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Manufacturing plan of frame of chess set.

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Introduction

Manufacturing plan of frame of chess set The wood should first measured with a rule and marked at the points corresponding to the lengths shown in the final design. Using a square, the lines which have been marked should then be checked to ensure that all of the angles at the corners are 90o. This guarantees that the pieces of wood are now perfect rectangles; this is a very important starting point for an accurately made product. This is associated with quality control. Then, using a band saw and following the marked out lines it should be cut down to the correct size; this should be repeated for all of the four pieces of mahogany. In industry, CAM could be used to complete this task and the measurements would only need to be entered once into the computer, which would then cut the wood accurately without the need for marking and checking each one. The quality control here would be carried out on a sample of the final cut piece of wood before cutting them in bulk. This will obviously not be possible or necessary in my situation and performing the same task in the way I have described will take around an hour. Then, after the wood is cut to the appropriate size, the next step in the manufacture would be to make the comb joints. ...read more.

Middle

This results in there being a small amount of material that is still to be removed. Now a chisel and a mallet need to be used to remove this material and leave a smoother finish. The material is clamped to a table using a g-clamp and MDF to protect the wood from damage. Now, the chisel is held on the wood, a small distance from the shoulder line and used to remove as much of the wood as possible, when there is only a small amount left, the wood must be on the table with the face that is to be used on the outside of the unit facing upwards. This is to ensure that when the frame is put together, the joints that will be seen will be off the highest quality. Now the chisel is put into the knife line previously made and held vertically and struck to remove all the material. This process needs to be repeated for all of the comb joints that have been marked out. These two completed pieces of wood are now used as a template to mark out the other two pieces. The cut piece is rested upon the wood to which it will be joined and the area where the material has been removed from is drawn around, not with a pencil, but a Stanley knife for more accuracy. ...read more.

Conclusion

This frame will then be held together using sash clamps, with off cuts of MDF to protect the surface from damage from the clamps. The frame would need to be clamped in all directions, ensuring that each joint is tight. Then, when the frame is clamped, a tape measure can be used to measure the diagonals of it to make sure that it is a square, if it is not, clamps should be adjusted until it is. When the glue has dried, the comb joints must then be finished. There should be excess material on the joints. Most of this should be removed with a hacksaw leaving a small amount overhanging the edge of the frame. In order to make the joint flush with the rest of the side and leave a good finish, a plane must then be used. Planing must always be done working into the wood, not off the edge, as doing so will increase the risk of chipping material off of the side. When the plane has been used and the comb joints are level, a power sander can then be used over the whole of the edge to ensure that all of the material is level, removing any imperfections the plane may have left and leaving a good surface finish. Green felt then needs to be attached to the inside of the base of the product. The felt should have a self-adhesive backing, so the it should simply be laid into place to glue. ...read more.

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