Operating Rules and Procedures Part Two

LATHE OPERATION:

1. CHECKLIST: a) Before applying power to the lathe, turn the spindle (by the chuck or collet holder) enough to see if the gears are fully meshed. Also do this any time you shift gears. This will also help tell you if the chuck is screwed on tight. b) Check that the key has not been left in the chuck. If the key is in the chuck, you should be holding it – never leave it there. c) Is the power feed engaged? Disengage it before starting the lathe. If the feed handles won’t turn easily by hand, it is either because the power feed is on, or a brake is on. d) Do the gearboxes have enough oil? Check the oil level sight gauges; if low, contact the shop supervisor. e) The chuck is heavy! When changing the chuck, put a piece of plywood underneath to protect the machine if you drop the chuck. For your safety, get help. Fingers have been broken changing chucks.

f) When done, clean off ALL (note this says ALL, not some) chips and excess oil from the lathe and the surrounding floor when you finish machining. Plan to spend 10 to 15 minutes cleaning up; look for hiding spots where chips might accumulate; move the crossfeed and carriage handles to reveal more hidden chips. Pick up larger turnings by hand or broom, then use the vacuum cleaner and the paint brush. Use compressed air only if nothing else works, and don’t aim the chips towards machine bearing surfaces, sensors, or people.

8. LATHE RULES: b. Never have the chuck key in chuck if your hand is not on the key. c. When changing speed settings, make sure you turn the lathe spindle by hand to make sure the gears mesh before turning on the machine. Ask for assistance if you do not understand this rule. d. Do not put your hand on the chuck to slow it down. e. If you hear any squeaking or if the tool is deflecting largely while cutting, something is wrong. Ask for help if you are not sure what is wrong. f. Clean up:

9. MILL RULES: a. Make sure all table and spindle locks are released if you feel any resistance to table or spindle motion. b. Do not over tighten the draw bar. Tightening the draw bar 15 degrees after you feel resistance is enough. c. Be careful not to drill into the mill vise, table, or parallel bars. Make sure there is clearance for the drill or mill bit to pass through your work piece without running into these surfaces. d. If using a mill without dial speed changing you have to change the belts by hand. The belt must remain horizontal - do not cross the belt. Ask for assistance if you do not understand this rule. e. If using a mill with dial speed changing, change speeds only while the machine is running. Note that when going between low/high gear the machine must be stopped. f. When shifting from low to high speed settings, make sure you turn the spindle by hand to make sure the gears mesh before turning on the machine. Ask for assistance if you do not understand this rule. g. If you hear any squeaking or if the tool/part is deflecting largely while cutting, something is wrong. Ask for help if you are not sure what is wrong. h. Clean up: - The following pertains to the mill table, table slots, mill ways, vises, mill base, and the floor. ~ remove all chips ~ wipe up all excess cutting fluid - Use small brushes found in the tool box and rags to facilitate the cleaning process.

SHOP SAFETY

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Shop safety is NOT something to be studied at the start of a training program and then forgotten; most accidents are caused by carelessness or by breaking safety rules. Remember this when your instructor insists on safe work practices. If you are DILIGENT and follow instructions with care, machining operations can be safe and enjoyable. Safe work practices, should become a force of habit!

Study all safety rules carefully and constantly apply them. When in doubt about any task, get help! DO NOT take chances!

SAFETY FOR THE SHOP

Keep the shop clean. Metal scraps should be placed in the scrap bin. Never allow them to remain on the bench or floor. Exercise extreme care when machining unfamiliar materials. For example, magnesium chips burn with great intensity under certain conditions.

Inhaling fumes or dust from some of the newer space age and exotic materials can cause serious respiratory ailments.

The shop is a place to work, not play. It is NOT a place for "horseplay". A "joker" in a machine shop is a "walking hazard" to everyone. Daydreaming also increases your chances of injury.

Secure help when moving heavy machine accessories or large pieces of metal stock. Back injuries are usually long term injuries!

Dress properly. Avoid wearing loose fitting sweaters or clothing. Rings and other jewelry should be removed.

Wear appropriate safety gear. In noisy areas, use a hearing protector. disposable plastic gloves will protect your hands when handling oils, cutting fluids and solvents.

Always protect your eyes. Eyesight that has been damaged or destroyed cannot be replaced. It is good practice to have your own personal safety glasses.

Take no chances! Wear eye protection whenever you are in the shop.

Know your job! It is foolish, and often disastrous, to operate machines without first receiving proper instructions. Get additional help if you are NOT sure what must be done or how a task should be performed.

GENERAL MACHINE SAFETY

Avoid operating a machine until all guards are in place! Stop your machine to make adjustments or measurements! Resist the urge to touch a surface that has been machined while the machine is running. Severe lacerations can result. Keep the floor around your machine clear of oil, chips and metal scraps. It is NOT considered good practice to talk to anyone while you are operating a machine. You might become distracted and injure yourself, or someone else. NEVER attempt to remove chips or cuttings with your hands or while the machine is operating. Use a brush. Secure prompt medical attention for any cut, bruise, scratch, burn or other injury. No matter how minor the injury may appear, report it to your instructor. IN CASE OF FIRE! Know what to do in case of a fire! Be familiar with the location of fire exits and how they are opened. Be aware of alternate escape routes. SPECIAL SAFETY NOTE: Think before acting! It costs nothing and you may be saved from painful injury that could result in a permanent disability.

