FTL1 1718 P2 Report Topics

Polytechnic Institute of Viseu
School of Technology and Management of Viseu

Wood Engineering Department
Furniture Technology and Design Bachelor
Manufacturing furniture in a simulated

production environment / CNC
Programation
Student Name, Anastasija Belonozko, Kamile Pilvelyte, Gabija Kelminskaite;
ESTGV, DEMad, LTDMOB, LTM/LTM1 17/18, Viseu – Portugal;
Abstract
Briefly, mention what was done.
This work aims to develop skills in the use of technologies for the manufacture of furniture products (in
this case manufacturing transport car) in a simulated environment.
Our furniture is developed to support the factory for the storage and transport of semi-finished stock:
wood (slabs or slabs obtained from cutting), wood composites (small cut panels) and cardboard-
materials used during manufacturing processes. The final report reflects the way in which the work was
carried out, with references to project interpretation, raw materials, techniques and technologies used.
The fabrication of the pre-series for RACKART (name of the project) mobile in simulated environment
presupposes the preparation of the program and production order and the respective manufacturing
orders, and the distribution of the groups of students by the different operations.
YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Introduction
Theory: Solid wood furniture; Medium density fiberboard (MDF); Furniture joints;
Wood and wood composites furniture has been widely used not only for convenience and comfort, but
also by the incorporation of eco-efficient raw materials. As there are a lot of different raw materials
there are also a lot of different ways to fabricate furniture, as different kinds of furniture itself.
The terms “composite wood products” or “replicated wood grain” refer to a family of engineered wood
panels that include particleboard, medium density fiberboard (MDF) and hardboard. Particleboard is
made from small wood particles pressed together with glue under extreme heat and pressure to make
a solid panel. MDF and Hardboard are made the same except the wood particles are further refined
into individual fibers to provide a smooth edge to the panel.
In general, composite wood products turn wood waste and residuals into useful products and protect
the environment. A USDA Forest Service study shows that, on average, only about 63% of a harvested
tree can be used to make solid lumber. When Engineered Wood and other products are made from the
remaining wood, over 95% of the tree can be saved.
Engineered Wood is the result of decades of research and development aimed at designing a
structurally superior wood product for use in the construction of today’s furniture, cabinets and other
home furnishings. It provides consistent, uniform strength and is free of defects. It is highly resistant to
warping, cracking and splitting, and has no knots, voids or other surface imperfections.
Engineered Wood panels are made from the wood that remains after a tree is milled into lumber. This
wood is cleaned and refined then combined with an ultra-strong adhesive under heat and pressure.
Engineered wood is real wood in an advanced form that makes it solid and durable (source: Furniture
carts).
In other words, composite wood is manufactured from a variety of materials. They usually contain the
same woods that are used in lumber, but they are combined to make them stronger and more durable.
Composite lumber is a material that is a mixture of wood fiber, plastic, and some type of binding agent.
These ingredients are put together to form a material that is denser, stronger, and heavier than wood
alone, a wood-plastic composite.
Talking about the solid wood, it is wood that has been cut from a tree. Unlike engineered wood, which
is composed of wood fibers that are held together with adhesives, solid wood contains wood fibers
throughout the piece of lumber. No fillers or adhesives are used. Solid wood is often used for furniture,
construction, cabinetry and flooring. It does not warp as easily as many engineered woods, but it is
more susceptible to stains. Solid wood is easier to repair than veneers or other engineered woods,
which is one reason that it is used for many types of projects. There are several types of solid wood
available, so woodworkers, cabinetmakers and carpenters can choose from a large selection for their
projects. Each type of solid wood has its own characteristics, including its grain pattern, color and
texture (source: Solid wood deffinition).

