PDIS-105 (PAPER –V)

SAFETY IN ENGINEERING INDUSTRY

ELECTIVE

HOT WORKING: - Hot working is accomplished at a temperature above the

recrystalization temperature of the metal. However, this temperature should not be too
high to reach the solidus temperature; otherwise the metal may burn and become
unsuitable for use. As a general rule, for any hot working process the metal should be
heated to such a temperature below its solidus temperature that after completion of hot
working its temperature should remain a little higher than and as close as possible to its
recrystalization temperature. The following are advantages and disadvantages of hot
working of metals.
ADVANTAGES: -
 Larger deformation & more rigidity can occur since the metal is in plastic
stage.
 Porosity of the metal is considerably minimized.
 Concentrated impurities if any in the metal are disintegrated and distributed
through out the metal.
 Grain structure of the metal is refined and physical properties improved.
 No residual stress is introduced in the metal due to hot working.
DISADVANTAGES: -
 Due to high temperature rapid oxidation or scale formation takes place on the
metal surface leading to poor surface finish and loss of metal.
 The surface layer losses it’s strength due to loss of carbon from the surface of
the steel being worked.
 It gives rise to fatigue; crake which may ultimately results in failure of the part
due to working of the part.
 Close tolerance can not be maintained.
 It involves excessive expenditure on account of high cost of furnace & tooling.
This however can be compensated with high production rate and high quality
product.
COLD WORKING: - In spite of a number of operations being common to both hot and
cold working of metal the latter has an altogether different effect in the structure and
physical properties of the worked metal unlike hot working; it distorts the grain structure
and does not provide an appreciable reduction in size. It requires much higher pressure
than hot working. Since crystallization does not take place in cold working the grains are
permanently distorted. As a result of the greater resistance affected by the metal to
deformation its strain and hardness are increased. This type of hardening of metal is
called strain hardening. The extent to which a metal can be cold worked depends up on
its ductility. The higher the ductility of metal the more it can be cold worked. Residual
stresses are set up during cold working. A suitable heat treatment is generally necessary
to neutralize these stresses and restore the metal to its original structure.
ADVANTAGES & LIMITATIONS: -
  Better dimensional control than hot working is possible because the
reduction in size is not much.
 Surface finish of the job is better as no oxidation takes place during the
process
 Strength and hardness of the metal increases.
 It is an ideal method for increasing hardness of those metals which do not
respond to the heat treatment.
 Only ductile metal can be shaped through cold working
 Over working of metal results in brittleness & it has to be annealed to
remove the same.
 Subsequent heat treatment is mostly needed to remove the residual stress set
up during cold working.