Hand threading safety

If a tap or threaded piece must be cleaned of chips with compressed air, protect your eyes from flying chips by wearing goggles. Take care NOT to endanger persons working in the area near you! Chips produced by hand threading are sharp. Use a brush or piece of cloth, NOT your hand, to remove them! Newly cut external threads are very sharp. Again, use a brush or cloth to clean them. Wash your hands after using cutting fluids or oils! Some cause skin rash. This can develop into a serious skin disorder if the oils are left on hands for extended periods. Have cuts treated by a qualified person. Infections can occur when cuts and other injuries are NOT properly treated. DRILLS SAFETY NOTE! NEVER attempt to operate a drilling machine while your senses are impaired by medication or other substances.

DANGER! Always remove the key from the chuck before turning on the drill press. It could hit something or fly out with considerable force.

DANGER! Serious injury can result from work that becomes loose and spins about on a drill press or milling machine. This dangerous situation is nicknamed a "merry-go- round".

DANGER! NEVER insert a tap into the drill chuck and attempt to use drill press POWER to run the tap into the work. The tap will shatter when power is applied. Turn the tap by hand!

DRILL PRESS AND MILLING SAFETY

Remove neckties and tuck in loose clothing so there is no chance of them becoming entangled in the rotating drill! Check out the machine! Are all guards in place? Do switches work? Does the machine operate properly? Are the tools sharpened for the material being worked? Clamp the work solidly. Do NOT hold work with your hand. A "merry-go-round" can inflict serious and painful injuries. Wear goggles! Place a piece of wood under drills being removed from the machine. Small drills can be damaged when dropped and the larger tools can injure you if dropped. Use sharp tools Clean chips from the work with a brush, NOT your hands! Treat cuts and scratches immediately! Always remove the key from the chuck BEFORE turning on the power. Let the drill spindle stop on its own after turning off the power. Do NOT attempt to stop it with your hand! Keep the work area clear of chips. Wipe up all cutting fluid that spills on the floor right away. Avoid trying to clean the tapered opening in the spindle while it is rotating. After using a drill, wipe it clean of chips and cutting fluid. Replace the tool to proper storage.

WARNING! Never activate rapid traverse with the cutter in a cut.

DANGER! Make sure the machine has come to a complete stop before attempting to adjust V-belts.

CHIPS are RAZOR SHARP; do NOT use your hands to remove them. NEVER remove chips with compressed air. The flying chips may injure you or a nearby person.

If cutting oil was used, the oily mist produced by the compressed air is highly flammable. If ignited by an open flame, it can produce explosive results. Finish by wiping down the machine with a soft cloth.

The following procedures are suggested for the safe operation of a milling machine.

Become thoroughly familiar with the milling machine before attempting to operate it. When in doubt, obtain additional instructions. Wear appropriate clothing and approved safety glasses! Stop the machine before attempting to make adjustments or measurements! Get help to move any heavy machine attachment, such as a vise, dividing head, rotary table or large work. Stop the machine before trying to -remove accumulated chips. Never reach over or near a rotating cutter! Be sure the work holding device is mounted solidly to the table, and the work is held firmly. Spring or vibration in the work can cause thin cutters to jam and shatter! Avoid talking with anyone while operating a machine tool, nor allow anyone to turn your machine on for you. Keep the floor around your machine clear of chips and wipe up spilled cutting fluid immediately! Be thoroughly familiar with the placement of the machine's STOP switch or lever. Treat any small cuts and skin punctures as potential infections! Clean them thoroughly. Apply antiseptic and cover injury with a bandage. Report any injury, no matter how minor, to your instructor or supervisor. Never "fool around" when operating a milling machine! Keep your mind on the job and be ready for any emergency! Be sure all power to the machine is turned off before opening or removing guards and covers.

DANGER! Stop the machine before attempting to make measurements.

PRECAUTIONS WHEN OPERATING A MILLING MACHINE

Avoid performing a machining operation on the milling machine until you are thoroughly familiar with how it should be done. Some materials that are machined produce chips, dust and fumes that are dangerous to your health. NEVER machine materials that contain asbestos, Fiberglass, beryllium and beryllium copper unless you are fully aware of the precautions that must be taken. Maintain cutting fluids properly. Be sure the cutter rotates in the proper direction. Expensive cutters can be quickly ruined. Carefully store milling cutters, arbors, collets, adapters, etc., after use. They can be damaged if not stored properly. Never start a cut until you are sure there is adequate clearance on all moving parts!

LATHE SAFETY

WARNING! Lathe chips are sharp; do NOT remove them with your hands.

DANGER! An air hose should NEVER be used to remove chips. The flying particles might injure you or a nearby person.

No attempt should be made to operate a lathe until you know the proper procedures and have been checked out on its safe operation by your instructor. Dress appropriately! Remove necktie, necklace, wrist watch, rings and other jewelry, and loose fitting sweaters. Wear an apron or a properly fitted shop coat. Safety glasses are a must! Clamp all work solidly! Use the correct size toot and work holding device for the job. Get help when handling large sections of metal and heavy chucks and attachments. Check work frequently when it is being machined between centers. The work expands as it heats up and could damage the tailstock center. Be sure all guards are in place before attempting to operate the machine. Turn the faceplate or chuck by hand to be sure there is NO binding or danger of the work striking any part of the lathe. Keep the machine clear of tools! Stop the machine before making measurements and adjustments. Remember--chips are sharp! Do NOT try to remove them with your hands when they become "stringy" and build up on the tool post. Stop the machine and remove them with pliers. Do NOT permit small diameter work to project too far from the chuck without support from the tailstock. Without support, the work will be tapered, or worse, spring, up over the cutting tool and/or break. Be careful NOT to run the cutting tool into the chuck. Check any readjustment of work or tool for ample clearance when the cutter has been moved left to the farthest point that will be machined. Stop the machine before attempting to wipe down, a machine surface. Before repositioning or removing work from the lathe, move the cutting tool clear of the work area. This will prevent accidental cuts from the cutter bit. Avoid talking to anyone while running a lathe! Do NOT permit anyone to fool around with the machine while you are operating it. You are the only one who should turn the machine on or off, or make adjustments to the lathe. If the lathe has a threaded spindle nose, never attempt to run the chuck on or off the spindle using power. It is also dangerous- practice to stop such a lathe by reversing the direction of rotation. The chuck could spin off and cause serious injury to you. There is also the danger of damaging the machine. You should always be aware of the direction of travel and speed of the carriage before engaging the half-nuts or automatic feed. Always remove the key from the chuck. Make it a habit NEVER to let go of the key until it is out of the chuck and clear of the work area. Tools must NOT be placed on the lathe ways. Use a tool board or place them on the lathe tray. When filing on the lathe, be sure the file has a securely fitting handle. Stop the machine immediately if some off sounding noise or vibration developsduring operation. If you cannot locate the trouble, get help from your instructor. Under no condition should the machine be operated until the trouble has been corrected. Remove sharp edges and burrs from work before removing it from the machine. Plan your work thoroughly before starting. Have all needed tools on hand. Use care when cleaning the lathe. Chips sometimes stick in recesses. Remove them with a brush or short stick. NEVER clean a machine tool with compressed air.

