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  1. #1
    Join Date
    Mar 2011
    Location
    Adelaide
    Posts
    59

    Default Blackwood Platter Incident

    Last Thursday I had an incident turning a large diameter platter I thought it would be worth detailing what happened.

    In November I recieved a commission to turn a blackwood platter around 1050mm diameter x 45mm thick. I have turned 5 similar sized platters before without any dramas.

    I client ideally wanted the platter before Christmas so in mid December I purchased the timber (150x50mm kiln dried and in the yard for around 25 years with no visible defects once dressed).

    I laminated the boards with megapoxy and then glued on a block of beech to give me something to screw the faceplate onto.

    This is were the first problem may have occured...it was a warm day and the epoxy I used on the beech mount was beginning to go off. This mean that when I applied weight to it (about 30kg sat on top, since I couldn't get a clamp on it) the setting epoxy prevented a tight bond between the timbers, staying as a 2mm layer between the blackwood and beech.

    I didn't think anything of it since I have used weights to 'clamp' blocks with epoxy many times before and it has always held; if anything the wood breaks before the epoxy bond.

    Anyhow, I mounted it on the lathe the next day and turned the back. The beech mount performed without a problem, despite heavy roughing cuts. I left it on the lathe over night and came back the next afternoon to find a 50mm split in one of the boards. I attributed this to the heat in the workshop (it was high 30's, low 40's in Adelaide leading up to Christmas and dry as usual). With the delay that this would cause (cutting out the split and re glueing) I decided I wouldn't get it done in time for Christmas and put it away in the cooler office area.

    I returned in the new year to find that the split had grown and the platter had also bowed.

    I was able to cut out 4mm of the platter to remove the split. I then made an incredibly effective clamping jig to re-glue the 2 halves (I didn't take any photos but probably should have and then posted them on here). But I think clamping the already bowed platter may have put strain on the laminated block, weakening the epoxy bond; almost 'popping' it off in effect.

    Anyhow, visually it seemed fine and I didn't even think what I'd done would be a problem. I remounted the platter on the lathe and began facing it to get rid of the bow. To do this I was using the carriage rather than doing it by hand (because I can! also, you can take very controlled, light passes and it ends up dead straight).

    Well within 5 mins of starting, the mount let go and the platter was splintered across the workshop. One second I was winding the carriage across the face, the next second there was a loud bang, the platter was gone and big splinters were falling on the top of my faceshield. I heard my colleague swear and run down the other end of the workshop. the platter ploughed into a large fabricated galv box next to the lathe and sheared into numerous pieces; the largest of which fractured and knocked over a piece of 3"x1" queensland maple I had leaning against my timber rack and continued to cartwheel a further 17m through the air before hitting the back wall of the workshop, bouncing off and landing on the mezzanine.

    See the attached photos and the explanation to the chain of events in the following few seconds:

    a-the offending faceplate mount that "let go" of the platter
    b-the distance from the lathe to the fabricated galv box
    c-the dent where the platter first hit the galv box (about 2in deep, right on the corner)
    d-the dent in the platter from the galv box
    e-the platter re assembled showing how after hitting the box it sheared into numerous large splinters that exploded in all directions
    f-a detail of the damage
    g-the largest fragment (around 3-5kg maybe) which another colleague saw cartwheeling through the air and hit the back wall above the mezzanine
    h-the fractured queensland maple (around 2.5m from the lathe)
    i-the view from the lathe up to the mezzanine where the largest fragment landed
    j-showing the distance from the lathe (bottom right) to the mezzanine (top left)

    Needless to say, it was lucky no one was hurt. I have no doubt that if I had been in the way I would likely be dead or at least have broken something, depending on where it hit.

    The lathe was spinning at 716 rpm. Obviously the surface speed on the outside of a 1m platter is fast and it has significant momentum but I would have never expected it to dent the box like it did, shear in pieces, snap a plank of wood (rather than just knock it over) and continue to fly 17m through the air only to be stopped by a brick wall. From what my mate saw, it was not at the end of its trajectory either!

