing machines, and then processed on four sides on a four-sided longitudinal milling machine to create a quarter, after which the tenons in the vertical bars and the eyes in the horizontal ones are cut on tenoning machines. Before cutting the tenons, the knots in the bars that have defects are sealed. After this, in one of the vertical bars, depending on the type of hanging (right and left), sockets for hinges are selected and half-hinges are installed, and in the other block of the box, sockets are selected for placing the bar under the lock. The box is assembled in an assembly machine (Vayma) using glue and dowels.

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

Hang each door leaf on two or three hinges, and the rods of the upper and lower hinges should 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 lock socket is selected using a template using an electric drill in several steps. The lock strips and cylinders cut flush with the surface of the door frame bars.

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

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

Wood is the most convenient material to process

Components

All door blocks are divided into entrance and interior. Since their purpose is somewhat different, they are installed differently. This applies to sizes technical characteristics and configurations.

A regular door block designed to fill interior openings, has the following constituent elements:

• box consisting of two vertical racks and crossbar;
• door leaf, that is, the leaf itself;
• platbands designed to frame the outer part of the opening and disguise 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 is joined to 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 covered by the frame and are, as it were, a continuation of it. They are also used to create slopes.

Main constituent elements

Types of structures

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

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

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. Cost and characteristics depend on the type of array and design.
• Metal. This mainly refers to entrance doors. High-quality products are made of steel with a thickness of 2 mm or more. Thanks to modern technologies and additional finishing gives the rough metal an attractive appearance.
• Plastic. 100% waterproof material. Mainly 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 based on the type of door structure and external design.

GOST requirements

To avoid problems during installation and operation, standards were established regarding the size of door units. All parameters are divided into three categories:

• Height. 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 entrance doors. For the former, 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. The maximum opening allowed is 2000 mm for double-floor structures.
• Thickness. This indicator is more important for determining the dimensions of the box. It correlates with the size of the septum. Wooden blocks usually have a thickness of 90-100 mm.

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

In order to ensure correct installation and normal functioning of the GOST design, the mandatory presence of 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 optimal value– 3 mm.

Manufacturing and installation of the box

If you decide to self-production and installation of the door block, 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 required thickness blanks. They have corresponding cutouts and recesses for the rebate of the canvas. Such products are sold on almost any construction market. To work, you will need 3 strips 2 meters high at , corresponding to GOST.

First, the perimeter of the passage is measured and the parameters of the box elements are determined, taking into account the clearances for installation. Parts are cut at an angle of 90 or 45 degrees. If there are no grooves or sawn tenons for the connection, it is best to choose the second option.

Two ways to fasten a door frame from finished parts

Assembly is performed in a horizontal position. The sawn parts are connected to each other using nails or bolts. They need to be hammered in on both sides of the contact of the planks. After preliminary assembly, the product is transferred directly into the opening.

This is done using anchors and studs. It is necessary to level the structure in compliance with the diagonal. Then its position is fixed with wedges and spacers, and holes for fastening are drilled using a drill. The bolts need to be tightened at 3-4 points on each side. Then the position of the box is adjusted and the gaps around the perimeter are filled with polyurethane 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 leaf. In principle, you can buy it, but if you need to adjust the dimensions specifically to the opening or create original design, you'll have to try.

According to GOST, the width of the door should be less than the dimensions of the frame. Therefore, it is recommended to start making the canvas simultaneously with cutting the frame. This way you can adjust their sizes.

Wooden doors can be manufactured different ways. To create a structure that is light in weight, but as simple as possible in terms of execution and design, it is better to use pine beams and plywood sheets. First the frame is made. It consists of bars connected around the perimeter. To do this, a so-called lock is cut out along the edges. The principle of such fastening is based on the insertion of sawn tenons into 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 diagram

Next, the cladding is installed. Fiberboard sheets fastened with small nails using glue. To give the product a decorative appearance, the base is further primed and covered with any available coating: film, veneer, laminate or simple painting.

The manufacturing process of frame-type fabric

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

Panel door assembly diagram

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

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 are enough. The fittings are mounted flush into the wood. The lower plate with a pin is attached to the box with self-tapping screws, and the upper one is attached to the end of the canvas. The door is then lifted and hung into the opening so that the halves of the fittings are connected.

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

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

Inserting fittings and hanging fabric

Finishing the opening

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

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

Final finishing of the opening

For better results, use special nails without heads. Installation is carried out in such a way that the nail enters the timber of the block being coated 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 during fitting. Additionally, a pair of nails are driven into the top of the plank, thus fastening the sidewalls to the horizontal crossbar.

Also take care of the proper design of the slopes. They can be coated 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.