THE COMMON COLD WORKING PROCESS ARE AS FOLLOWES: -

1. COLD ROLLING: - Cold rolling is generally employed for
providing a smooth and bright surface finish to the previously hot rolled sheet. It is also
used to finish the hot rolled components to loose tolerances, improve their toughness and
hardness. The items generally subjected to cold rolling are sheets, plates, strips, wires,
bars etc. Before being put in to cold rolling the hot rolled metals are cleaned through
pickling. The same types of rolling mills in connection with hot rolling are used in cold
rolling. In order to obtain a smooth surface finish the rolled surface are polished and
scratches if any removed. The part being rolled is usually annealed and pickled before the
final pass is made so as to bring it to accurate size and obtain a perfectly cleaned surface.
2. COLD DRAWING: - Drawing operations involve the forcing of
metal through a die by means of tensile force applied to the exit side of the die. Most of
the plastic flow is caused by the comprehensive force which arises from the reaction of
the metal with die. Usually the metal has a circular symmetrical shape. Rolled tubes
and extrusion are often given a cold finishing operation to reduce the size; to increase
the strength, to improve the surface finish and to provide better accuracy. In general,
the preparatory step in cold drawing of bars, tubes that have been hot rolled is that of
removing all traces of scale. This is best done by immersing them in a hot bath of dilute
H2SO4 from 15 to 30 minutes and then washing in fresh water and then with lime water
to remove the acid. The lime + soap/oil acts as a good drawing lubricant.
3. WIRE DRAWING: - in case of wire drawing the material is being
drawn through dies. The raw material for drawing is rolled bar/rod from hot rolling.
The size of the bar/rod varies from 6 to 19 mm in diameter which is available in coils of
several hundred meters. Dies are made of chilled cast iron, hardened alloy steel,
cemented tungsten carbide etc. The selection of the die material depends upon the
composition of the wire as well as upon the size of the wire to be drawn and the
finishing. Before passing through the dies the material must be annealed. To soften the
wire it must be passed through a furnace where it is heated up to a temperature slightly
lower than the critical range. Either the single draft or continuous drawing process may
be used. In the first case the drawing operation can be started by pointing the end of the
road and pushing it through the tapped hole in the die. The end is gripped by tongs and
sufficient wire is pulled through the die real. The real is then rotated to draw the wire
through the die at the desired speed. In single draft method the wire is drawn several
 times through a single die till the required reduction has been obtained. In view of the
pressure between the die and the rod is being drawn, it is necessary to lubricate the area
of contact. In continuous drawing the wire is feed by several dies and as draw blocks
are arranged in series to obtain the required reduction.
4. TUBE DRAWING: - This method produces tubes having smaller
diameters and thinner walls which has been obtained by hot rolling. This is also used to
get dimensional accuracy, smooth surface and improved physical properties. Hot rolled
tubes must first first be treated by pickling and washing to remove all scales and then
covered with suitable lubricant. One end of the tube has to be reduced in diameter to
permit it to enter in to the die. A mandrel that has an out side diameter smaller than the
work piece is passed through the tube stack. In drawing through with the tongs, inside
and out side diameter of the tube plastically confirmed to the diameter of the mandrel and
the die respectively. Light finishing is required only in case of a single pass.
5. COLD BENDING: - Bending is the process by which a straight
length is transformed to a curved length. It is one of the most widely used forming
process for changing plates, sheets, into drums, corked channels etc. Bars, rods, wires,
tubes & structural shapes as well as sheet metal are bent to many shapes in cold
conditions through dies. In all metal bending the metal stretched beyond the elastic limit
in tension on the out side and in compression on the inside of the bend. Bending of a flat
strip of metal is coming under roll forming.
6. ROLL FORMING: - There are two types of main roll forming. One
uses continuous strip material for high production and the other uses sheets, plates stock.
Materials used for roll forming include carbon steel, stainless steel, bronze, bras, cupper
zinc and aluminium. Its main products are metal windows, screen frame members, by
cycle wheel rims, furnace jacket rings etc. Present days tubing is rolled in cold condition
and then resistance welded. In continuous roll forming a series of rolls are used to
gradually change the shape of the metal. As the metal passes between the roles in a first
moving continuous strip, the cross section shape is changed to the desired shape. The
intricacy of the shape, the size of the cross section, the thickness and the type of material
will determine the number of rolls required. Bending rolls are used for bending sheets
and plate stock into cylindrical shape. A roll bending machine is made up of three rolls of
same diameter, two of them being held in fixed position and being adjustable. As a metal
plate enters and goes through the role it’s final diameter is determined by the position of
the adjustable roles. After the job is removed from the rolls, it is placed in a fixture to
close the gap prior to welding. Bending roll machine ranges in size from those that are
able to roll heavy steel plate 25mm thick, to small bench models used for light gauge
sheet metal work.
7. COLD SPINNING: - It is the operation of shaping very thin metal
passing against a frame while it is rotating. The method is exactly similar to hot spinning
except the condition of the metal. In cold spinning the metal is worked at room
temperature. Equipment required for spinning comprises of a lath machine, forming tools
and a metal or wooden former to shut the shape required. A round nose tool is used while
the lath rotates the blank. Thinning of material can be resolved by lubricants such as soap
wax, oil. Cold spinning process is frequently used in the making of bells of musical
instruments and also for light fixtures, kitchen wire, reflectors funnels and large
processing materials.
8. COLD EXTRUSION: - The principle of cold extrusion is exactly
similar to that of hot extrusion. Impact extrusion is limited primarily for small work
pieces from the more ductile metals. The work material is placed in position in to a blind
die and a piston/ram punch clearance is forced in to the die causing the metal to flow
plastically round the punch. The out side diameter of the tube is same as the diameter of
the die and the thickness is controlled by the clearance between the die and the punch.
The extruding force is usually supplied by mechanical press. Collapsible medicine tubes
and tooth pest tubes are made in this dies.
THE PRINCIPAL METHOD OF HOT WORKING ARE AS FOLLOWS: -
HOT ROLLING, HOT PEARCING, HOT DRAWING, HOT SPEENING, HOT
EXTRODING & HOT FORGING.
1. HOT ROLLING: - Rolling is the most rapid method of forming metal in to desired
shape by plastic deformation in between roles. The crystals are elongated in the direction
of rolling and they start to reform after leaving the zone of stress but in cold rolling they
retained substantially the shape given to them due to the action of roles. In deforming of
metal in between roles is subjected to high compressive stress from the squishing action
of the roles. The frictional forces are also responsible for drawing the metal in to the
roles. In hot rolling process metal in a hot plastic state is passed between the two roles
revolving at the same speed but in opposite direction. When the metal passes through the
roles it is reduced in thickness and increased in length. The forming of bars, plates,
sheets, rails and other structural section requires many passes through plane or grooved
roles.
a) Beam Section, b) Channel Section, c) Equal Angle Section, d) Unequal Angle
Section, e) ‘T’ Section etc.
TYPES OF ROLLS: - A set of housing in which the roles are mounted are known as
stands. Incase of continuous mill the stands are fixed one in front of the other. When
there are only top and bottom roles fixed in a stand is called “Two high mill”. If three
roles are mounted in a stand so that rolling may be done between the top or bottom role
including the center one is called three high mill. Like wise a four high mill has four role
stands. A cluster mill consists of two working roles of smaller diameter and four or more
back up rolls of larger diameters. These mills are made of cast steel with or with out
alloy. Finishing rolls are usually made of chilled cast iron.
When the material is to be used for bars, blooms are reduced in size to billets by passing
through a continuous series of rolls known as “Billets Mill”. The billets which has
dimensions between 50mm to 150mm2 is then cut in to shorter lengths which are re heated
for further rolling in the bar mill.
The blooming mill also feeds the rail mill with blooms and the plate mill with slab. Slabs
are flat rectangular pieces of steel, 50 to 100mm thick. In the rail mill the heavier
structural section and rails are made. The materials commonly hot rolled are aluminium,
cupper, magnesium and their alloys and many grades of steel.
2. PIERCING/ SEAMLESS TUBING: - Piercing is employed to produce seamless
tubing which the natural form is made by any thin walled round objects. Seamless tubing
is a popular and economical raw stock for machining and it saves drilling and boring
costs. The process of making hot pierced tubing consists of passing a hot rolled billet
between two conical shape rolls and over a mandrel which assists in the piercing and
controls the size of holes as the billet is forced over.
The solid billet is uniformly heated to about 11000c & the piercing action is started prior
to policing in between the rolls by drilling, punching/piercing with a hole 25mm deep. It
is then pushed in to the two piercing rolls which impart axial as well as rolling movement
to the billet and force it over the mandrel.
The first pass makes a thick walled tube which is again passed over a tapered plug and
through group rolls in to a two high mills where the thickness is decreased and the length
is increased. It is then passed through a reeling machine which has two rolls similar to the
piercing rolls of flat surface. If more accuracy and better finish is required the tube may
run through sizing rolls. The tubes are then put in to a pickling bath of dilute H 2SO4 to
remove the scales of oxides after cooling.
DRAWING: - Drawing is pulling the metal through a die/set of dies to achieve a
reduction in diameter. The material to be drawn is reduced in diameter for a short
distance, at one end by swaging to permit it in to the die orifice and gripped in the jaws.
The process requires a very large force in order to pull the metal through the die. The die
& the material are kept well lubricated to reduce the frictional force.
3 .DEEP DRAWING: - It is the extension part of drawing operation. It can be defined as
a process for making cup shaped parts from flat sheet metal blanks. The flat is first heated
to provide necessary plasticity for working. The heated blank is then placed in position
over the die or cavity. The punch descents and pushes the through the die to form a cup
size. This process is also known as cupping.
The process can be continued through a series of successive smaller dies and punches to
obtain cup shape pieces of the desired size and wall thickness. On many occasions
several dies of successive decreasing diameter is set up on a bench known as hot draw
bench. Seamless tubs and cylinders made through this process are used for thick walled
cylindrical tanks.
4. PENNING: - This method is employed to set up a superficial state of surface
compressive stress, causing the interior of the member to assume and opposite tensile
stress, because fatigue generally occurs from surface cylindrically loaded in tension. The
useful lives of such members are frequently extended by short opening. This method is
some times employed to achieve ornamental effect.
Short penning is done by blasting or hurling a ram of small short at high velocity against
the work piece.
5. HOT SPINNING: - Parts that have circular cross sections can be made by spinning
then from flat sheet metal. The principle of metal spinning is illustrated as follows: -
A heated circular blank of sheet metal is lightly held against a chuck by the pressure of a
freely rotating pad on the lath tail stock. This chuck may be made of plaster, wood or
metal. A rounded stick or roller is pressed against the revolving piece and move in a
series of sweeps. This displaces the metal in several steps to confirm to the shape of the
chuck. Once the operation is started considerable frictional heat is generated which aids
in maintaining the metal at a plastic stage.
Spinning is highly specialized job. To avoid excessive thinning of the metal the pressure
of the forming tool (round stick) should be directed some time back word (towards the
tail stock) as well as forward (towards the head stock). During spinning with large parts
made from relatively thin metal, a hard wood bar is commonly used as a back up support
opposite to the spinning tool to avoid wrinkling at the outer edge.
6. EXTRUSION: -It is a process in which a heated billet or slug of metal is forced by
high pressure through an orifice that is shaped to provide the desired form to the finished
part. An every day analogy is the squiggling of tooth past from a collapsible tube,
because of the large force required in extrusion. Most metals are introduced under hot
condition where the deformation resistance of the metal is low. Cold extrusion is possible
for many metals and rapidly taking an important commercial position. Most commercial
metals and their alloys are cupper, aluminium, manganese and nickel which are directly
extracted at elevated temperature. Rods, tubes, molding trim, structural shapes, brass
cartridges, lead covered cables, air craft parts and many hard wire items such as window
and door items etc are typical products of extrusion.
The reaction of the extrusion billet with the container and die results in high compressive
stresses which are effective in reducing the cracking of the materials. This is an important
reason for greater use of extrusion in the working of metals difficult to form such as stain
less steel, nickel based alloys etc.
Most hot extrusion is done on horizontal hydraulic press specially constructed for this
purpose. Common sizes are rated from 250 to 5500 tons. Temperature of the billets are
350 to 4250c for manganese, 425 to 4750c for aluminium, 650 to 13000c for cupper alloys
and 1200 to 13000c for steel. Pressure normally varied from 498 to 7038kg/cm 2.
Lubrication of extrusion chamber, die and ram is necessary and is done by oil supported
graphite. Vegetable oils are better than petroleum oils for this purpose. The extrusion of
steel at high temperature is most successfully done by using glass which acts as a
lubricant at this elevated temperature. Metal is extruded in a number of basic ways: -
A) DIRECT OR FORWARD EXTRUSION: - Direct extrusion employees a press
operated ram and a cylinder/container in to which the work piece is placed. A
dummy block is used between the ram and the hot metal. With application of ram
pressure the metal first plastically fills the cylindrical shape and then forced out
through the die opening until a small amount remains in the container.
B) INDIRECT OR BACKWARD EXTRUSION: -Indirect extrusion is similar to
direct extrusion. Here the extruded part is forced through the hollow ram. It
involves no friction between the metal billet and the container walls, as the billet
does not move through the container. Less force is required compared to direct
extrusion. The equipment used is mechanically more complicated in order to
accommodate the passage of the extruded shape through the center of the hollow
ram. It is a form of direct extrusion but uses a mandrel to shape the inside of the
tube. The die containing the mandrel is pushed through the billet after the heated
billet is placed inside the container. The ram then advances and extrudes the metal
through the die and around the mandrill.
 SAFETY IN FOUNDRY OPERATION: -
Foundry process consists of melting metals, sand preparation, core making, pattern
making, mould making and then pouring molten metal in to a molding box which is made
to be the out side shape of a pattern of the article required and. In some cases a core
which will determine the dimension of any internal cavity. A schematic flow chart is
given below.

