Unit-1

SAFETY IN METAL WORKING MACHINERY AND WOOD WORKING

MACHINES
 General safety rules and Principles of
Machine Shop
• 1. These job safety rules are in addition to the General Safety Rules.
You must know and follow both.
• 2. Workers must not remove or make ineffective any safeguards,
unless authorized. Safeguards removed for repairs must be replaced
promptly or temporary guards installed.
• 3. Machines and equipment shall be operated by authorized personnel
only.
• 4. No machine shall be left unattended while it is in motion.
• 5. Cleaning, oiling or adjusting any machine shall not be done while
the machine is in motion.
Cont…
• 6 Materials to be machined shall be securely fastened or clamped to the working
surfaces before starting the machine.
• 7. Keys or other adjusting tools must never be left so that they may creep, be thrown, or
fall when machine is started.
• 8. Use a brush, special tool or hook to remove chips, shavings or other material from
work. Flowing shavings shall not be handled with bare hands; metal hooks shall be used.
• 9. Revolving shafting, although apparently smooth, will catch loose or ragged clothing,
hair or wiping rags. Proper clothes and caution are always necessary when working
around any revolving machinery.
• 10.When tightening work in chuck jaws with chuck wrench, operator shall see that
wrench fits properly; operator should take proper stance when tightening jaws to
prevent falling if wrench slips.
Cont….
• 11.When placing or removing heavy castings or billets from machines,
operator shall get help or crane service to prevent injury.
• 12.Operators shall keep hands away from cutters and bars while
operating machines. Operators shall keep hands off work while
machine is in operation.
• 13.Operators shall stand so that they can easily reach the machine
controls.
• 14.Cutters and tools shall be in the clear before machines are started.
• 15.Clean-up chips, spills, etc., on and around machinery after each use.
 Safety rules and principles of Lathes
Lathe machines require special safety precautions while being used. These are in addition to those
safety precautions described in previous slide.
• All materials shall be properly secured in chucks and collets before machines are started.
• Do not leave chuck wrench in chuck after removing work from chuck.
• Keep hands off chuck rims when lathe is in motion.
• Do not attempt to screw chuck on lathe spindle with power on, as it may get cross-threaded and
cause an accident.
• Safety-type lathe dogs shall be used when turning work on centers.
• See that tail stock, tool holder and work are properly clamped before turning on power.
• It is dangerous to shift step pulley belts with the hands while the belts are in motion with power on;
use a belt pole or other suitable stick.
• Do not attempt to adjust a tool while the lathe is running.
• Operators shall not attempt to use micrometers on revolving work.
Lathe
Safety Guards used in Lathe
Safety rules and principles of Boring
Machine
Boring machines require special safety precautions while being used. These are in addition to
those safety precautions described in previous slide.
• Wear proper eye and ear protection.
• NEVER leave the key in the chuck. Remove the key from the chuck IMMEDIATELY after
securing or removing the bit.
• Never wear jewelry, gloves, ties, loose clothing or clothing with long sleeves. Keep long hair
tucked under a hat. Jewelry, gloves, ties, clothing and hair could become entangled in the bit.
• Use the rip fence as a backstop and hold the stock firmly against both the worktable and the
fence. If you can't use the rip fence, use the miter gauge or clamp the stock to the worktable.
• Use only accessories and bits designed to be mounted in power drills.
• Never drill or bore metal freehand. Always clamp the metal to the worktable and backup
stock, or the rip fence and back-up stock.
Boring Maching
Safety Guards used in Boring Machine
Safety rules and principles of Milling
Machine
Milling machines require special safety precautions while being used. These are in
addition to those safety precautions described in first slide.
• All work shall be secured properly and all loose objects removed from tables before
machines are operated.
• Cutters shall be checked for cracks or breaks before mounting and shall be securely
mounted before operations are started.
• Operators shall keep head and hands away from cutters when machine is in
operation.
• File tangs or other makeshift drifts shall not be used to remove taper shank tools.
Proper drifts are available in tool rooms.
• Safety guards shall be placed around any work item extending beyond machine table.
Cont…
• Milling cutters and other hardened tools shall not be struck with steel
hammer. Blocks of wood, rawhide, or copper hammers should be used.
• Proper feeds and speeds shall be selected before operations are started.
• Machines shall be stopped before any attempts are made to measure or
to check work.
• Guards and baffles shall be used to protect others from flying chips, oil
or coolants.
• Operators shall be sure that cutters and feeds are turning in the proper
direction so the cutters will not climb up or jam. Such an accident can
cause injury to the work, the machine, and to the operator as well.
Milling Machine
Safety Guards used in Milling Machine
 Safety rules and principles of Planning
machine
Planer machines require special safety precautions while being used. These are in addition to those
safety precautions described in first slide.
• Jobs shall be securely mounted and all tools removed from tables before machines are started.
• Machine stroke shall be properly adjusted so as to clear work and machine tables.