    So, attributing factors:

    pour exoxy bond
    anbient temperature (causing bowing and possible effecting the epoxy???)
    re-clamping bowed platter straining epoxy bond

    I did have screws penetrating throught the epoxy and into the platter but only about 8mm as I couln't afford to loose too much blackwood trying to get rid of screw holes (in the end I lost aroun $450 of blackwood!)

    I have no doubt that epoxy is strong enough alone to hold such a platter as I have used it numerous times in this sort of application.

    Anyway, I'm not wanting to turn people off large diameter turning. It can be dangerous, don't get complacent (where all the safety gear just in case, stand clear as much as possible) and be aware of the forces involved. If you agree with the attributing factors I have listed, don't make the same mistakes.

    I look forward to your comments.

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  3. #2
    Join Date
    Feb 2008
    Location
    N.S.
    Posts
    252

    Default

    A rough mental calculation indicates that the speed of the outer rim of the plate was around 7000 FPM using your original dimension of 1050 dia. That seems fast unless that is a hard, dense wood. Any catch at all could be dangerous.
    It is great that no one was hurt.

  4. #3
    Join Date
    Feb 2009
    Location
    Bristol, UK
    Age
    66
    Posts
    1,540

    Default

    A very worthwhile tale, well told. It's these learning experiences that make the forums more useful than just asking Q's and getting answers.

    Someone once said 'Don't trust to luck, rely on it.'

    I think you need to allow a little time for your 'Luck' quotient to build up again!

    Just glad that you and everyone else in the building came out unscathed.
    Dragonfly
    No-one suspects the dragonfly!

  5. #4
    Join Date
    Aug 2008
    Location
    Normanhurst NSW 2076
    Age
    81
    Posts
    484

    Default

    Hello HSS,
    I tend toturn big bowls/platters and I appreciate your information. I have found (from experience) that turning at a slower speed until the block is in balance is the preferred safety position. I turn at about 350 - so at 250mm it is 3500 rpms, 500 - 7000. I tend to use a large glue chuck on the outboard or if inboard I use that chuck and bring up the tailstock for added support. To reverse I use the glue chuck, several sizes and attach to the turned foot etc. Having said all of that, sometimes wood factors come into play and maybe that was what happened in your case. I might add that for the glue chuck I use a good thick smear of hot glue on a heated chuck and then snap if cold with a frozen lump of steel that I keep in the old frig. The glue chuck is simply a large round of aluminium (130mm) tapped out and threaded to fit the spindle thread. Works very well with a packer to aid easier removal. Hope this helps a little. Please take my comments as constructive. Regards, John M.

  6. #5
    Join Date
    Jan 2010
    Location
    Melbourne
    Posts
    2,636

    Default

    What would of been more effective in your narrative would be a description of your feelings. Because as I read this I felt sick and nearly lost control of my bowels. Thanks for sharing though, your disclosure of this situation has made me think a litle harder on how I should be doing this kind of work at the lathe.
    -Scott

  7. #6
    Join Date
    Oct 2004
    Location
    Oakleigh East, Sunny Vic
    Posts
    656

    Default

    Wow!
    I bet that had your heart thumping!
    Cheers,
    Steck

  8. #7
    Join Date
    Apr 2007
    Location
    Adelaide Hills, South Australia
    Posts
    4,332

    Default

    Thanks for sharing this with us HSS.

    We all need to learn from these incidents and a post event analysis shared with everyone is an invaluable contribution to our collective well being.

    I have only ever had one 'projectile' off the lathe. A gum vein parted letting a slice come off the the side of a deep bowl. I eventually found the shard up in the rafters with razor sharp edges that had done some damage on the way. Fortunately it missed me as I think it would have sliced through my face shield had it hit it. Lesson for me: Never use a blank with gum veins, there is enough other wood in the world to see me out.