Pattern Shop Core Shop Sand Plant

Pattern making Core making Sand Preparation
Core box making Core storing
Core blowing
Core shooting

Foundry Sand
Mould making preparation
Cast (pouring, stripping, knockout,
deco ring)

Furnace Section Fitting shop

Charging/melting/slagging/ Blasting/fitting/dressing/
Refining/tapping/furnace grinding
maint.

In course of time foundry process are modernized and mechanized, wooden patterns are
replaced with metal or plastic once. A wide range of alloys are used as base metal
casting. The traditional cast metals, iron, steel brass and bronze are now replaced with
aluminium, titanium, bromine, nickel, manganese, berkelium, cadmium and thorium etc.
New techniques for mould and core making are utilized. In die casting a light alloy is
forged in to a metal mould under pressure of 70 to 700kg/cm2. The metals and alloys are
melted and prepared in a furnace. (Cupola, Rotary, Reverbertory, Crucible, Electric Arc,
& Induction type). After metallurgical & chemical analysis the molten metal is poured in
a ladle to pour in to moulds, or directly in to the assemble mold. When the metal is
cooled the mould are removed and the casting is cleaned and dressed. Certain castings are
requiring more finishing like heat treatment, welding, grinding and painting. Generally an
iron foundry comprises of six sections, (1) Molding, (2) Core Making, (3) Metal melting
& pouring (4) Knock out, (5) Fitting & Dressing, (6) Finishing jobs.

The hazards and safety measures in these sections are explained as follows.
(1) Molding.

Hazards Safety Measures

Preparation of sand, additives & molding Good house kipping, local exhaust system
boxes. Health hazards due to handling of on mechanized plant & vacuum cleaning.
sand, free silica causes silicosis.

Irritation due to phenolic resins in Use of rubberized hand gloves, washing

thermosetting process. with hot water & if necessary medical
attention
Asthmatic systems due to methyline Protective goggles, hand gloves, local
bisphenyl/icocyanide used in cold self exhaust ventilation while dealing with hot
setting process. sand resign mixtures, clean the storage
vessels with 5y sodium carbonate solution.
Skin and eye irritation due to sodium Protective goggles, emergency showers,
silicate in the gas hardened molding eye wash bottles etc.
process.
Fire risk due to isopropyl alcohol sprays on Fire retardant protective clothing, hand
mold surface for better finish. Dermatitis protection, well ventilated system to
due to such solvent prevent organic vapor exposer.
Strain, sprain due to lifting and shifting of Avoidance of excessive weight and using
heaving molding boxes. mechanical lifting devices.

2. Core making (inserting core of sand & binder in to mold)

Hazards Safety measures
Harmful fumes from core backing oven Well maintained chimney to take out
fumes.
Disease due to dusty in handling finished Dust mask and ventilation system to be
cores. provided.
Toxic/fire/explosion hazards where Fire hydrant, portable fire extinguishers
mixtures are used. and hood extractors to be used to remove
fumes.
Core boxing machine, sand blower & hand Parting lines with dike seal, two hand
trapping between core box and Ram. control for operator & four hand controls
for two operators, core box with handles.
 3. Melting & poring (Furnace melted metal is pored in to a molding box through
ladle)

Hazards Safety Measures

Work near cupola furnace toxic effect of Breathing apparatus to be kept ready,
CO2 emergency work order, supervision, natural
& mechanical ventilation.
Repair work in furnace Safety helmet, safety shoes & safety belt
while working at height.
Tapping ( transpiring of molten metal in to Goggles & PPES (fire retardant jacket,
a ladle) helmet with face shield, neck guard, fire
Radiation & burn injury due to fall of hot proof hand gloves) refractory or sand floor
metal core to be taken in opening the jam doors,
spillage cleaning and mechanical handling .
Health hazard due to Alumina, Antinomy, Local exhaust ventilation, air dilution by
Barium, Chromium fluorides & iron oxide general ventilation, PPEs, respirators,
fumes, dust of lead, manganese, screens against radiant heat. Precautions
phosphorus & silica. against lead poisoning etc.

4. Knock out: - (removal of rough casting, cores, runners & risers from the
molding box)

Hazards Safety measures

High noise level over 90dba
Hot sand, dust & metal being separated.
Crushing/ breaking of hands and fingers.
Dust hazard near knock out grill.
Reduction of noise by engineering method
or by using ear plug or muff.
Eye protection, face shelled & other PPEs
SOP (standard operating practice) to be
followed strictly and hand gloves to be
used during operation.
Fire water spray near knock out grill.