It has many benefits: it’s strong, sturdy and beautiful in its grain. However, solid wood contracts when
subjected to changes in heat and humidity. Unless these conditions are carefully controlled, cabinets,
doors or paneling made from solid wood can shrink, crack or buckle (source: Solid wood).
To start making a furniture it is important to decide what kind of system you will be using: framed or
frameless. Frame construction is a popular method for making a variety of furniture and architectural
components. Its primary purpose is to create a large panel with minimal wood movement. Whereas
solid wood shrinks and expands with changes in humidity affecting its overall dimensions, a frame
doesn’t. Instead, the panel is able to expand and contract freely inside a unchanged frame.
Scarcely another system in the whole range of woodworking has more variation and broader
application than the frame and panel. In the frame-and-panel system, pieces of solid wood are joined
together into a structure whose overall dimensions do not change. This is vastly different than a single
solid panel of the same size, which will shrink and expand with changes in humidity.
The frame is usually rectangular, mortised and tenoned together, with a groove cut into its inside edge.
The panel fits into this groove: tightly on its ends since wood does not move much in length, but with
room to spare on the sides because wood moves most in width. Wood is not uniform and as it moves in
response to changing moisture conditions, it cups, twists, springs and bows. Trapping the panel in the
groove inhibits this misbehavior.
Moreover, it is also important to choose what kind of joint techniques you will use. There is plenty
different kinds of them, some are better some are not, but you can also mix them depending on a
furniture you plan to make. Joinery is a part of woodworking that involves joining together pieces of
timber or lumber, to produce more complex items. Some wood joints employ fasteners, bindings, or
adhesives, while others use only wood elements. The characteristics of wooden joints - strength,
flexibility, toughness, appearance, etc. - derive from the properties of the materials involved and the
purpose of the joint. Therefore, different joinery techniques are used to meet differing requirements.
In our work we used three of the techniques: dowels, mortise and tenon and biscuit
The doweled joint is merely a butt joint that uses wooden dowels to help align and strengthen the bond
between two boards. Often times a doweled joint is made into a very visually appealing joint by passing
the dowels completely through the side piece allowing them to show through and sanding them flush
with the surface. A well-made dowel joint is as strong as a mortise and tenon joint.

Picture 1 Dowel joint
The mortise and tenon is a classic wood joinery method. These joints have been used since the early
times of woodworking, and are still among the strongest and most elegant methods for joining wood.
Learn methods for creating tight, beautiful mortise and tenon joints.
Picture 2 Mortise and Tenon joint
Another method for joining boards along the edges (like the tongue and groove joint) is to cut slots and
use beechwood wafers (known as a biscuit) to hold the boards in place. This is a very useful modern
woodworking joint, particularly for creating table tops, relying on glue and the swelling of the
beechwood biscuit to hold the boards in place. Learn how to cut consistent slots and get reliable results
from biscuit joinery (source: Furniture joints).

Picture 3 Biscuit joint
Another way to join the pieces is using the srew. Screw is a short, slender, sharp-pointed metal pin with
a raised helical thread running around it and a slotted head, used to join things together by being
rotated so that it pierces wood or other material and is held tightly in place. Although there are
different types of them too, you can see it in the picture underneeth.
Picture 4 Srews

Material and Methods
Raw material
Raw material (s) used; A paragraph to describe each raw material; Summary table with reference values
for the property we have determined - density (do not forget to refer source).
Since ancient times wood has been one of the first materials to be used in construction. Following
mankind development, technologies, methods and principles of materials utilization have evolved,
allowing solid wood, mostly used in the manufacture of furniture until the middle of the 20th century,
to be replaced by new materials derived from wood, such as Fiber or particleboard and plywood,
among others. To date, wood composites have evolved in their quality as well as in their range, are less
polluting and more practical.
In our work we used to test solid (pine) wood and medium density fiberboard.
Short description about Pine wood