DANGER! Stop the machine before making measurements or cleaning out chips.

SAFETY NOTE! NEVER turn on the lathe until checking that you did NOT accidently leave the chuck key in the chuck.

NNSC Machine Shop Safety Rules 1 of 5 March 2000 ONLY TRAINED AND AUTHORIZED OPERATORS MAY OPERATE TOOLS and EQUIPMENT located in the NNSC Machine shop (room 241). Training may be formal (classroom, machinist union apprenticeship, etc.) or on-the-job, but it must be documented and it must include training on each piece of equipment to be used. Training documentation must be forwarded to Peter Ross prior to authorization being granted. KEY POINTS AND SUPPORTING INFORMATION 1. State of Mind. Do not operate power tools when you are ill, taking strong medications, fatigued or consuming alcoholic drinks. Do not smoke while working with tools. 2. Wear proper clothing for the type of work being done. Do not wear loose-fitting clothes or jewelry that can get caught in moving parts. Do not roll up long sleeves. Do not wear highly flammable clothes. Do not wear sandals, open-toed or canvas shoes. Wearing safety-toed shoes is preferable for protection of feet and toes. 3. Protect your eyes, face, head, and scalp. At a minimum, wear industrial-quality safety glasses with side shields. (Safety glasses must have the Z87.1 logo on them to assure they qualify as impact resistant.) Add a face shield or wear impact resistant goggles if flying particles are expected during the machining process. For welding wear eye and face protection appropriate for the kind of work being conducted. Pull back long hair in a band and tuck it under your shirt collar or a cap to keep it from getting caught in tools. 4. Avoid distractions. Keep your mind on your work. Talking or listening to the radio while running machinery can lead to accidents. Stop working and turn off the power tool you are working with if distracted by something or someone. Never look away from your work when operating a power tool. 5. Keep the work area clean. Keep the floor free of scraps and oil. Cluttered work areas invite accidents. Keeping workshop and storage spaces clean and dry can help prevent many accidents. Sparks can ignite scraps, sawdust and solvents. Water can conduct electricity. Do not stand in water, on damp floors or in the rain when working with electrical tools. Keep hands and tools dry. 6. Use the correct tools for the job. Do not use a tool or attachment for something it was not designed to do. Select the correct bit, cutter or grinding wheel for the material with which you are working. This saves time and improves the quality of work and reduces the risk of mishap. If necessary, consult the instructions or shop manual, or call a dealer or an expert on tool use. 7. Metal work. When working with metal, secure the metal materials with clamps or in a machinist's vise to keep it from moving. NNSC Machine Shop Safety Rules 2 of 5 March 2000 8. Work only at operating speed. Do not use a power tool before it has reached operating speed or while it is coming to a stop. Never force a tool by applying too much pressure. Let each tool work at its own speed without forcing it. Once a power tool has been turned off, allow it to coast to a stop. Never force an object into moving parts to stop a machine. 9. Keep tools clean and in good repair. Always clean up power tools before putting them away. Avoid using tools that are or appear to be in disrepair. Use power tools only for their intended functions. 10. Repairing and Cleaning Power Tools. Always turn off and unplug a power tool before (1) adjusting, oiling, cleaning or repairing it; (2) attaching an accessory; or (3) changing bits, blades or grinding wheels. Unplug or lockout tools when not in use. Unplug tools by pulling directly on the plug. Jerking on the cord can cause damage to the tool. Do not leave tools, hardware and other materials out when not in use. Before making adjustments or changing bits or cutters, disconnect the power cord to avoid accidentally touching the switch and possible injury when the tool starts. 11. Compressed Air Used for Cleaning. OSHA regulates the use of compressed air for cleaning in 29 CFR 1910.242(b) as follows: Þ Employees shall not use compressed air for cleaning themselves or their clothing. Þ The operator shall not direct compressed air at nearby employees. Þ Compressed air used for cleaning work areas, such as work benches, table saws, and drill presses, shall not exceed 30 psi at the outlet, statically or dynamically, and shall be permitted only with effective chip guarding or personal protective equipment (as described in section 1910.133) to protect the operator and other employees from flying debris. 12. Keep guards in place. Safety guards cannot protect you if they are not in place and in proper working order. 13. Do not leave a machine running unattended. Make sure all moving parts have come to a complete stop before you leave the work area or before you make minor adjustments. 14. Know the machine. Before using any tool, read the operator's manual, or comparable literature as available, to learn the applications, limitations, and potential of each power tool. Never use a tool unless trained to do so. Inspect it before each use and replace or repair if parts are worn or damaged. Repair tools only if you are trained to do so. Inspect screws, nuts, bolts and movable parts to make sure they are tightened. Make sure the cord will not become caught or tangled. The cord should be flexible, NNSC Machine Shop Safety Rules 3 of 5 March 2000 but not easy to knot. Clean the cord regularly and inspect the grounding connections. Use a ground fault circuit interrupter when working with power tools. 15. Know the switch location(s). Remember where the switch is located so you can turn off the machine quickly. 16. Use safe blades. Never use cracked or kinked saw blades. Keep saw blades sharp and properly set. 17. Ventilation. No welding, cutting or brazing may occur in the shop. Move equipment to the welding table located under the awning in the courtyard. Avoid operating power tools in locations where sparks could ignite flammable vapors. Keep the shop well ventilated and flammable materials properly stored. 18. Rags. Used rags, especially oily and greasy ones, should be kept in a covered, marked container. Rags should be a safe distance from the welder and other sources of ignition. 