5. Fitting, Dressing & Finishing of stripping away unwanted metal by grinding &
blasting.

Hazards Safety measures

Noise of metal hammer during knocking. The metal hammer head to be covered with
rubber
Throwing fragment of hot metal Proper PPEs and eye protection.
Noise of barrels during dressing. Noise enclosure to barrels with local
ventilation.
Hazard due to abrasive polishing & buffing Safe operation of machine and tools to be
equipments. followed. Eye, face, head and foot
protection to be made.
Dusting of dry abrasive wheels. Local exhaust ventilation at the point.
Flying objects from cleaning & chipping. Screen to protect other workers & face
protection hood, exhaust system.

6.Misalliances: - (pattern making, painting etc).

Hazards Safety measures

Noise in pattern making shop. Reduce noise by engineering method, ear
protection.
Hazards of wood cutting & finishing Guard of machines & SOP.
machine.
Wood dust from sowing. Local exhaust ventilation.
Electrical work. All electrical equipments should be earthed
properly
Painting, fire hazard from flammable Speedy removal by exhaust system, no
compounds. smoking & fire prevention system.
General dusting. Vacuum cleaning exhaust system at the
point of origin, H2O compressed air
cleaning.

Different types of furnaces: -

Cupolas: - Cupolas are vertical, cylindrical furnaces used to melt iron in a foundry.
Charging & blasting that takes place in a cupola generates CO and other health hazards.
Charging: - The dangers in charging of the cupolas are confined to: -
 Never unevenly or over load buggies or skip cars, as they are some times so
improperly balanced that they may not stay at the tipped up position after being
empted out.
 To prevent an explosion in the cupola, back up with scrap, empty cylinders, tanks
and drums.
 The use of mechanical devices for charging cupola not only save labor but also
reduces the number of material handling injuries. Most cupolas are now charged
either by fully automatic charging machine, equipped with crane and cone
bottomed buckets or lift trucks equipped with lifting boxes.
 The charging openings in some cupolas is covered by door or chain curt ten,
which is kept closed except during charging, to prevent material dropping on
workers while charging .
 Install railings or other safe guards for the space underneath the cupolas, charging
elevator, machines lifting hoists, skip hoists and cairns.
  Never allow workers to rest during ideal period under the charging platforms
close to the hot chamber & flues, because of the danger of falling objects from
platform and possibility of CO escaping from the flues.
 Never allow the workers to place their lockers under the platform, because of the
above reasons.
Charging floor: -
 Use steel floor plates for charging floors, which should be heavy
enough not to luchup, securely fasten these plates.
 Install break work flooring laid on the solid plates frame work at the
immediate vicinity of the furnace to avoid heat.
 Keep charging floor free from materials & provide rakes for unused
materials/equipments.
 Provide standard railings of 42inch height and 4inch toe boards around
all floor openings. Railings on the charging floor receive much abuse.
 Fabricate the railings from angle iron, which can be more easily
repaired then pipe railings.
 Provide hang gates or chains at the tapping platform, which should be
hooked in place.
 Place a guard rail across the charging opening where cupolas are
manually charged.
 Provide curve of a height equal to the radius of the wheel of the skip
car, where cupolas are charged with skip cars. This prevents the skip
cars from pitching over and falling in to the cupolas.
Carbon Monoxide (CO): - It is generated during the operation of cupola. CO is an
explosion hazard if it gets in to the wind boxes and pipe during shut down. To eliminate
this hazard provision of adequate natural or mechanical ventilation at the back of the
cupola and two or more wind boxes to be kept open during shutdown. The large volume
of blast air from the cupola generally carries the CO out, through the stack, which some
times may not burn in the stack before it discharged. CO indicators or monitors should be
located around the cupola which gives light and a local sound since CO gives no warning.
Provision of trained workers with good condition breathing equipment should be
available at site. An engineering assessment should be done if CO concentration is
suspected to be more. In addition, +ve pr. Self containing breathing apparatus or an air
line respirator with emergency escape root should be provided.
Blast Gates: - Blast gates and explosion doors successfully used to prevent damage from
the gas explosion. They are some times placed in front of the tiers so that they can be
opened to admit fresh air when the blowers are under shutdown. Never close the blast
gates, explosion doors until the blast has been entered in to the wind box and the
accumulated gas has driven out. Provide blast gates in the blast pipes so that air can be
supplied in to the melting equipment. Close the blast gates when the air supply fails or
the melting equipment is under shutdown. This prevents accumulation of combustible gas
in the air supply system. In the cupola the alternative tiers are kept opened to permit air
circulation.
Motorized dampers with centrifugal blowers are installed to close automatically when the
air supply fails. Equip +ve pr. Blowers with safety valves at discharge pipes to prevent
pressure build up in them.
Tapping out: - The tapping operation should be done exclusively by experienced and
skilled operators. The operator should not directly expose to steam of the molten metal,
because that could cause spattering. To eliminate the hazard the operator should
immediately place the batt over the stream of metal, close to the hole and aim to down
towards the hole at a sharp angle. Keep a supply of botts ready for use within the
convenient reach of the operator who does the tapping.
When the cupola is tapped, hold the back end of the tapping bar below the level of the
hole. This prevents the rupturing the sand bed and causing molten metal to run out
through the bottom. A tapping spout directly fixed with cupola’s spout mounted on a
stand implies safety and efficiency. Operator can tilt in, back and forth with a foot leaver.
The rear end of the tilting spout is kept closed so that when that end is tilted down it
forms a reserver to receive the molten metal from the cupola. The metal run it into the
waiting ladder or mould when the supplementary spout is tilted forward. At the same
time more metal containers to be kept ready to keep the stream of metal run from the
cupola continuously so that the tilting spout can act as a reserve between ladders. Equip
the slag spout of the cupola with a guard to protect workers from spray of molten slag.
The slag is some times collected through a wet slaging system in which slag is thrown off
into a water fitted container.
Dropping the cupola’s bottom doors: - Support the bottom doors with a solid prop/bar
with two adjustable screws prop of the required structural strength on a metal base when
the cupola is in operation. The base should be set on a concrete or on a fabricated footing
of required strength.
Place temporary supports (timbers, blocking) under the cupola bottom doors. This
prevents the doors from falling on employees while the metal pores are being adjusted to
proper height. Provide mechanical means for raising the bottom door of the cupola.
Dropping the bottom doors of a cupola requires extra ordinary care. One of the best
methods for closing it is to use a block and tackle with a wire rope and chain attached to
the props that supports the doors. The props can then be pulled out by means of the block
and tackle from a safe distance or from behind a suitable barrio. Special locking devices
for bottom doors may be used if the cupola drop is to be caught in a container or skid.
Carefully inspect the area underneath the cupola to see that no water has spieled under
the sand before the bottom doors are dropped. One worker should make sure by whistle
or by other signals that no one is in the danger zone and that worker should stay away
before the bottom doors are dropped.
If the cupola’s bottom doors are failed to drop, do not permit employees to enter the
danger zone to force the doors to release the materials from the cupola. Blast fans can be
used to release the materials from the cupola. A mechanical vibration attached to the
bottom doors is also effective. Anther method of releasing the jam material is to drop a
demolition ball from the charging door. If all these methods fails, then flame cut the
doors, only after the cupola has cooled to a safe temp.
Repairing Linings: - Allow only care full and experienced workers under special
procedures and permits to repair a cupola’s linings. Observe the following precautions: -
 Install a guard over the cupola charging door to protect workers against falling
objects. Construct the guard with heavy gauge metal and cover it with a screen.
Securely support the guard by means of over head slings to resist falling objects.
 An alternative method is to place a solid steel plate on the bucket ring in the
cupola at the level of charging door.
 Implement a confined space program for workers entering cupola including PPEs.
 Provide approved respiratory protection for the workers engaged for relining the
cupola & place a blower fan at the bottom to keep away the dust from the
workers.
 Place warning sign or cross bars at the charging door to indicate that workers are
in the cupola.
 Before relining work begins, all loose slag and the deposited material in side the
cupola should be removed through bottom door.
 Check the condition of the shell while the cupola is down for relining. A weak
shell is likely to increase the risk of gas explosion.
 Leave ample clearance (at least 2cm) between the new brick lining and the shell
to allow for expansion. Fill this space with a dry sand to serve as a cushion to
protect the shell against serious stress.
 Before the cupola is started up make sure that all personal have existed from the
cupola & the area near it. The lining is thoroughly checked, all tools and other
equipments have removed.

