SAFETY

At the end of this lesson you shall be able to

 State the importance of safety
 List out the safety precautions to be observed in a machine shop
 List out the personal safety precautions to be observed
 List out the safety precautions to be observed while working on the machines.

Generally accidents do not happen; they are caused. Most accidents are avoidable. A
good craftsman, having knowledge of various safety precautions, can avoid accidents to
himself and to his fellow workers and protect the equipment from damage. To achieve this, it
is essential that every person should follow safety procedures.
Safety in a workshop can be broadly classified into 3 categories.
 General safety
 Personal safety
 Machine safety
GENERAL SAFETY
1. Be sure that all machines have effective and properly working guards that are always in
place when machines are operating.
2. Replace guards immediately after any repairs.
3. Do not attempt to oil, clean, adjust or repair any machine while it is running. Stop the
machine and
lock the power switch in the "Off" position.
4. Do not operate any machine unless authorized to do so by the teacher, or under his
supervision.
5. Even after the power is off, do not leave the machine until it has stopped running. Some
one else may not notice that it is still in motion and be injured.
6. Do not try to stop the machine with your hands or body.
7. Always see that work and cutting tools on any machine are clamped securely before
starting.
8. Keep the floor clear of metal chips or curls and waste pieces. Put them in the container
provided for such things. Scraps are tripping hazards, and chips or curls may cut through a
shoe and injure the foot.

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9. Do not operate machinery when the instructor is not in the shop.-
10.All setscrews should be of flush or recessed type. If they are not, move with caution when
near them. Projecting setscrews are very dangerous because they may catch on sleeves or
clothing.
11. Get help for handling long or heavy pieces of material. Follow safe lifting practices—lift
with your leg muscles, not your back. If you do not know how to lift safely, ask your teacher
to show you.
12. When working with another student, only one should operate machine or switches.
13. Do not lean against the machines.
14. Do not run in the shop; there should be no "fooling around" in the shop at any time. Don't
be a "wise guy".
15. Concentrate on the work and do not talk unnecessarily while operating the machine.
16. Don't talk to others when they are operating a machine.
17. Get first aid immediately for any injury.
18. Be sure you have sufficient light to see clearly. Check with the teacher if you do not have
enough.

PERSONAL SAFETY
Clothing And Safety Equipment
1. Always wear safety glasses, goggles, or face shields designed for the type of work when
operating any machine.
2. Wear clothing suited for the job. Wear shoes with thick soles— safety shoes if heavy work
is being done.
3. Do not wear rings, watches, bracelets, or other jewelry that could get caught in moving
machinery.
4. Do not wear neckties or loose or torn clothing of any kind.
5. Wear shirts or jumpers with sleeves cut off or rolled above theelbows.
6. Always remove gloves before turning on or operating any machine. If material is rough
or sharp and gloves must be worn, place or handle material with machine turned off.

Housekeeping
1. Keep floors free of oil, grease, or any other liquid. Clean up spilled liquids immediately;
they are slipping hazards.
2. Aisles should be clear at all times; to avoid tripping or other accidents.

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3. Store materials in such a way that they cannot become tripping hazards.
4. Do not leave tools or work on the table of a machine even if the’ machine is not running.
Tools or work may fall off and cause toe or foot injury.
5. Put tools away when not in use.
6.Place all scrap in scrap boxes.

MACHINE SAFETY
Shapers
1. Be sure ram, tool head, tool, work, table-support clamping screws, and vise are properly
secured in place, or position, and that the tool head and tool clear the work before starting
the shaper. Place a metal shield or heavy, close-mesh wire screen over the, tool to catch the
chips.
2. After setting the stroke length and position, check to see that adjusting nuts are tight.
3. Remove all wrenches from machine after completing setup.
4. If magnetic chuck is used, be sure current is “On” before-starting machine.
5.Stand parallel to direction of stroke of machine when it is running and never reach across
the table between strokes of the ram.
6. Never remove chips while ram is in motion.
Planers
1. After work is fastened, check to see that it clears cross rails;see that stop pegs are in
proper places and safety dogs are secured in position..
2. See that feed rod and its attachment are properly located and in proper working order.
3. Have planer idle when adjusting length of bed stroke and speed of machine to suit work.
4. Do not reach over-a moving job and never ride the bed or platen.
5. Do not leave any tools of any kind between the ways.
6. When loosening tool holders, hold tool with one hand or place a wooded support under it.
Milling Machines
1. Make sure that the cutter and arbor are secure and that cutter and arbor support clear the
work.
2. Use only cutters that are correctly ground and in good condition.
3. To avoid striking hands on cutter while setting up, more table with work as far away from
cutter as possible