19. Hazardous materials. Take extra care when working with hazardous materials. Due to the extreme fire hazard, machining or grinding of magnesium is prohibited in the NNSC Machine Shop. Handle fiberglass with care. Its particles can irritate the skin, eyes and respiratory system. When soldering, remember that lead solder is toxic. The work area should be ventilated or you should wear the appropriate respirator if you have been properly trained to do so. 20. Fires. Shop fires can be any, or all, of three fire classes: Class A, ordinary combustibles; Class B, combustible liquids; and Class C, fires in live electrical equipment. To eliminate the need for extinguishers for all three classes, install at least one 20-pound ABC Class extinguisher in a convenient location, and possibly more, depending on the size of the shop. 21. Storage. Develop a system of racks, bins and tool panels to make it easy to find the right tool or materials quickly. Don't store tools, supplies or spare parts in the aisle or on the floor where they become tripping hazards. Keep other flammable materials away from heaters and welding areas to prevent fire. Grease, oil, paint and solvents should be stored in a closed metal container, preferably in metal cabinets. Gasoline or other fuels should never be stored inside the shop. Supplies and equipment should be stored in an area designed specifically for them. 22. Personal Tools. Personal power tools may not be brought from home for use in the NNSC machine shop. If having a personally owned power tool at work is required for a work-related project, then it should be used and stored in your lab. 23. Housekeeping. Each user is expected to clean up after him/herself. Good housekeeping helps ensure long tool life and a safer work area for everyone. NNSC Machine Shop Safety Rules 4 of 5 March 2000 Safety for Specific Power Tools Band Saws: Keep the saw blade set evenly and with the correct tension. Push the stock through the blade with your hands on both sides of the line of cut or, preferably, use a push bar designed for this purpose. Do not push with excessive force as this leads to slipping or to blade failure. If excessive force is required to cut, either the blade is dull and needs to be replaced, or the material is too hard for the saw. Excessive guard clearance can lead to serious accidents with the fingers losing! ALWAYS LOWER THE GUARD so that it just clears the work and return it to its lowest position when you have completed your cut. Grinders: Never operate a grinder without protecting your eyes with safety glasses, goggles, or a face shield. If the material being worked on will produce a lot of dust or other particles, you should wear a filtering face piece (dust mask) respirator. (NOTE: you must receive information from EH&S before using a dust mask for any reason.) Make sure the grinder has guard housing. Place the tool rest 1/8 from the wheel on bench-mounted units. Before starting a portable grinder, look to see where the sparks might fall. Clean the work area if necessary. When starting a grinder, stand to one side of the wheel and turn on the switch. Allow the wheel to reach full speed before stepping into the grinding position. Grind on the face of the wheel unless otherwise designed. Use a vise-grip pliers or clamp to hold small pieces. Move the workpiece slowly across the wheel face. Allow the wheel to stop naturally when turning it off. Periodically check for soundness of grinding wheels. If wheels are badly worn, cracked or out-of-round, lock the grinder out and contact Facilities for maintenance. Abrasive wheels should be stored hanging from a hook or in a vertical position to lessen the change of cracking that can occur from stacking horizontally. Note: Different abrasive wheels are manufactured for different metals/uses. Never grind soft metals on a wheel designed for hard metal grinding as the soft metal fines/dusts can become incorporated within the wheel resin, causing overheating and subsequent wheel disintegration. Be sure the abrasive wheel you are using is correct for the job. (Refer to the posted chart on how to read abrasive wheel markings.) Lathe: Before operation, lubricate the spindle bearings and the ways with the appropriate oil provided. Do not wear loose fitting clothing when operating the lathe. This lathe is equipped with a screw-type mount for the lathe chuck and faceplate. DO NOT run the lathe backwards under load, as the chuck will unscrew itself from the spindle. This is a tool room lathe, not a production lathe. Take light cuts and use low feed rates. Do not clear chips from the cutting tools with your fingers! Stop the machine before you attempt to clear chips wrapped around the tool or the work. NEVER, never let go of the chuck wrench, unless you have placed it back in the drawer. Do not ever take your hand off of this wrench when you are using it to tighten the chuck. A chuck wrench left in the chuck during start up of the lathe is disastrous to operator, bystanders and equipment. When you are through with the machine, put all tools back in the lathe cabinet and clean up all chips from the machine and floor. NEVER attempt to operate a lathe if you are unsure how to set up or how to mount your work in the machine. Milling Machine: Always wear safety glasses when using the milling machine. Before starting the machine, lubricate the machine ways with way oil. Use the lowest acceptable spindle speed and feed rate to get the job done. Always ensure that there is adequate clearance of the work to the vise and the milling machine table. DO NOT allow the cutters to touch the vise or the table. DO NOT use your fingers to clear chips from the work, the vise or the milling machine while the machine is running! NEVER attempt to operate a mill if you are unsure how to set up or how to mount your work in the machine. NNSC Machine Shop Safety Rules 5 of 5 March 2000 The following principles for personal safety relate to hand tools that are used most frequently for service work: Chisels and Punches. Wear eye protection when hammering on chisels and punches or on metal objects. The hardened face of a hammer, or the end of a tool, may chip or shatter to send metal fragments flying. Grind off the "mushroomed" heads. Keep a smooth bevel on the heads of all punches and chisels. Hold the tool steadily but loosely. The best place to hold it is just below the head. If you miss and strike your hand, it is much less likely to be caught between the hammer and the object being worked on. Files. A file without a handle can be extremely dangerous. Keep a handle on every file to prevent the tang from piercing the palm or wrist if the file should slip or catch. Wrenches. Wrenches are the cause of many cut and skinned knuckles. When possible, use the open palm of your hand to push on the wrench. When this is not possible, pull the wrench toward you. This may prevent the wrench from slipping to cut or skin your knuckles. Make sure that the wrench is the proper size for the bolt or nut. NOTE: Adjustable wrenches should only be used as a last resort because they tend to round off the bolt heads if not tightly adjusted. When using adjustable wrenches, keep the open jaw of the adjustable wrench facing toward you. This forces the movable jaw onto the nut to reduce its tendency to slip. It also prevents damage to the wrench. Hammers. Keep your hammers in good repair. Check the fit and condition of the handles. Keep handles tightly wedged into the heads to prevent injury to you and others nearby. Replace cracked or splintered handles. Select the right size hammer for the job. A light hammer bounces off the work. One that's too heavy is hard to control. Portable Grinders. Portable grinders and brushes are difficult to handle because of their size and weight. Extra care is needed to avoid injury and to protect the grinding wheel and brushes from damage. When using a portable grinder, hold it firmly with both hands. When finished, make sure that the grinder has completely stopped turning before you lay it down.