SAFETY IN FORGING OPERATION

Forging process is used for the plastic deformation of metals& alloys either hot or cold
by applying compressive force. Hammer or impact forging exerts multiple forces while
press or roll forging exerts single force. Hammer or drop forging are carried out on hot
metal only while press forging is also possible on cold metal. Forging can be carried out
manually or by mechanically.
Accidents in forging shops are generally due to hot or cold metal falling on people
working, accidental starting of equipments, crushing hazards, radiant heat, burns, high
noise etc. Forging workers may suffer from chronic asthma, digestive disorders,
inflammatory, skin diseases respiratory troubles hearing loss due to noise and vibration.
General safety features are good plant & process lay out, guarded machines, good house
keeping & ventilation, good draft to furnace and efficient exhaust to flues, effective and
insulation screen for protection against radiant heat and hot air. Local exhaust system at
the furnace, cold air blowers at hot work places, noise absorbent pads, deep and massive
foundation to minimize vibration. rest rooms, proper ventilation, water showers etc.
Protective heat resistance aprons, safety foot wear, eye and face shields, ear muff/plugs
should be provided to the workers and periodical medical examination and safety training
are also necessary.
Specific Safety measures in forging operation: -
1. Raw Materials: - In the sequence of forging operation the first stage is
receiving, storing and preparation of raw materials for actual forging
process. Raw materials in various shapes are received by rail way wagons
or by trucks. Unloading operation should be carried out safely under the
experienced supervision.
2. Storage: - Adequate storing facilities should be provided with over head
cranes/hoists facilities for safe material handling. When piling is done in
 racks, returning posts for separating the different types of material should
be used. The benders should be separated by timbers of sufficient strength
to prevent being crushed. Spacers should be placed between the benders
to facilitate the hooking of slings.
3. Handling: - The handling of bar stock in storage areas creates specific
hazards which must be prevented. Most storage areas have over head
cranes & either electromagnet or sling suspension method to carry. The
electro magnet should be energized by reliable circuit which is separate
from the crane control circuit. Control should be equipped with a switch
that can be locked in position. The temp. of the magnet should be closely
watched as its capacity drops due to temperature rise. The magnet must be
loaded to rest and power to magnet must be made “off” at all times, when
the crane operator is not at the control cabin.
4. Shearing & Cutting: - Most bar stocks are reduced in size for forging
depending upon the requirement of products. Some multiples are cut by
saws. Saw table for bar stock must be substantial & should be provided
with rollers/slides to assists in positioning the feed to the saw and for
transferring cut multiples from the machines. Transmission parts should
be adequately guarded. The wheels and other moving parts of bend saw
should be metal encased. Sliding and adjustable guards should be used.
The blade of circulator saw and bend saw with the exception of the point
of operation.
FORGING FURNACE: - Various types of furnaces are used to preheat metal
before forging. The principle type of furnaces used are box, pushes, rotary and slot type.
A lighting torch should be provided, when lighting an oil fired furnace. The torch should
be placed on the furnace hearth (middle of the furnace, where maxim. temp. can be
achieved). The operator should be away from the furnace opening so as not to be exposed
to possible flash back. The charge & discharge doors of gas fired furnaces should be kept
open. The furnace must be purged to remove concentration of gas. Pilot burner should be
lit first after which the burners may be put “ON” one after anther. Furnace doors should
be kept open until the walls of the heating zone becomes cherry red. The furnace should
be ignited by means of a gas torch if it is not equipped with a pilot burner, which should
be inserted through a opening in the furnace wall or near the burner block. Those who
assigned to lighting operations (either oil or gas fired furnaces) should wear fire
protection jackets and face protection safety appliances which should be free from
flammable grease or oil. Checks should be made to locate the source, whenever any gas
leakage is detected at and around the furnace. Only a gas detecting instrument or soap
solution should be used. The use of any type of ignition adds to the hazard already
present and possibility of explosion. Do not attend to extinguish fire if any, until the fuel
source has not been shut off. All fuel lines should be equipped with safety valves and
easily operated manual valves at the floor level which must be readily accessible and
easily identified. The floor area at the valve should be kept clear of stock or other
materials. Leaks in fuel line are a common occurrence in the forging shop due to
vibration by the impact of the forging equipments, which should be attended as soon as
detected. Regular inspection schedule should be set up by the maintenance group to
locate and repair fuel line.
Forging furnace should be shield as much as possible to protect workers from radiant
heat. This can be done by means of glass wool, covered screens, metal shield backed by
refractory material and stainless steel or aluminium sheet having radiant heat reflecting
qualities. A steam or air line may be installed along the bottom of the furnace opening,
drilled with small holes in it, which helps certain the heat. Movable plates suspended
from a road across the furnace opening will help controlling the radiant heat. These plates
must be free to slide along the supporting rod so that the operator may move them back
or forth at the time of furnace operation.

Hazards of Forging Hammer: -All types of forging hammers have identical

hazards. The most frequent cases of injuries are: -
 Being struck by flying drift and key fragments.
 Using feeler gauge to check the guide’s wear, matching of dies.
 Using material handling equipments improperly such as tong lifts.
 Having fingers, hands and arms crushed in between dies.
 Having fingers crushed in between tongs.
 Using scale blowing pipes with short handles.
 Being burned by hot scale.
 Dropping stock on feet.
 Getting foreign objects, such as iron dust or scale in the eyes.
 Noise induced hearing loss.
A hearing conservation programme that includes proper hearing protection, annual
audiometric examinations, as well as engineering controllers will greatly reduce or limit
noise induced hearing loss. Injuries may also occur from a steam drop hammer when the
ram pulls off a new piston rod. Some times the rod must be set in the ram several times
before it holds. If the piston rod breaks the ram will fall. This hazard emphasis the
importance of operator’s using a safety prop to support the ram before reaching under it.
Operating a hammer with a warn cylinder sleeve is also hazardous hence shut the
hammer down and repair it. Operating a hammer with broken piston rings is also
dangerous. A piece of broken piston ring passing through the steam ports and loading in
the throttle valve may cause the ram to drop out of control. When this happens, the
operator’s tong/transfer tool may caught and cause serious injury.