It was used in this work the wood species of Pinus pinaster Ait., which is extracted from the common
name pine tree.
Pine wood is medium-weight and relatively soft. Its strength and elasticity are good. As with other
coniferous woods, the properties of the wood depend upon the density of the annual growth rings: The
higher the proportion of summerwood, the heavier and harder the wood. Therefore, pine is a very good
decision as it is also inexpensive, lightweight wood that can be yellowish or whitish with brown knots.
It's low-cost, it takes paint well and it resists shrinking and swelling.
However, because it's a softwood, it's prone to scratches and dents (source: Pine wood).
Short description about MDF

Talking about MDF, it is medium density fiberboard, which , is a manufactured (engineered) wood
product composed of wood fibers that are mixed with resin and wax and pressed into flat panels under
high temperature and pressure. It is used much like plywood as a building material in residential and
commercial construction. Unlike particleboard, with which it is sometimes confused, MDF cuts well and
has a smooth surface that is ideal for painting (source MDF).
There are a number of reasons why MDF may be used instead of plywood or chipboard. It is dense, flat,
stiff, has no knots and is easily machined. Because it is made up of fine particles it does not have an
easily recognizable surface grain. MDF can be painted to produce a smooth quality surface. Because
MDF has no grain it can be cut, drilled, machined and filed without damaging the surface. It may be also
dowelled together and traditional woodwork joints may even be cut. MDF may be glued together with
PVA wood glue. Oil, water-based paints and varnishes may be used on it. Veneers and laminates may
also be used to finish MDF.

However, MDF can be dangerous to use if the correct safety precautions are not taken. It contains a
substance called urea formaldehyde, which may be released from the material through cutting and
sanding. Urea formaldehyde may cause irritation to the eyes and lungs. Proper ventilation is required
when using it and facemasks are needed when sanding or cutting MDF with machinery. The dust
produced when machining MDF is very dangerous. Masks and goggles should always be worn at all
times. Due to the fact that MDF contains a great deal of glue the cutting edges of your tools will blunt
very quickly. MDF can be fixed together with screws and nails but the material may split if care is not
taken. If you are screwing, the screws should not be any further than 25mm in from the edge. When
using screws always use pilot holes. Urea formaldehyde is always being slowly released from the
surface of MDF. When painting it is good idea to coat the whole of the product in order to seal in the
urea formaldehyde. Wax and oil finishes may be used as finishes but they are less effective at sealing in
the urea formaldehyde
It may be used to make display cabinets, wall-panels and storage units (source: advantages and
disadvanteges of MDF).

Project interpretation
(Raw and final component tables with references to type, dimensions, raw materials and other aspects
that influence initial planning. Program production order e fabrication orders preparation).
In the beginning we received a piece of paper with the product picture (what we should built), in this
case it was manufacturing transport car. At the back of the paper there were listed
first dimensions. You can see them underneath.
Picture 5 Picture of the manufacturing transport car Rackart

Picture 6 The back of the manufacturing transport car with the first given dimensions

Picture 7 The front of the manufacturing transport car with the first given dimensions

Picture 8 The side look of the manufacturing transport car

Picture 9 The seperator look of the manufacturing transport car as some important notes
After we got this information, we were told that we had to make some changes on dimensions. Some of
them you can see in our upper listed pictures, where we crossed the previous dimensions with the new
ones.
So we started to interpretate the given project. First of all we made the table with needed component
types, regarding the raw material we will use for them, as the (new) dimensions for each component
and their quantity needed to build the transport car. You can see the table underneeth.
Table 1 Pine wood components needed
Quantity Component type Raw material Dimension (L x W x T)
3 Stile Pine wood 1065 x 80 x 38
6 Rail “ 530 x 80 x 38
3 Connecting rail (big) “ 247.6 x 80 x 38
3 Connecting rail (small) “ 159.5 x 80 x 38
1 Fixed stopper “ 1300 x 80 x 22

Table 2 MDF components needed
Quantity Component type Raw material Dimension (L x W x T)
1 Base MDF 1300 x 800 x 25
4 Separator “ 726 x 230 x 12
1 Front “ 1300 x 456 x 19
1 Back “ 1300 x 913 x 19
2 Shelf “ 1300 x W x 19