The Basic Rules

1. Never work alone. At least two adults must be in the shop when power tools are being used. 2. Never work when you are impaired. This includes when you are too tired, stressed or hurried to work carefully. 3. If you cannot do a job safely in this shop, don’t do it. There are limits to what we can build here. 4. Always wear closed-toe shoes in the shop. Tools, chips and fixtures are sharp, and often hot. Shoes will help protect your feet from injury. Leather shoes are preferred when welding. 5. Eye protection is essential. Always wear safety glasses when working or cleaning tools. Prescription glasses sold in the US with plastic lenses meet ANSI Standard Z87.1 for safety. 6. Remove or secure anything that might get caught in moving machinery. Rings, necklaces, long hair and loose clothes that get caught in tools can drag you along. 7. Keep your hands away from sharp tools. Make sure that nothing that you do will cause you to be cut. 8. Dust, chemicals and smoke can be dangerous – work in well-ventilated areas, minimize contamination and use appropriate protective equipment. The safety equipment cabinet is on the patio. 9. If you’re unsure about the safe operation of a tool or any aspect of a job – ask for help! Have shop staff check you out on a tool the first time you use one with which you are unfamiliar. 10. Clean up after yourself. Before you leave the shop each day all tools must be returned to the toolbox, the machine cleaned and wiped down and the floor swept. Leave 10-15 minutes for cleanup.

Information about the Shop

The Student Machine Shop is available to all College of Engineering students, staff and faculty working on University projects. Everyone must read this safety handout and pass a safety test before using the tools in the shop. The goal of this handout is to summarize the risks that are inherent in metalworking and to provide some guidelines for working safely. It is not intended to be a machining training manual. There are several good books in the library and references on the web. The first step in preventing personal injury or machine damage is to make sure that you know how to operate the equipment you will be using correctly. If you are unsure – ask! Because it is a communal area, used by so many people, it is important to keep the shop clean and orderly. This means that every user must clean the machines and work areas they use, and put away all tools and material before leaving the shop. Inattention, hurried work, horseplay, bad judgment, fatigue, improper clothing, defective tools, and poorly secured workpieces cause most accidents. Avoid accidents by following all of the rules in this handout and asking for help if you are unsure about the safest approach. Disregarding shop rules, working unsafely or leaving a mess will result in suspension of shop privileges. These rules apply to the entire shop area including the patio and student project work room.

In an Emergency: Call 9-911 from the shop phone, or 893-3446 from a cell phone. The shop is in Arts, Building 534 room 249. This is in the basement and is reached through the service road by the Faculty Club.

Shop Hours: Regular hours: M-F 8-12, 1-5. Access to the student shop may be limited during scheduled classes, and holidays.

By special permission during busy periods in the quartrer the shop may be opened by T.A.'s or other staff in the evening or on weekends. Contact shop staff for additional information.

Sign-in Book: All users must sign in before beginning work! The sign in book is on the storage cabinet across from the tool board in the shop.