DIES
Set up & Removal of dies: -When forged dies are set up or removed, the
hammer operator should act as a leader of the group. He should see that all activities are
coordinated and all safety rules are observed so that the work will be done efficiently and
safely.
Preset up Activities: - Clean the immediate area around the hammer and clear
the obstructions before set up of dies. Do not perform any maintenance work on the
equipment during setting of dies. The hammer screw should make the following check up
before set up: -
 The hammer should be in good working order.
  The seats of both the block & ram should be flat and clean.
 Dowels and die keys should be in good condition.
 Dies should be checked for other defects like such as cracks or sharp corners.
 The over all height should be greater than the height of the hammer.
 Good illumination is essential for accurate setting of dies. It gives the operating
screw a better view of the potential hazard. Portable light may be used with heavy
duty cods, with bulbs protected by heavy screen guards.
 If lifting trucks are used (fork lift) be sure that floor is labeled, in good condition
and free of obstruction.
 If cranes are used, check that the lifting chains or slings are in good condition.
Setting of dies: - Dies are generally heavy and hazardous to handle with out proper
equipments. Drill uniform holes on both sides of the each heavy die block and insert pins
to make lifting and moving them easier. The diameter of the holes and pins depends up
on the weight of the die. Standard practice is to have the pin 1.6 mm smaller in diameter
than the hole. Keep the depth of the hole and pin uniform in dies of a certain weight
group. This assures there will be enough pressure to prevent the pin from falling out.
Do not use transfer boards to remove dies between the workbench and the machine.
Transfer trucks preferably of elevating type are safer and more efficient. Use power lift
trucks or die trucks for moving or installing dies. Block/secure lift trucks to the base of
the hammer when dies are to be set or removed, otherwise the truck may slip from the
hammer, causing the die to sleep and fall. In addition the operator must check the safety
control prior to starting the die set.
Many methods are used in setting dies with hammers. The type and size of dies and
hammers determine the method to be selected to set dies.
 The ram should securely fixed and short off, then lock out the power whether
steam, electricity or air.
 Drive die dowels in to the dowel holes in the die sank. Dimension should be
accurate to ensure a tightly driven fit.
 After the bottom die of steam hammer has been set in place drive the bottom
key to help line up the die and partially tighten it.
 Invert the top die and set in position so that dies are face to face with the
match aligned. (Reverse this practice for a gravity drop hammer set and key
the top die first, some times both the dies can be at once)
 Remove the safety prop (locking device) between the ram and block.
 Let the ram descend slowly until it engages the top die.
Using shim on the down or on the top dies creates an extra hazard. Normally spring steel
can be used as shim dowels which must be properly set. The hammer operator should
record the number and location of shims used so that the next shift or different hammer
crew can refer to it. If a die has to be moved to match, use a prop after the ram is raised,
so that the operator can work under the hammer to fix the shims. This prop must be
strong and long enough to support the ram and extend from the top of the die of the ram.
If allowance is made for moving the die, make the allowance on a steam hammer only in
the top die. The bottom die should have a light fit on gravity draft hammer. The general
safe practice is to have the top die tight, allowing the movement in the bottom die. The
die keys are to be driven only with a hand sledge. The safe procedure for bouncing is as
follows: - (a) bounce, (b) short of the power, (c) ram the key, (d) bounce, (e) short of
the power etc.
The impact helps to alien the dies but creates an additional hazard if luck dies are being
set. Take extra precaution and use special equipments for abnormally large and long dies.
In setting such dies the regular safety procedure for propping and handling may have to
be changed. Get the approval of proper facility and authority for any change. After
driving the die keys and before adjusting the wedges apply heat to the dies if they have
not preheated. On deep impression jobs it is a good practice to preheat dies in special low
temperature furnaces or hot water baths or with hot scrap steel for better setting them up.
Driving die is of two types, when dies are cold may crake the shanks, blocks or ram.
After heating the dies to approximately 150 0c drive the die keys tight again by means of
either a pneumatic ram or a light suspended ram. If any further adjustment to the hammer
is required it can be done after a forging has been made. The hammer screw should use
any welding time to make the following final check before getting ready for production.
 Check the dies for proper alignment & for proper wing clearance.
 Check that all tools have been at their proper place.
 Move the guards in to position.
 Make final adjustment to the billet heating furnace.
Removing of Dies: -Before dies are removed, clear the immediate area around the
hammer of over head trolleys, suspended tongs, portable conveyors, tools, billets, stands
& other equipments. Tie down over head trolleys so that they will not trip back in to the
work area. Move the scale guard back and remove accumulated scale that would interfere
with safe footing. Forgings to be moved immediately away from the unit and may be
placed in the next work system.
If more set of forging equipments has been delivered, place it near by but not directly in
the area where the hammer crew will work. To eliminate unnecessary handling, make
sure that service personal (trucks, crane operators & hookers) are familiar with the proper
procedure. Shut off and lock out hammer’s energy source (electrical, air, steam,
hydraulic) before loosening the die key. The top key is generally loosened first, unusually
with a mounted pneumatic ram. A light will balance ram, suspended from a cross beam
or from an over head crane or chain fall can also be used successfully.
Using a manually held drift pin or a knock out on a die key after it has been loosened &
driven to position even with the face of the ram or the block is a hazardous operation.
Instead use a spherical type of adjustable knock out that is held in position mechanically
rather than manually. After the dies keys have been driven out raise the ram prop at once.
The prop must be in good condition & must be placed in a surface. On a gravity drop
hammer use a jack to raise the ram. A spherical prop may be required.
Don’t attempt to raise the hammer to propping level if the top die has a tendency to
hang’s, instead first free the die with in the shortest possible distance from the place of
the bottom die. Prop the ram on the air lift, drop hammer with special care. After securely
positioning the prop under the ram, shut off and lock out the power. Use special platform
trucks with winches for this operation. They are practical and safe because the dies are
horizontally winched or pulled out directly on the table of the truck. Don’t permit the dies
to be dumped out of the hammer or the floor.
After removing the dies from the hammer extract the dowels. Two workers should drive
out the dowels with the proper tools, usually a drift and a sledge. These tools should be in
good condition and have sound handles because there is metal to metal contact. See that
workers are care full and ware PPEs.
Load the removed dies on to low steel pallets and take them from the area as soon as
possible. If dies required repair and modification, the hammer operator should notify the
supervisor. The supervisor should than have the die servicing group who take care of any
repairs before the next use.
Safe Operating Practices: - Make the supervisor who directs the activities of
workers in the hammer crew responsible for the following safe working practices: -
1. Keep all guards in place when the hammer is in operation.
Make sure all guards in good position.
2. Make materials, tools away from the aisles & from the
operator’s work place. Store them in the proper place. Keep the floor area
around hammers free of scale, oil, water and other material to ensure safe
footing.
3. Before starting work, have the hammer crew make its own
inspection, to see that the equipment and work area are in order. Have them
frequently check breakage of all critical points that are subject to sever
strain. If any unsafe condition is found they should inform the supervisor
immediately.
4. Never operate drop hammer when dies are cold. Dies should
always be preheated by hot steel placed in between them.
5. don’t permit any adjustment, repairs or service until (a) All
energy sources i.e. electrical, air, steam, hydraulic or compressed spring)
have been isolated & cocked out. (b) The tradel has been blocked to prevent
un intentional tripping. (c) The ram has been propped.
6. When dies are being set on a board drop, steam or air lift
gravity drop hammer, have operators fit the dowel in the upper die & the
ram with as few shins as possible. First move the bottom die which should
have enough shines so that it can be lifted easily. This procedure is the
opposite of that followed in setting dies in double casting, steam drop
hammer.
7. On steam drop hammers place a prop between the ram and the
shank of the top die before die is moved. When it is necessary to move the
bottom die place the prop between the block & the ram on the side
containing the dowels so that the die can be moved.
8. On steam drop hammers, don’t just the bolt until the main
steam valve has been turned “OFF”. This prevents the ram from being un
intentionally activated, while the operator is adjusting the bolt.
9. Laying liner stock between the dies to loose a stuck forging is
dangerous. When a forging stick stop the hammer, remove the forging.
Relay the die & continue the operation. On some operations where this
method is not possible use a safety liner made of soft steel.
10. When ever operator leaves the hammers even it only for a few
movements they should leave the upper die resting on the lower die to
prevent tripping.
 11. Carefully observe fly wheel speeds. As a rule don’t permit
them to exceed the number of RPM given on specification sheet. These
