Mechanical Principles Workshop

Task One
Identify the potential hazards that exist when operating machine tools and
bench fitting equipment.
Working in a mechanical workshop can come with a large number of health and
safety risks, especially when operating machine tools or bench fitting equipment. The
number one cause of accidents is carelessness. Not paying attention to the task at
hand or being overly fatigued can cause serious injuries.
Not wearing the right attire is another hazard. Loose fitting clothing can get caught in
machinery, improper footwear or jewellery can also be an issue.
If the machinery and equipment is not well maintained or cleaned, workers can be
injured by moving parts or shrapnel. Furthermore, parts of their body could be
trapped between something or sharp edges can cause severe cuts where sharp
points can stab the skin and rough surfaces can cause abrasive injuries. The
machine could also overheat or have emissions such as steam that could cause
burns. Should the electrical parts of the machine malfunction or be handled
carelessly then the electricity becomes a hazard itself. Electrical shock, electrical
burn, fire or explosions are all major hazards. Fire from damaged equipment,
overloaded sockets etc is a further potential threat.
A list of signs which indicate what kind of
potential hazard a substance or container
can prove to be.
(a) Danger – explosive. (b) Danger – extremely flammable. (c)
Warning – corrosive. (d) Danger – fatal if swallowed. (e) Danger –
may cause cancer, allergy or asthma symptoms or breathing
difficulties if inhaled. (f) Warning – causes skin irritation, harmful if
swallowed. (g) Warning – contains gas under pressure; may explode
if heated. (h) Warning – very toxic to aquatic life. (i) Danger – may
cause or intensify fire; oxidiser

The noise from operating machinery can cause damage to a workers hearing if he is
not properly protected. In general lack of the correct personal protection equipment
is severely unsafe. Workers being uninformed and uneducated about how to
properly and safely operate tools poses a great risk.
Furthermore, the area around the tools and equipment can become dangerous if it
lacks lighting, cleanliness, proper ventilation etc.
A workshop without clearly marked warnings and emergency equipment is
dangerous.

Task Two
Describe the safe working practices and procedures to be followed when
preparing and using a manual lathe and milling machine
Before beginning manual lathe or milling work, or any kind of work really, ensure that
the workshop is safe and the workers are wearing the correct kind of protective gear
which in this case would mean safety overalls, eye protection, gloves and safety
boots. Do not have jewellery, loose clothes and keep long hair tied back.

Example of different type of eye protection

The workshop must be clean which no old materials like metal chips from past
projects, for example, on the floor or at the workstation. There has to be sufficient
space to ensure that others can safely walk past the machines without accidentally
injuring themselves. On top of that it should be a well-lit and well-ventilated area.
Everything should be marked properly so it is clear where the start/stop buttons are
or what the different type of fire extinguishers are.

Example of markings

Lastly, the workshop should be well prepared in case of an emergency, for example
a first aid kit has to be on site as well as clearly marked instructions on emergency
procedures.
The equipment itself needs to be properly maintained at all time which includes
inspection, appropriate repairs, lubrication and cleaning. To make sure it is safe to
use it needs to be well secured and on stable and level ground. Before use, it should
be known to the operator how to stop the machine in case of emergency. Once
connected to a power supply and started, never leave the machine unattended or
attempt to clean it. Always switch it off and disconnect power before attempting to
clean it and even then, never use bare hands. Before and during use make sure that
all guards are in the correct position. Use fixed guards with jigs and fixtures to load
and unload parts away from the tool.
Before working with manual lathe and milling machines it is important to know how
the safeguards work, familiarize yourself with all the components, how to load and
unload components, how to get rid of shavings and how to adjust the coolant.
Knowing all that, the operator is ready to start working on a lathe or milling machine.
While it is still disconnected from the power, inspect the machine to ensure that it is
installed correctly and free of any kind of damage. That includes the inspection of the
cutter, for example on the milling machine, for broken or chipped teeth.

Basic Manual Vertical Milling

Machine
An obvious step is to keep away
from the cutter while the machine is
operating at all times and keep your
safety gear on so no stray particles
can injure you. Always remove chips
with a brush or rake to protect
hands. If cutting oil is required for the
milling action, then use a splash
guard and make sure it doesn’t get
the floor slippery.

Manual centre lathe machine

Have the guard places in position at all times during the operation of the mill and
lathe.
Ensure the work piece is adequately prepared then place it into the chuck and make
sure it is secured properly and always remember to take the chuck key out of the
chuck so it doesn’t fly off once the machine is started and injure someone.
In the milling machine ensure that the spindle guard is in place and ensure that the
work piece is fastened properly to the working table.
Next, the metal piece that is being machined in a lathe should only stick out from the
chuck a small distance. Rotate the work piece by hand to check the clearance
between tool rest and chuck/bed.
The operator needs to know at what speeds the machine has to operate for the
specific type of metal that is being worked on. Too high or low speeds increase the
likelihood of accidents.
If adjustments need to be made, then the machine has to be switched off completely
and be at a standstill before those can be done.
Once it is complete switch the machine off properly and reset the guards. Then
remove the work piece from the chuck and again remember to remove the chuck
key.
Lastly, tidy up the machine and the workspace to ensure the safety of the next
person operating it.