General Safety Guidelines

1. Do not attempt to remove foreign objects from the eye or body. Report to the student health service for medical treatment. If chemicals get in the eye(s), wash eye(s) for 15 minutes in an open flow of water before proceeding for medical treatment. Notify campus rescue at 9-911. 2. Avoid excessive use of compressed air to blow dirt or chips from machinery to avoid scattering chips. Never use compressed air guns to clean clothing, hair, or aim the gun at another person. 3. Machines must be shut off when cleaning, repairing, or oiling. 4. Do not wear ties, loose clothing, jewelry, gloves, etc. around moving or rotating machinery. Long hair must be tied back or covered to keep it away from moving machinery. Hand protection in the form of suitable gloves should be used for handling hot objects, glass or sharp-edged items. 5. Wear appropriate clothing for the job (i.e. do not wear short sleeve shirts or short pants when welding). 6. Do not work in the shop if you are tired or in a hurry – this almost always ruins the work, and often results in injury. 7. Never indulge in horseplay in the shop areas. 8. All machines must be operated with all required guards and shields in place. 9. A brush, hook, or special tool is preferred for removal of chips, shavings, etc. from the work area. Never use your hands to clean cuttings – they are sharp! 10. Keep your fingers clear of the point of operation of machines by using special tools or devices, such as, push sticks, hooks, pliers, etc. Never use a rag near moving machinery. 11. A hard hammer should not be used to strike a hardened tool or any machine part. Use a soft-faced hammer. 12. Keep the floor around machines clean, dry and free from trip hazards. Do not allow chips to accumulate. 13. Think through the entire job before starting. Ask for help if you have questions. 14. Before starting a machine, always check it for correct setup and always check to see if machine is clear by operating it manually, if possible. 15. Do not drink alcoholic beverages before or during work in the machine shop area. Do not bring food or snacks into the shop. 16. If you have not worked with a particular material before, check the hazardous materials data sheets book for any specific precautions to be taken while working with the material. Also, ask the shop personnel before cutting any unusual material. 17. Heavy sanding and grinding should only be done in well-ventilated areas, preferably on the patio. Painting on the patio only – make sure that the doors to the shop are closed. 18. Follow all appropriate precautions when working with solvents, paints, adhesives or other chemicals. Use appropriate protective equipment. 19. Safe procedures for most shop operations are described in the Health and Safety Procedures Notebook located by the safety cabinet. 20. Check the power cords and plugs on portable tools for before using them. 21. Always store oily rags in an approved metal container.

Drill Press Safety Guidelines

1. Run drill at correct RPM for diameter of drill bit and material. Ask shop personnel for the correct RPM. 2. Always hold work in a vise or clamp to the drill table. 3. Use a correctly ground drill bit for the material being drilled. Shop personnel can help select the correct bit. 4. Use the proper cutting fluid for the material being drilled. Ask the shop staff about the appropriate fluid for the material you are machining. 5. Remove chips with a brush, never by hand. 6. Ease up on drilling pressure as the drill starts to break through the bottom of the material. 7. Don't use a dull or cracked drill. Inspect the drill before using. 8. Don't drill with too much pressure. 9. Always try to support part on parallels or a backing board when drilling thru material. 10. Never place taper shank tools such as large diameter drills or tapered shank reamers in a drill chuck. Only straight shank tools such as standard drills can be clamped in chucks. 11. Always clean drill shank and/or drill sleeve, and, spindle hole before mounting. 12. Remove taper shank tools from spindle or sleeve with a drill drift and hammer. 13. Never try to loosen the drill chuck while the power is on. 14. Lower the drill spindle close to the table when releasing the drill chuck or taper shank drill to reduce the chance of damage should they fall onto the table. 15. Never clean a machine while it is in motion!! 16. If the drill binds in a hole, stop the machine and turn the spindle backwards by hand to release the bit. 17. When drilling a deep hole withdraw the drill bit frequently to clear chips and lubricate the bit. 18. Always remove the drill chuck key, or, the drill drift from the spindle immediately after using it. 19. Wear safety eye protection while drilling. 20. Let the spindle stop of its own accord after turning the power off. Never try to stop the spindle with your hand. 21. Plexiglass and other brittle plastics can be difficult to drill. Ask the shop superintendent for advice on drill and coolant selection when drilling these materials.

Lathe Safety Guidelines

1. Make sure that the chuck, driveplate, or, faceplate is securely tightened onto the lathe spindle. 2. When removing the chuck, driveplate, or faceplate do not use machine power. 3. When installing the chuck, driveplate, or faceplate do not use machine power. 4. Move the tool bit a safe distance from the collet or chuck when inserting or removing work. 5. Don't run the machine faster than the proper cutting speed – consult a speed and feed table to determine the best speed. 6. In setting up the tool holder place it to the left side of the compound slide to prevent the compound slide from running into the chuck or spindle attachments. 7. Always clamp the toolbit as short as possible in the toolholder to prevent it from breaking or chattering. 8. Always make sure that the toolbit is sharp and has the proper clearance. Ask for assistance making adjustments. 9. If any filing is done on work revolving in the lathe, file left handed to prevent slipping into the chuck. Never use a file without a handle. 10. If work is turned between centers, make sure that proper adjustment is made between centers and that the tailstock is locked in place. 11. If work is being turned between centers and expands due to heat generated from cutting, readjust centers to avoid excessive friction. 12. Do not grasp or touch chips or turnings with your fingers, but get rid of them using a blunt instrument. It is safer to turn off the lathe before clearing chips then to leave it running. 13. Set the toolbit on the centerline of your work to prevent work from climbing over tool or cutting above center and dragging. 14. Don't cut work completely through when turning between centers. 15. Remove chuck key from chuck immediately after using. 16. Turn chuck or faceplate through by hand before turning on the power to be sure there is no binding or clearance problem. 17. Stop the machine before taking measurements. 18. Before cleaning the lathe remove tools from the tool post and tailstock.