speed is the one up on which proper operation of the press is based.
BORING MACHINE
Boring consist of cutting a round hole using a drill, boring cutter or reamer. Drilling
machines are equipped with rotating spindles, handles and chucks that carry pointed
cutting tools. Operation perform with drilling machines include counter sinking, reaming,
tapping, facing, spot facing and routing. Boring mills use a cutter, either single or multi
edged, i.e. mounted on a supporting spindle or shaft. The cutter enlarges a hole that has
already been rough form by drilling, casting or forging.
DRILLS: - Drill press accidents are more likely to occur during unusual jobs because
special vices for holding the job are not usually provided. Radial drill accidents are
frequently caused by incorrect manipulation. The drill head, arm and the work piece
should be clamped properly prior to cutting the metal. The most common hazards in
drilling operation are: -
 Contacting the rotating spindle or the tool.
 Using defective drills.
 Being struck by a broken drill.
 Being struck by insecurely clamped work.
 Latching loose garments or gloves in the revolving parts.
 Sweeping chips or trying to remove long spiral chips by hand.
 Leaving the key or drip in the work.
 Being struck by flying metal chips.
 Facing to replace the guard over the speed charge pulley or gears.
Observing safety precautions and good operating habits can protect operators from the
hazards. To guard the operator from contact with a spindle, use a plastic shield, a simple
wire mesh guard or other barriers. Guard the tool with a telescopic guard that covers the
end of the tool. This gives enough safety of the tool exposed to allow easy placement of
the job being work. The telescopic drill shield has a stationary ribbed cage which gives
high visibility. A frequent cause of breakage is using a defective drill. A thin drill smaller
than 3mm in diameter will often break and cause injury. A larger and frozen drill may
strike in the hole and break. Insecurely clamped work may spin and cause injury to the
operator. Clamp the job (thin material) firmly between a piece of metal or wood to avoid
spinning before drilling. Grind the drill point to an angle of about 1600 while drilling thin
ferrous stock. Frequently remove the drill and clean out the chips when deep holes are
being drilled, otherwise the tool may jammed if the chips are allowed to pile. Maintain
counter way charge in good condition & installed a shield around the counter way.
Boring Mills: - Some common causes of injury in boring mills are: -
 Being stock by insecurely clamped work or by tools left on or near a revolving
table.
 Catching cloths or the materials of wiping in revolving parts.
 Falling against revolving work.
 Checking work/job while the machine is in motion.
 Allowing turnings to build up on the table.
 Removing turnings by hand.
Horizontal Boring Mills: - The same accident prevention methods are effective on
both table and floor type of horizontal boring mills. While the machine is in motion the
operator should never attempt to make measurements near the tool or adjust the machine
or the job piece. Frequently inspect clamps & blocking to make sure the clamping is
good. Always avoid to make shift set ups. The operator should make sure that the clamps
on the column has been loosened before attempting to raise or lower boring mills head,
other wise the boring bar may be bent or the clamps and bolts may break. This can cause
damage to the machine & cause injuries to the operator.
Before the boring bar is inserted into the spindle, the operator should make sure that the
spindle hole, the bar is clean & free from jams. The operator should not attempt to drive
the bar in to the tail stock striking with a hammer or other heavy tool. Instead the operator
should use a soft metal hammer to drive the bar in to the spindle. The operator should
hold a peace of soft cupper or brash against the bar while driving it in to the spindle if
steel hammer or a piece of steel is to be used.
Vertical Boring Machine: - The same procedures can be applied for the safe
operation of vertical boring mills. Each boring table particularly those tables, of 2.5 mtrs
or less in diameter should have the rim enclosed in a metal band guard to protect the
operator from being struck by the revolving parts or by projecting work. Such guards
should be hinged so that they can be easily opened during setting up or adjustment. If the
table is with the floor, install a portable fence usually of iron pipe sections. The operator
should never attempt to tighten the job, tool or never try to measure the job or feel the
edges of the cutting tool or oil the mill or try to ride the table while the machine is in
motion. There is one exception in some large mills; the operator may have to ride the
table in order to observe the work progress. In such cases he should always make sure
that no portion of his body will come in contact with a rotating part of the mill. In
addition if steeps are provided to access the machine or to the job, should have a pitch of
not more than 500 and should have slip resistant plates or floors. Stairs with four or more
steeps must have hand rail.
Milling Machine: - Bringing a piece of metal to the contact with a rotating multi
edged cutter and machining it is called milling. This procedure can be done by horizontal
and vertical drilling machine, by gear Hobbs, profiling machines, circular & bent saws
and the number of other type of rotating machines. Many accidents with milling machine
occur when operators load/unload or do the adjustments. The causes of injuries are: -
 Failure to draw the job back to a safe distance during loading and unloading.
 Using a zing/vise that prevents close adjustment of the guard.
 Placing the zing/vise for locking arrangements in such a position that force must
be exerted towards the cutter.
 Leaving the cutter exposed after the job has been with drawn.
 Leaving the work tools on the work table.
 Failing to securely clamp the job.
 Racing around the cutter or hob to remove chips while the machine is in motion.
 Removing cuttings by hand instead of with a brush.
 Adjusting the coolant flow while the cutter is turning.
 Callipering/measuring the job on a running machine.
 Using a cotton rag to clean excess of oil from the table while the cutter is turning.
  Wearing hand gloves, rings, ties or loose clothing, catching in fingers, gloves or
clothing in power clamps.
 Using incorrectly dressed cutters.
 In correctly storing cutters.
 Attending to remove a nut from the machine by applying power to machine.
 Striking the cutter with hand/arm while setting up or adjusting.
 Wrong judging the clearance between the cutter and other parts of the machine.
 Try to clean the machine while it is in motion.
Basic Milling Machine: -Regardless of the classification, direction of movement or
special attachments that make various operations possible on a milling machine.
Basically the safe guarding requirements are same. Several methods such as mound hand
adjusting wheel, for quick and automatic adjustment on the shaft, by either clutches or
ratchet device are available to guard the cutters. In this way the wheels do not revolve
when the automatic feed is used. Compression spring wheels with removable handles can
be provided. These handles can’t remain in the wheels, unless held in place by the
operator. The horizontal milling machine should have a splash guard and collecting pan
for catching thrown cuttings and lubricants running from the tools. Direct the lubricant
flow on the job so that the distribution set up will not be disturbed by the rotation of the
cutter. Make all cords towards the travel of the table rather than away from the direction
of the travel.
Gear Cutter: - both the tool and work piece will move during the operation of gear
cutters and hovers, there fore keep the operation guards simple and adjustable. A simple
barrier guard of proper size to cover the point of operation and fit the work piece is
necessary as the work piece moves towards the tool. Mount the guard on a spindle which
carries the work piece. This causes the guard to fit over the point of operation, where the
work piece is brought in to position.
Attach an encirculating type of guard to the tool head where the tool is brought to the
work piece and both the tool and the work piece are adjustable. Such a guard can be an
automatic drop gauge device. These devices can be equipped with both, a realize latch to
open the guards enclosure and a spring realized to return to a position, for clearing the
work. Each guard should have an automatic interlock so that the machine will not operate
except when the guard is in position. In some machines the leaver that controls the
spindle direction is located in such a way that there are chances of catching the operator’s
hand on the back gear driving spindle. In such cases, install an auxiliary leaver which can
be operated at a point out side the danger zone created by these gears.
On large machines where the operator is not close to the regular control switch, install a
pendant switch mounted on a arm or sweep. This switch acts as a magnetic break to stop
the machine instantly in case of emergency. The operator should make sure that both the
arbor and spindle holes are clean and free from jams before inserting an arbor in to the
spindle. He should draw the arbor firmly in to place by a sleeve nut and securely tighten
the nut. He should also make sure that the machine is at a stand still position before
removing the arbor from the machine.
Planning Machine: - planning machines are used for smoothen the metal surface.
Here the cutting tool remains stationary while the work piece moves back and forth under
it. The process is reversed while shapers are used as planning machines. Slotters and
brooches can also use as planning machines.
Accidents with Planners : -Accidents with planners & shapers frequently results
from unsafe practices caused by inadequate training & supervision are as follows.
 Placing hand or finger between the tool and the work piece.
 Running the bare hand over sharp metal edges.
 Measuring the job when the machine is running.
 Failing to clamp the work piece or tool securely before starting to cut.
 Haring insufficient clearance for the work piece.
 Coming in contact with reversing feed.
 Failing to make sure the current is turned “ON” before starting the machine
when the magnetic chucks are used.
 Unsafely adjusting the tool holders on the cross head.