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4. When using cutters in a vertical milling machine, do not take an excessively heavy cut or
feed. Such a feed or cut could break the cutter and injure operator.
5. Do not try either to tighten or to take off arbor nut by applying power to machine. Make
sure motor is " Off."
6. Check speeds and feeds, and feed work against direction in which cutter is rotating.
7. Keep hands away from work when machining.
8. Never reach over a revolving cutter, especially the side of cutter, which cuts into the work.
9. Use a brush not the hands to remove chips.
Drill Press
1. Use drills properly sharpened to cut to the right size and see that the drill is running true.
2. Small drills should revolve at high speeds, large drills at low speeds. Reduce speed about
50 percent when drilling cast iron.
3. Chuck wrenches must be removed from drill chucks before starting the machine.
4. Never attempt to hold work under the drill by hand. Always clamp work to table.
5.Rundrill only at proper speedy; forcing or feeding too fast may result in broken or splintered
drills and serious injuries.
6. Change belt for speed regulation only when power is " Off" and machine has come to a
dead stop.
7. If work should slip from clamp, never attempt to stop it with the hands. Stop the machine
and make adjustments.
8. If drill stops in work, shut off the motor and start drill by hand.
9. File or scrape all burrs from drilled holes.
10. Do not reach around or in back of a revolving drill.
11. Keep your head back and well away from any moving part of the drill press.
Lathes
1. Before turning on the power, check to see that the tailstock, tool holder, and job are
properly clamped.
2. Use hand power only when putting on or removing chuck or faceplate; do not use the
power that operates the lathe.
3. When assembling or removing the chuck, place board on ways to prevent damage to
machine and possibly to operator in case the chuck falls. Have firm grip on chuck as it nears
the end of the thread.

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4. Do not leave chuck wrench or any other tool in the chuck. If machine is turned on, wrench
may fly out and injure the operator or any other person.
5. Do not use wrench on revolving work or parts.
6. Never try to measure work or feel the edge, or adjust a cutting tool when lathe is running.
7. Do not take heavy cuts on long slender work; doing so may cause the job to fly out of the
machine.
8. When filing, be sure tang of file is protected by a strong wooden handle. Stand to one side
so that, if the file is forced upward, it will go past the body rather than against it.
9. As a general rule, do not shift or change gears while lathe is running.
10. Stand erect. This keeps head away from flying chips.

Metal Saws
1. When turning on power, stand to one side of saw frame, then adjust speed to suit work.
2. When saw is operating, do not bend over it.
3. Mount work only when saw is stopped.
4. Support protruding end of long work so material cut of will not fall and possibly injure any
one. Be sure that the protruding end is well guarded against any one coming in contact
with it.
5. When using the sliding stock guide, do not allow fingers to project beyond the end so that
they could come in contact with the saw teeth.
6. Be sure that the blades for both circular and band saws are in good condition before using.
An indication that the blade is cracked is a sharp, regular clicking sound as the work is fed.
Change the blade at once if this condition arises.
7. Always inspect blade before using.
8. If blade does break in work, shut off the power and do not attempt to disengage blade from
work until the machine has come to a complete stop.

Grinders: pedestal type

1. Stand to one side out of line of wheel when starting it up, especially if wheel is new.
2. The face of the wheel must be flat and free from grooves.
3. Work should be fed slowly and gradually. Using too much pressure, or striking wheel
suddenly, may cause it to break.
4. Make sure that the tool rest is only 1/8 in. from the face of the wheel. Check this
distance. Too Much clearance may cause job to jam the wheel and break it.

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 5. Do not set tool rest while machine is in motion.
6. Use face of wheel only, unless it is designed for grinding on the side; otherwise, side
pressure may break the wheel. Whenever possible, use entire face of wheel to avoid
grooving.
7. Never use a grinding wheel that is loose on the shaft or if its rate of speed is not safe
for the number of r.p.m.of the spindle. Check with the teacher for this information.
8. Stop wheel if it chatters or vibrates excessively. This may be a danger signal that the
wheel is not properly balanced or not attached securely to spindle.