Milling Machine Safety Guidelines 1. Work must be clamped securely in a vise and vise clamped tightly to the table, or, work must be clamped securely to the table. 2. Do not take climb milling cuts on the shop’s mills unless instructed to do so. 3. Make sure cutter is rotating in the proper direction before cutting material. 4. Before running machine the spindle should be rotated by hand to make sure it is clear for cutting. 5. Make sure the power is off before changing cutters. 6. Always use the proper cutting fluid for the material being cut. 7. Never run the machine faster than the correct cutting speed. 8. Make sure that the machine is fully stopped before taking any measurements. 9. Always use cutters which are sharp and in good condition. 10. Don't place anything on the milling machine table such as wrenches, hammers, or tools. 11. Always stay at the machine while it is running. 12. Don't take too heavy a cut or use too rapid a feed. 13. Remove the collet tightening wrench immediately after using it. 14. If at all feasible rig a guard or shield to prevent chips from hitting other people. 15. Use the milling machine spindle brake to stop the spindle after the power has been turned off. 16. Before cleaning the mill remove cutting tools from the spindle to avoid cutting yourself.

Band Saw Safety Guidelines 1. The upper guide and guard should be set as close to the work as possible, at least within 1/4 inch. 2. If the band breaks, immediately shut off the power and stand clear until the machine has stopped. 3. Examine blade before installing to see if it is cracked, do not install a cracked blade. 4. Use the proper pitch blade for the thickness of the material to be cut. There should be at least 2 teeth in the material when cutting aluminum, and three teeth when cutting steel. 5. Check the speed table for the material that you are cutting. Do not run the band saw too fast or the blade will wear out quickly. 6. If the saw stalls in a cut, turn the power off and reverse the blade by hand to free it.

Grinding Safety Guidelines

1. Special training is required before using the surface grinder. Ask shop staff to demonstrate proper use of this tool. 2. Abrasive wheel machinery shall not be operated without the appropriate guards in place. 3. Toolrests on bench or pedestal grinders shall be set no more than 1/16 inch from the wheel. 4. Never use a wheel that has been dropped or received a heavy blow, even though there may be no apparent damage. Such wheels may be weakened or unbalanced enough to fly apart on startup. 5. Stand to one side when starting a grinding machine. Damaged wheels will sometimes fly apart, and this is most likely to happen when the machine is being started. Stand to the side so that you will not be in-line with the debris. 6. Do not grind on side of wheel unless wheel is specifically designed for such use. 7. Do not use excessive pressure while grinding. On surface grinder do not exceed . 0005 inch downfeed at any time. 8. Report to the area supervisor immediately any cracked, broken or otherwise defective wheels. 9. Have the area supervisor mount and balance new wheels. 10. Keep the grinding wheel dressed. Dressing a small amount frequently is better than having to dress a lot later and will allow the wheel to cut faster, cooler and with a better surface finish. Dressing is cleaning and smoothing the surface of the grinding wheel. 11. Hold work securely while grinding, use the toolrest to support the work when off- hand grinding on bench or pedestal grinders. 12. Do not grind aluminum. Aluminum dust is explosive. Check with shop staff for safety instructions if aluminum must be ground. 13. Wear goggles over safety glasses when grinding on bench or pedestal grinders. 14. If a magnetic chuck is being used, on the surface grinder, make sure it is holding the work securely before starting to grind.

Table Saw Safety Guidelines

1. Special training is required before using the table saw. You may not operate it without permission from the shop supervisor. 2. Stand to one side, never directly in line with, of work being fed through the saw. 3. Use the proper blade for the material and type of cut. Do not use a rip blade for cross cutting, or, a crosscut blade for rip sawing. Do not use a plywood blade for anything but plywood. 4. Inspect the blade before using it, to make sure it is the proper blade and is sharp and free from cracks. 5. Never allow your fingers to get near the blade when sawing. Use a pusher stick to rip narrow pieces of stock. Don't use pusher stick to remove scrap. For scrap removal, shut off machine and wait until blade stops, then remove scraps. 6. Appropriate guards must be in place at all times. Never remove the guard. Ask one of the shop personnel for help if you think the guard is in the way. 7. If the piece of material you are cutting is large, get someone to assist in tailing-off for you. Never try to do it alone. Tailing off refers to supporting a large workpiece by supporting it underneath with your hands. 8. If you are tailing-off for someone else let them guide the work through the saw. You should just support the work without influencing the cut. 9. Never reach over the saw to obtain something from the other side. 10. When shutting off the power, never attempt to stop the saw quickly by shoving anything against the blade. Make sure the saw has stopped before leaving it. 11. Never make any adjustments to the saw while it is running. Turn off the power and make sure the saw is completely stopped before attempting to adjust it. 12. Do not allow material to collect on or around the saw table. Sweep up sawdust and material scraps regularly while working to minimize chances of slipping or stumbling. 13. Make sure that you clean up thoroughly around the saw before leaving the area. If you don't you could be the cause of someone else having an accident. 14. The circular blade of the table saw should be set to 1/8 inch above the work.

Power Hand (Skill) Saw Safety Guidelines

1. Unplug the tool before making any adjustments. 2. Before using any power tool, inspect it to make sure the cord is not damaged in any way, that the ground pin is intact, and that the blade is sharp and undamaged. 3. Do not use the saw in a wet area. 4. Do not run the extension cord across walkways where people might trip over it or where the cord may be run over and damaged. 5. Keep your head out of the path of particles thrown out by the blade. Wear eye protection. 6. Disconnect the power cord before cleaning, changing blades, or making any adjustments to the saw. 7. When it is necessary to raise the guard for certain types of cuts, use the guard lever. 8. Never wedge, wire, or otherwise jam the guard to prevent it from working. This is a particularly dangerous practice and will cause your permission to work in the machine shop to be revoked immediately!!! 9. Wait until the saw stops before lifting it from a cut. 10. Before setting the saw down, make sure the guard is closed, as the blade may still be turning. 11. Don't carry the saw with your fingers on the switch trigger. 12. Don't pull the saw backwards in a cut if you can avoid it. 13. Use the proper blade for the type of cut to be made. 14. Do not use the cord to move or drag the saw. 15. Do not use the power hand saw for cuts if you cannot keep a firm and secure grip on the saw and the material being cut. A hand saw is still the best for some kinds of work and often faster. 16. Before cutting small workpieces shop personnel should be consulted. 17. Adjust the depth of cut 1/8” greater than the material thickness.