To avoid these accidents, install guards on planners. Cover the reversing feed dogs on
planners. Keep the planner bed fully extended. Remove unwanted stock from the bed.
Travel with in 18” (4bcm) of a wall or fixed objects. Close the space between end of the
travel & the obstruction with a guard on either side of the planner. Fabricate the guard so
as not to cause an accident when the bed is extended.
Accidents with Shapers: - Accidents with shapers have essentially the same causes
as those with planners. In addition injuries frequently result from contact with projections
on the work piece or with projecting bolts or brackets, especially when the table is being
adjusted vertically. Leave the shapers ram projected over the table to alert the operator
that the table is high enough. Failure to properly locate the stops or dogs can also injure
shaper operators. Rigidly bolt the stops to the table especially on the heavy jobs.
The shaper operator should make sure that the tool is properly set. If it shifts away from
the cut during operation, then it will rise away from the cut & not fit in to the work.
Remove the handle of the stroke change screw before starting the shaper. Install guards to
prevent injuries to the operator & workers near by from flying chips, also cover the
reversing feed dogs on shapers.
Accidents with Slotters: - During slotter’s operation the most serious accident is
catching the fingers between the tool & the work piece. Fingers can also be cut between
the ram & the table when the ram is at the end of the down stroke. Since the ram works at
a slow speed & the machine table is small, operator may instantly reach across the table
& under the ram to pick up a tool or other object thus catching their fingers. To avoid this
kind of accident enclose the ram’s eccentric with a hinged guard made of sheet metal or
cast iron.
Grinding Machine: - This shapes material by bringing it in to contact with a rotating
abrasive wheel or disk. Operating includes surface, internal, external, and cylindrical &
center less operations as well as polishing, buffing, horing & wire brushing.
Hazards in Grinding: -
 Failure to use eye protection in addition to the eye shield mounted on the grinder.
 In correctly holding the work.
 In correctly adjusting or not using the work rest.
 Using a wrong type (a poorly maintained or imbalanced wheel or disk).
 Grinding on the side of a wheel, not designed for side grinding.
 Taking too heavy cut.
  Applying work too quickly to a cold wheel or disk.
 Grinding too high above the wheel speed.
 Failure to use wheel washers.
 Vibration & excessive speed that lead to pursting a wheel or disc.
 Using bearing boxes with insufficient lubricants.
 Using a spindle with incorrect diameter or with the threads damaged so that the
nut loosens when the spindle revolves.
 Installing flanges of the wrong size with on equal diameter or with damaged nuts.
 Incorrect wheel dressing (tapering).
 Contacting un guarded moving parts.
 Using controls that are out of the operator’s normal reach.
 Using an abrasive blade instead of a grinder disc.
 Failure to run a wet wheel dry , with out coolant for a period of time before
turning of the machine.
 Using an untested, broken or cracked grinding wheel.
 Reaching across or near the grinding wheel to load, unload or adjusting the
machine during set up.
Abrasive Wheel & Disc: - An abrasive disc is made of bonded abrasive, with
inserted nuts & washers, projecting studs or tapered plates, holes on one side of the disc.
The side is mounted on the face of a grinding machine. Only the exposed flat side of an
abrasive disc is designed for grinding.
An abrasive wheel is made of bounded abrasive & is designed to be mounted either
directly or with adopters on the spindle of a grinding machine. Only the periphery or
circumference of many abrasive wheel are designed for grinding.
Adopter: - Media extensions part must be used for heavy material grinding.(to be checked
periodically).
Handling Abrasive Discs & Wheels: -
This requires careful handling. Do not drop or throw them. Do not roll large discs or
wheels on floor. Too large and heavy discs & wheels are to be carried by trucks or by
other such means which can give the correct support.
Storing Abrasive Discs & Wheels: -
The discs & wheels are to be stored at a dry place. Do not expose to extreme temperature
changes especially below freezing temperature. Wet wheel may break or crack if stored
below 00c. Breakage can occur if a wheel/disc is taken from a cold room & work is
applied to it before it has warmed up.
Store it in racks in a central storage area under the control of a specially trained person.
The storage area should be as closed as possible to the grinding operation area to
minimize the handling and transporation.
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