    I share the above because the slice coming off the side of the blank was slung away at very high speed, whereas intact blanks that come off tend to drop slowly while they continue to spin and only get going when they hit the deck.

    There was probably still enough spin in the blank when it hit the galvo box and split up for the centrifugal forces to take over and fling the shards away as they did. Had the blank begun to split up as it left the chuck block that would also explain the projection distances.

    What a relief that you have come out of the incidence unscathed (except the $s) and the wiser for it, John.
    Stay sharp and stay safe!

    Neil



  9. #8
    Join Date
    Jan 2002
    Location
    Melbourne, Aus.
    Age
    71
    Posts
    12,746

    Default

    Blackwood is one of those timbers that move in the heat and maybe you got some minor internal checking. A bit of platter flex, high speed and too deep a cut for the circumstances?

    Also, kiln-dried timbers appear to be more brittle than air-dried as far as I know.

    The splintering of the wood in the pics might hold the answer, at least if that's how they were before the ricochets.

    Good to see the Sapporo tonic in the pic.

    Live to fight another day. Maybe get a motorbike helmet and chest armour ;-)
    Cheers, Ern

  10. #9
    Join Date
    Jan 2012
    Location
    algeria
    Posts
    9

    Default

    it's very dangerous

  11. #10
    Join Date
    Jan 2012
    Location
    Toowoomba QLD
    Posts
    62

    Default

    Lucky escape buddy!!
    Does anyone know if there is a certain grade of perspex we should use in our face shields to protect against this type of thing??

    This has only ever happened to me on smaller stuff, although my heart races for few minutes after!!!

  12. #11
    Join Date
    Jan 2010
    Location
    Melbourne
    Posts
    2,636

    Default

    Quote Originally Posted by Dez Built View Post
    Lucky escape buddy!!
    Does anyone know if there is a certain grade of perspex we should use in our face shields to protect against this type of thing??

    This has only ever happened to me on smaller stuff, although my heart races for few minutes after!!!
    You wouldn't want to use perspex, it'll shatter and slice your face. Polycarbonate is what you should be using, it's actually what they use for bullet proof glass.
    -Scott

  13. #12
    Join Date
    Apr 2007
    Location
    Adelaide Hills, South Australia
    Posts
    4,332

    Default

    As sjt said, Polycarbonate is what you need and make sure it is marked High Impact according to the AS/NZS 1337 Standard.
    Stay sharp and stay safe!

    Neil



  14. #13
    Join Date
    Aug 2011
    Location
    bilpin
    Posts
    3,559

    Default

    When a timber platter becomes a flying saucer!
    One of the good things in life is to be blessed with a great mentor. As an apprentice I was so endowed.
    Some 42 years later I still often hear his voice in the back of my head as I undertake yet another brainstrainer. A favourite of his was "wood talks to you" or "the wood will show you." We young fellas thought he had lost the plot. With time, I have come to understand what he meant. Once, we were visiting a mill, his comment to me was, "That saw doesnt sound happy." Next thing the blade disintergrated, with a large piece embedding itself into a post close to where we were standing. On another occasion, I had set up a large piece of forrest red gum on the lathe to turn a large wheel hub.
    Old Ron came over and said," What did it say?" I said, "I dont know, it was too big and heavy to listen." He said, "The wood has spoken.....Start it slowly."

  15. #14
    Join Date
    Jun 2007
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    North Of The Boarder
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    68
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    16,794

    Default

    Good to know you and others were not injured.

    A darn good write up and timely warning for all turners regardless of size. I'll be reviewing this often as a reminder.

    Rusty Nail Old blokes know they have learnt or being taught well themselves. One such fellow with me always said "Follow your gut instincts, if in doubt DON'T"

  16. #15
    Join Date
    Nov 2005
    Location
    West Gippsland, Vic
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    72
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    4,608

    Default

    Quote Originally Posted by rsser View Post
    Blackwood is one of those timbers that move in the heat ...
    Which is why I use it for firewood....it's only glorified wattle after all..
    If you never made a mistake, you never made anything!


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