Disc and Belt Sander Safety Guidelines 1. Do not operate sanders without the guards in place. 2. On the disc sander always use the downward motion side of the disc to sand. Never the upward motion side as this can throw your part upwards with tremendous force. 3. Always attempt to place your work against the rest on the disc and belt sanders. 4. On the horizontal belt sander, always sand, so that the belt motion is away from you. 5. Do not operate machines with torn or ripped belts or disks. 6. Do not sand any material that will give off a dangerous dust. Such materials as berylium or copper berylium alloys must not be sanded or filed. Asbestos must not be sanded. Asbestos is an ingredient of brake shoes and pads.

Welding Safety Guidelines

1. Shop staff approval is required before using any welding equipment. 2. Welders, assistants, and anyone else in the welding area shall wear glasses or shields of recommended shades during welding operations. 3. The welder is responsible for erecting a screen around the welding area to protect other personnel in the shop from eye injury. 4. Inspect all welding equipment to be used, prior to each use, for possible damage. 5. Avoid handling oxygen bottles with greasy hands, gloves or rags. Fatal explosions have resulted from this cause. 6. Always strap tanks to a welding cart or a fixed object. Never allow a gas cylinder to be free standing. Replace the safety cap on all cylinders when not in use. 7. When arc welding, make sure work and/or work table is properly grounded. 8. Do not arc weld in a wet area. 9. Be alert to possible fire hazards. Move the object to be welded to a safe location, or, remove all flammable materials from the work area. 10. Never weld in the same area where degreasing or other cleaning operations are performed. 11. Keep suitable fire extinguishing equipment nearby and know how to operate it. 12. Shut off the cylinder valves when the job is completed, release pressure from the regulators by opening the torch valves momentarily, and back out regulator adjusting valves. Never leave the torch unattended with pressure in the hoses. 13. Utilize all protective equipment and clothing. Do not arc weld with any part of the body uncovered, the arc light is actinic light (excessive ultraviolet) and will cause burns similar to severe sunburn. 14. Never weld inside drums or enclosed spaces without adequate ventilation, or, the use of airline respirators or self-contained breathing apparatus. 15. Check the ventilation system before starting to weld and periodically thereafter to insure adequate performance. Welding fumes should not be allowed to get into the rest of the shop working areas. 16. Never cut or weld any container that has held explosive or flammable materials. Use prescribed methods for cleaning or flooding. 17. Never use wrenches or tools except those provided or approved by the gas cylinder manufacturer to open valves. Never use a hammer to open or close valves. 18. Abide by any other safety measures required for each particular type of welding. 19. Allow for proper ventilation when brazing or soldering. The fluxes are acidic and toxic. 20. Do not weld on painted, galvanized or greasy, oily metals. Not only can the fumes be toxic, but the welds will not be satisfactory and will fail in use.

Safety Guidelines for Working with Solvents, Resins and other Chemicals

1. Learn about the chemicals that you are planning to use before opening them. Read the instructions and MSDS sheet. Consult shop staff or EH&S if you have any questions. 2. Use water-based cleaners instead of solvents where possible. 3. Avoid skin contact. Wear latex gloves. 4. Work in a fume hood if possible. Respirators are available when necessary. Shop staff can give you the necessary paperwork for an exam at Student health and a respirator fitting at EH&S. 5. Do not use solvents around hot metal surfaces and flames. 6. Do not smoke or light flames in areas where solvents are used and stored. 7. Report and clean up any spills immediately. Call EH&S at x3194. 8. Do not pour any chemicals down the drain. Waste containers are available in the solvent cabinet. 9. Only use solvents in well ventilated areas - do not work with them in confined, unventilated areas. 10. Do not drink alcoholic beverages or take medications containing alcohol before or during working with solvents. Alcohol in the bloodstream sometimes causes synergistic reactions with various solvents that can lead to loss of consciousness, and even possibly, death. 11. Report any ill effects and skin disorders to the area supervisor. 12. Develop and maintain good personal hygiene habits. Remove protective equipment and wash thoroughly after contact with solvents. 13. Fumes from paints, solvents, adhesives, and the abrasive cut-off saw used on the patio can drift into the shop. Work with staff to minimize these problems. 14. Mix resins in small batches.

Safety Guidelines for Heavy Sanding of Wood and Foam

1. Sand in a well ventilated areas away from other machines, only on the patio with the doors to the shop closed. 2. Use a vacuum or a dust collector to collect dust while sanding to prevent the dispersal over a large area. 3. A dust mask may be worn if desired. They are stored in the safety cabinet. 4. Safety glasses must be worn when sanding.

Guidelines for Cleaning

1. Turn off power to the machine before cleaning. This will avoid accidentally starting the machine and injuring yourself. 2. Remove cutting tools. Take out drill bits, mills and remove lathe tools to reduce the chances of getting cut. On the table saw lower the blade completely. 3. Put away all hand tools and other items around the tool so that you don’t make them dirtier. 4. Clean chips from the tool, the chip pans. Recycle clean chips where possible. 5. Put a light coat of way oil on the machine ways. Ask staff to show you where this oil is kept. 6. Sweep the floor in the area where you have been working. 7. Do not over use compressed air. Do not blow air into the bearing surfaces, and do not scatter chips all over the shop. Sometimes a shop vacuum works better than the air gun. 8. Report missing, broken or damaged tools to shop staff. 9. Spend five minutes on general cleaning around the shop. We’re all in this together.