Techniques and technologies used as the Fabrication sequence
(References to applied construction techniques, industrial equipment and related technologies and
tools, focusing on features and applications. Reference to the sequence of operations that defines the
layout circuit with indication of the machines and / or equipment used at each stage of manufacture).
Moving further, we also had to think about connecting techniques for the components. We made
another table to plan our production to manufacture the transport car. Here comes the time where we
had to choose different kind of joinary techniques, they dimensions etc. Here we decided to choose:
Mortise and tenon joint technique; Dowel joint technique; Biscuit joint technique and we also desided
to use some screws. You can see all this information in out table nr 3 underneeth.
Table 3 Content types , tools and dimensions
Nr. Conectings between the Tools Dimensions DBD Dimension

content types (mm) (distance inside the
between hole
tools)
1. Fixed stopper + Base 8 dowels 10x50 160 15/35
2. Stiles + Base 1 tenon (LxWxT)

18x60x15
3. Back of the box + Base 6 screws
4. Seperator + Base 3 dowels 8x40 64 20/20
5. Front of the box + Base 8 dowels 8x40 160 18/22
6. Conecting raile + Stile 1 tenon 25x60x15
7. Conecting rails + The 2 screws

back of the box
8. Shelf + Conetcing rail Biscuit joints (2

on big, 1 on
small)
9. Front of the box + 4 dowels 8x40 96 14/26
Seperator
10. Seperator + The back of 5 biscuit joints 150

the box

11. Rail + Stile 2 dowels 10x50 32
As we planned what the way we will connect the components, and the joinery techniques we will use
for it, we noticed, that we had some extra planning to do for some joineries. It happened to be that
some of our joinery techniques should be done on the right needed angle. In this case, we had to do
some drawings using AutoCad program. We also had to plan the base correctly. You can see the
drawings underneath.
Picture 10 Measurments for needed joinary angle cutting

Picture 11 Plan of the base
As the first phase was finished, the interpretation of the project (measurements and component types
as the picked raw materials) and picked techniques of connecting components with each other (with
joints and screws), we started to plan what kind of systems we will use (which is framed and unframed),
the machines, technologies and tools (fabrication order) we would have to use to prepare the
specimens.
Let’s start with the framed system.
To prepare our specimens first of all we had to make a perpendicular cut of the pine wood in the
‘’Radial saw’’. In our manufacture this machine stands for number 12. After this, we made the
longitudinal cut in the ‘’Band saw’’, which is placed in manufacture as a number 3. The next step we
made, was planning two surfaces in the ‘’Surface planner’’, a machine used in making joints, which is
placed in manufacture as a number 4. As we planned the surface, we also had to plan a thickness of the
two surfaces on the ‘’Planner thicknesser’’, which is placed in manufacture as a number 5.
It is important to mention, that you have to plan the cutting of the wood correctly, because with every
use of the machine you would have to take out some centimetres away from the specimens. It means
you can’t use the final dimensions of the specimens from the beginning and leave it only for the final
step/ cut. Before planning the surfaces we were using bigger dimensions than we needed, as moving

further to each machine we were taking out a bit from them to reach needed dimensions. This way we
secured our job from any mistakes.
The next procedure we made was the length cut on the ‘’Panel saw’’, which is placed in manufacture as
a number 26. Then, we had to prepare mortise and tenon joint on “Single end tenoner”, which is placed
in manufacture as a number 9. We cut the pieces until the dimension that is needed to fit in the mortise
hole. The next procedure was holes drilling in the “Horizontal boring machine”, which is placed in
manufacture as a number 7. We had to bore holes in a horizontal direction with a needed dimension.
The last procedure we had to do was modifying the final dimensions of the pieces with the “Arm Radial
Saw”, which is placed in manufacture as a number 15.
Let’s move further with unframed system (MDF) sequence.
We started to prepare our unframed specimens from making the cuts that is needed for next
operations; we made it on the “Pannel saw”, which is placed in manufacture as a number 26. After, we
went to the “CNC machine”, which is placed in manufacture as a number 29. Here we had to insert the
necessary dimensions into the machine, for it to perform automatically steps like: making the holes
with a right depth and the right distance between each of the holes.
The last procedure was mounting the final product. This process was done on “Workbenches (big)”,
which is placed in manufacture as a number 24. At this stage we merged wood framed constructions
with wood unframed constructions and we got the final result.