9. All wheels should be tested for soundness. The teacher usually does that.
10. Hold job against wheel firmly so that it will not slip out of the hand and cause hands
and fingers to come in contact with the wheel.
11. Use clamp or other suitable holding devices for grinding short pieces.
12. Always use face shield or goggles even if grinder is provided with protective glass
shields.
Surface type
1. Be sure magnetic chuck is thoroughly clean.
2. Test holding power of chuck before starting the machine.
3. Stand to one side of wheel before starting up.
4. Check to see that wheel properly clears work.
Hand Tools:
Screwdrivers
1. Select screwdrivers to fit the screw head being used.
2. Keep screwdriver handles smooth.
3. Do not use a hammer on a screwdriver handle.
4. Avoid holding work in the hand when using a screwdriver on it, as it may slip and
cause stab wounds.
5. Never grind a screwdriver to a chisel edge.
Wrenches
1. Discard wrenches that are spread.
2. Select open-end wrenches to fit the job.
3. Where possible, avoid using an adjustable or monkey wrench.

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 4. If a wrench has become burred, grind off the rough spots to avoid cutting the hands.
5. It is generally safer to pull a wrench toward yourself than to push it away from you.
6. Be sure that your knuckles will clear obstructions when the wrench turns.
Hammers
1. Hammers that are chipped should be discarded.
2. Never use a hammer that has a loose or split handle.
Chisels
1. In using a chisel and hammer, keep the chisel head free from burring by grinding it if
necessary.
2. Where chips may fly, use a chip screen.
3. Hold the chisel and hammer firmly and keep the chisel head and the face of the
hammer clean and free from grease.
Scrapers
1. Keep scrapers in a place away from the rest of the tools.
2. Keep guard from handles on all scrapers. Guard against scraping towards the body.
3. Avoid holding work in one hand and the scraper in the other; stab wounds are likely to
result.
4. Scrapers that must be carried in a toolbox should be guarded with a wooden or
leather sheath for their own protection as well as yours.
Files
1. Always use a file with a handle.
2. When filling in the lathe, learn to file with a left-handed.
3. Keep the file and your hand clear of the chuck jaws or dog.
4. Do not use a file as a pry bar.
5. If filing in a lathe, do not use a pad of cloth or waste under the thumb on the end of the
file.
6. Keep a firm grip on the file at all times.
7. Do not blow filings so that they can go into anyone's eyes.
HACKSAW

1. Use the correct blade for the job.

2. See that the blade is correctly secured in the frame.

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 3. When the saw breaks through the work, ease up on the pressure so that the hand will
not strike the work or vise.
4. Be sure that the work is held securely in the vise.
5. Do not force cut.
Taps And Dies
1. Be sure work is firmly mounted in vise.
2. Secure the proper size of tap wrench.
3. Avoid cutting the hands on a broken tap end.
4. If a broken tap is removed by using a punch and hammer, wear goggles.
5. If a long thread is cut with a hand die, keep the arms and hands clear of the sharp
threads coming through the die.

CAUSES OF ACCIDENTS

1. Lack of interest
2. poor judgement
3. Lack of confidence
4. Lack of Knowledge
5. Over confidence
6. poor physical fitness
7. personal problems
8. improper working condition

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 QUESTIONS ON SAFETY
1. There are usually five areas of hazards connected with the operation of any machine
tool. These are listed below and you are to name the pre- cautions necessary for these
hazards:
A. Machine—moving and loose parts.
B. Tools—inserting and removing the tool and handling the wrench.
C. Materials—holding, handling, cooling, lifting, removing from machine, and removing
chips.
D. Floor around the machine—chips, coolant, and oil.
E. Operator—hands, eyes, and feet.
2. What should an apprentice learn to do at once? Why?
3. Name five accepted practices when operating a drill press.
4. Many accidents have occurred when handling materials. Name at least three safe
methods in handling materials.
5. Lifting is also a hazard. Explain how one should lift with safety. Give a concrete
example.. 6. If a casting is too heavy for one person to lift, what should he do? Why?
7. Why are you cautioned against wearing rings, wristwatches, etc., when working on
a machine tool?
8. What are the dangers involved in the wearing of loose clothing and ties?
9. What is meant by housekeeping when applied to the machine shop?
10. Name at least five good practices of housekeeping.
11. In the school shop, one is usually told to report any accident no matter how slight. Why?
12. Name three safe practices when using a hammer, a chisel, a screwdriver.
13. Why should handles on hammers be checked before using?
14. Why are the heads of chisels always checked before using?
15. Why should deep cuts and fast cutting speeds be avoided whenever possible?
16. What should be done to a grinding wheel before it is mounted in the machine? Why is it
done?
17. In chipping, why should a guard be placed around the piece being chipped?
18. What should always be worn when grinding? Why?
19. Name/three safe practices when operating a lathe, a milling machine, a shaper, a rinder.
20. Revolving drills are very dangerous. Name three things that a drill-press operator should
always look out for.

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