Task 5
Identify the information that is required from a drawing to plan, machine and
check the accuracy of a complex engineering component
Drawings are needed to provide a method of exchanging information to the relevant
departments or people that will have a part in producing a component. Once a
drawing has been finalized as many identical parts as are needed can be produced
from those specifications. When a larger part is initially designed it is then proper
down into smaller units which are then broken down into individual parts that all will
be drawn and referred to as detail drawings.
There are different types of drawings. The ones relevant to an engineering
component are the assembly drawing, the detail drawing and the projection drawing.
The assembly drawing shows, as the name suggests, the exact positions of the
smaller parts and how they all fit together. It needs to have a parts list on it where the
item number, part description, the number of the part and the quantity needed. It is
needed to assemble all the parts into the final product. Later on, it can be revisited
when maintenance is required.
The detail drawings hold all the information that is needed to actually produce and
manufacture the component. It needs to have enough information to describe the
part completely. It has to include:
- Material specifications
- Dimensions
 - Tolerances
- Heat treatment needed
- Kind of surface finish
- Protective treatment required
- Tools that are required
- Title block at the bottom
o Scale
o Date/time
o Company
o Name
o Unit of measurement
o Drawing number

Lastly, a projection drawing is a drawing of a three-dimensional object on a piece of

paper.
Orthographic projection
This is the most common way to draw a detailed drawing and can either be first or
third angle which has to be marked on the paper by the proper symbol. In this
drawing only the essential and necessary views are included.
Isometric Projection
This shows a single view but a three-dimensional picture of the component.
Vertical lines in this projection are shown as vertical whereas horizontal lines are
drawn at a 30-degree angle to the horizontal on each side of the vertical

isometric view on top

first angle projection on bottom
 isometric view on top
third angle projection on bottom

Oblique projection
This shows a single view but a three-dimensional picture of the component.
In this projection one edge is horizontal whereas in the isometric projection the
horizontal views are at an angle.
Vertical edges stay vertical so there are two axes that are at a right angle to each
other. Therefore, one face stay true to its shape and the third edge can be drawn at
any kind of angle. If those were to be drawn at full size however the view would be
distorted so they are drawn at half size. The face that has the most detail should be
used as the front, so it remains undistorted.

oblique view on top

Orthographic on bottom
If a part has a lot of detail inside as well then, a sectional view drawing has to be
provided as well. The sectional view can be drawn by imagining a slice of the
component being taken from its middle and illustrated.
sectional view on top

types of lines and what they represent in a drawing

Task 6
Describe the function of precision measuring
equipment used to check the dimensional
accuracy of machined components

Precision measuring
equipment is needed to ensure
that parts will fit together as they
are supposed to. Many different
types of equipment exist with
different purposes.
Micrometres show the linear
movement of a rotating
precision screw thread.

A Vernier compares two scales

which have different length between
them.
One scale is fixed and the other
can move. The one that is fixed is
in millimetres and centimetres along the length of the instrument. The moving part is
split into 50 parts which is the same length as 49mm on the fixed scale. If both
scales are at zero and the moving part is moved by one graduation, then it will have
moved 49/50mm or 0.02mm so it can measure to a 0.02mm accuracy.
5*0.02mm = 0.1mm which is marked by 1 on the movable scale.
To read the scale look at how far the 0 on the moving scale is away from the 0 on
the fixed scale. After that, look at the movable scale and check which division lines
up exactly with a line on the fixed scale.

For example

The top is the movable scale and the bottom is the fixed scale.
4cm = 40mm
11th line lines up perfectly so, 11*0.02 = 0.22mm
Total reading = 40+0.22 = 40.22mm

There are different types of Vernier measuring tools although how you read the
measurement remains the same.

Vernier calliper

It can measure the outside of an object, internal part of it, step and depth.

Vernier height gauge

Vernier depth gauge

Micrometres

The Micrometre has a spindle screw thread that is rotated in a fixed nut by means of
the thimble. The thimble opens and closes the between the spindle and the anvil.

external micrometre

One rotation, the spindle and thimble will move 0.5mm in the longitudinal direction.
As shown in the image below, the sleeve has a division of 1mm on the bottom and
divisions of 0.5mm at the top. So, ignoring the rotational scale for now, the fixed
scale is accurate to 0.5mm.
The thimble is divided into 0.01mm divisions. In the image the rotational scale, or
thimble, has uncovered 9mm. The longitudinal line on the fixed scale lines up with 44
on the thimble.
So, 9mm + (44*0.01mm) = 9.44 mm

There are different types of micrometres but the process of reading them stays the
same.
depth micrometre

internal micrometre
Reference Page

https://www.hse.gov.uk/pUbns/priced/hsg129.pdf

https://mcgill.ca/engineering/files/engineering/machine_safe_work_procedure_rev_02.pdf

http://www.technologystudent.com/equip1/cenlath1.html

https://www.industrybuying.com/articles/how-to-use-a-milling-machine-safely/

UC RIVERSIDE – MECHANICAL ENGINEERING DEPARTMENT – MACHINE SHOP STANDARD

OPERATING PROCEDURES for MANUAL MILLING MACHINES REVISION: V5 DATE: 11-15-2011

Workshop Processes, Practices and materials 5th Edition, Bruce J. Black, 2015