Report deviations
(In case of occurrence, report deviations from the project and respective justifications).
As in any work, it is impossible not to make any changes during the preparation, especially when some
errors appear in the middle of the work. This project was not any different. As we were told some
errors occurred in the middle: it was needed to change the mortise and tenon dimensions (panels are
not the same as it was listed in the beginning, instead of width being 80 it was changed to be the same
width as the piece, it was easier way to fix the problem); as in the beginning we had to make fabrication
for 3 pieces, but instead we managed to finish only 2 of them etc.

Record production times by operation or task

Unframed system production timing: 3 hours and 24 minutes.
To cut the ‘’base’’ with panel saw machine it took- 12 minutes.

To cut the ‘’front’’ with panel saw machine it took- 17 minutes.
To cut the ‘’back’’ with panel saw machine was done in 2 times (first – 14 min., second – 5 min.), overall
-19 minutes.
To cut the ‘’separator’’ with panel saw it took- 8 minutes.
To drill the ‘’base’’ with CNC machine it took- 15 minutes.
To drill the ‘’separator’’ with a CNC machine it took- 26 minutes.
To drill the ‘’back’’ with CNC machine it took- 8 minutes.
To drill the ‘’front’’ with CNC machine it took- 5 minutes.
To mill the’’ back’’ with biscuit joint machine took- 35 minutes.
To mill the’’ separator’’ with biscuit joint machine took- 19 minutes.
To mount the box (base, separator, front, back) it took- 40 minutes.
To produce unframed system overall took 3 hours and 24 minutes.
Framed system production timing: 7 hours and 9 minutes
To select the wood it took-18 minutes.

To make the transversal cut (raw slabs cut) on radial saw was made in two times (first – 9 min., second
– 5 min), overall it took- 14 minutes.
To make the longitudinal cut on the band saw took- 35 minutes.
Surfaces planning (pieces) with the surface planner was made in two times (first – 9 min., second – 13
min.), overall- 22 minutes.
Thicknessing the pieces with planner thicknesser was made in three times (first – 2 min., second – 2
min., third – 18 min.), overall- 22 minutes.
To make the cut for ‘’fixed stopper’’ with panel saw took- 4 minutes.
To make the cut for ‘’stile’’ with panel saw took- 4 minutes.
To make the cut for ‘’rail’’ with panel saw took- 5 minutes.
To make the cut for ‘’connecting rail (big)’’ with panel saw was made in 3 times (first – 5 min., second –
7 min., third – 5 min.), overall- 17 minutes.
To make the cut for ‘’connecting rail (small)’’ with panel saw was made in 3 times (first – 4 min., second
– 7 min., third – 6 min.), overall- 17 minutes.
To make the’’ tenon’’ with a single end tenoner took- 59 minutes.
To drill the ‘’rail’’ with horizontal driller was made in two times (first – 25 min., second – 30 min.),
overall- 55 minutes.
To drill the’’ stile’’ with horizontal driller was made in two times (first – 16 min., second – 10 min.),
To drill the ‘’stile (left)’’ with horizontal driller was made in two times (first – 6 min., second – 4 min.),
To drill the ‘’stile (right)’’ with horizontal driller was made in two times (first – 10 min., second – 4 min.),
To drill the ‘’stile (central)’’ with horizontal driller was made in two times (first – 12 min., second – 5
min.), overall- 17 minutes.
To cut the hole for tenon with a radial saw took- 23 minutes.
To cut the hole for dowels with a radial saw took- 16 minutes.
To mount two frames (incomplete) it took- 50 minutes (two stiles plus three rails).
To produce framed sy stem overall took 7 hours and 9 minutes, as there was more
operations to be done then in unframed system.

Conclusions
To prepare that kind of furniture (or any other) it is important to plan all your process before. It
includes: choosing the raw materials which you will use in your product; to separate the product into
needed components to make the product (write the dimensions for each component); think of what
kind of joint techniques (tools) you will need to use, including the dimension for each technique, the
distance between each of them, the depth of the joint techniques or screws and angles, as think what
you would have to connect between each other regarding the components; what kind of system you
will use (framed or unframed); what kind of the machines you will use as think of the sequence of them.
You would also have to notice, that it is always better to make some extra pieces while using the
machines, in case something will go wrong. It will save your time as secure your work. Also if you will
use framed system you have to know that it always takes more time to do it in comparison with
unframed system, as for framed system there is more operations to be done.

Bibliography
1. Furniture carts: https://furniturecart.wordpress.com/2016/01/21/what-are-composite-
engineered-wood-products-and-replicated-wood-grain/
2. Solid wood deffinition: https://kitchencabinetkings.com/glossary/solid-wood/
3. Solid wood: https://www.woodmeister.com/solid-wood-vs-mdf-whats-the-story
4. Furniture joints: https://www.thespruce.com/wood-joinery-types-3536631
5. Srew: https://en.wikipedia.org/wiki/Screw
6. Pine wood: http://www.musterkiste.com/en/holz/pro/1029_Pine.html
7. MDF: https://www.thespruce.com/what-is-mdf-1398198
8. Advantages and disadvantages of MDF: http://www.design-technology.org/mdf.htm

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Polytechnic Institute of Viseu

School of Technology and Management of Viseu

Manufacturing furniture in a simulated

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Picture 1 Dowel joint

Picture 2 Mortise and Tenon joint

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Picture 3 Biscuit joint

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Material and Methods

Short description about Pine wood

Short description about MDF

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Picture 5 Picture of the manufacturing transport car Rackart

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Picture 8 The side look of the manufacturing transport car

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Table 1 Pine wood components needed

Quantity Component type Raw material Dimension (L x W x T)

3 Stile Pine wood 1065 x 80 x 38

3 Connecting rail (big) “ 247.6 x 80 x 38

3 Connecting rail (small) “ 159.5 x 80 x 38

1 Fixed stopper “ 1300 x 80 x 22

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Quantity Component type Raw material Dimension (L x W x T)

1 Base MDF 1300 x 800 x 25

4 Separator “ 726 x 230 x 12

1 Front “ 1300 x 456 x 19

1 Back “ 1300 x 913 x 19

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Techniques and technologies used as the Fabrication sequence

Table 3 Content types , tools and dimensions

Nr. Conectings between the Tools Dimensions DBD Dimension

2. Stiles + Base 1 tenon (LxWxT)

4. Seperator + Base 3 dowels 8x40 64 20/20

5. Front of the box + Base 8 dowels 8x40 160 18/22

6. Conecting raile + Stile 1 tenon 25x60x15

7. Conecting rails + The 2 screws

8. Shelf + Conetcing rail Biscuit joints (2

10. Seperator + The back of 5 biscuit joints 150

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

11. Rail + Stile 2 dowels 10x50 32

Picture 10 Measurments for needed joinary angle cutting

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Picture 11 Plan of the base

Let’s start with the framed system.

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Let’s move further with unframed system (MDF) sequence.

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

Record production times by operation or task

To cut the ‘’base’’ with panel saw machine it took- 12 minutes.

To produce unframed system overall took 3 hours and 24 minutes.

Framed system production timing: 7 hours and 9 minutes

To select the wood it took-18 minutes.

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

YEAR 2017/2018 | 2nd YEAR – 1st SEMESTER

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