• Operators shall stand clear of work that projects over side of planer tables.
• Operators shall not try to adjust stroke or position of ram while cut is being taken.
• Operators should stand so machine controls are easily reached.
• While machines are in operation, hands shall be kept away from clapper boxes. Adjustment shall
not be made to tools when clapper boxes are raised.
• Screens shall be provided against flying chips or cuttings to protect other employees
working nearby.
• Operators should take proper stance when pulling on long wrenches to bolt down work on
machines to prevent falling and strain should the wrench slip.
Planer Machine
 Safety rules and principles of Grinding
machine
Grinding machines require special safety precautions while being used. These are in addition to those
safety precautions described in first slide.
• Caution: All grinding wheels operate at dangerous speeds.
• See that the grinding wheel fits easily on the spindle. It is dangerous to force it on, nor should it be
too loose.
• Washers or flange facings or compressible material shall be fitted between the wheel and its flanges.
If blotting paper is used, it should not be thicker than .025 inch.
• After a wheel is mounted, allow it to develop full operating speed for at least one minute;
meanwhile, stand to one side and out of danger. Never apply the work until this speed test has been
made and the wheel has been properly dressed. Under no condition should the wheel revolve faster
than the safe R.P.M. recommended by the manufacturer as shown on the label.
• Do not force work against a cold wheel, but apply it gradually, giving the wheel an opportunity to
warm, thus reducing the chance of breakage. This applies to starting work in the mornings in cold
rooms and to new wheels which have been stored in a cold place.
Cont…
• Wheel dressers, except the diamond type, shall be equipped with guards over the
tops of the cutters to protect against flying pieces, broken cutters, or wheel particles.
• Operator shall see that wheel turns freely and is properly mounted before operating.
• All wheels should be given the "ring" test before they are mounted on machines.
• Gloves should not be worn while operating grinders.
• Dust collectors or other exhaust systems shall be in operation during grinding
operations on machines so equipped.
• Tools or other loose objects shall be kept off machines in operation.
• Wheel guards shall be kept in place and in good condition while machine is in
operation.
• Safe operating speeds are marked on wheels by manufacturers.
Cont…
• Operators shall not run wheels faster than recommended speeds.
• Operators shall avoid standing directly in front of grinding wheels, especially when starting.
• Wheels loaded or clogged with metal shall not be used until dressed.
• Grinding wheels out of round or out of balance shall be trued before using.
• Eye protective equipment with side shields shall be worn while grinders are being operated.
• Grindings wheels shall be equipped with tool rests, same must not be worn more than one-eighth
inch from stone and work held firmly thereon.
• It is unsafe to adjust a work-rest while the grinding wheel is in motion. The rest may slip and break
the wheel.
• The side of an emery wheel shall not be used for grinding unless it is a special-type wheel for that
purpose.
• Be especially careful when grinding narrow tools. They are apt to catch between the rest and the
wheel.
Grinding Machine
Safety Guards used in Grinding Machine
Safety rules and principles of CNC Machine
CNC machines require special safety precautions while being used. These are in addition to
those safety precautions described in first slide.
• Always ensure that you wear proper ear protection and a good pair of safety glasses when
operating a CNC machine.
• Ensure that your safety glasses are firmly in place every time you are closely observing the
cutting tools.
• Ensure that you wear suitable footwear such as safety boots at all times.
• If you have long hair, ensure that you keep it covered when you operate the CNC machine.
• Keep your hands away from any moving parts during machining processes.
• Stand clear of the machine whenever it is operational. You should also warn any other
people near the risk of being too close to it.
• Whenever you are handling or passing tools, avoid touching the cutting edges.
Cont…
• Ensure that you turn the machine off completely and clean it
whenever you have finished using it.
• You should never wear gloves while operating the CNC machine.
• You should never wear jewellery or any loose clothing.
• You should never try to reach into the machine while it’s running
• You should never put your hands anywhere near the spindle when it’s
revolving.
• Never leave the machine when it’s not completely powered down.
CNC Machine
Maintenance of Turning machines
• Step 1:
Turn the machine off from the main power point and fit your tag???
Out of Order??? , to avoid someone can try to use the machine during
your machinery maintenanace procedure.
• Step 2:
Open side cover and check;
• Driving belts, if the belts are damaged, excessive cracks, or an excessive
wear, they must be replaced
• Check tension of belts.
• Check brake conditions ( on models with pedal brake)
Cont…
• Step 3:
Turn the lathe ON and :
• Run the lathe for a couple of minutes.
• Check level of lubricant oil on visor main gearbox.
• Refill if required with gear oil.
• Step 4:
During running test check that:
All the automatic feeding movement are working properly
• Step 5:
Check tailstock locking condition.
Both lever must lock properly.
Cont…
• Step6:
Check top bench lubrication manual pump.
Pull or pouch lever to verify that oil is coming to the sliding bench.
Check level of lubricant oil of tank , bench lubrication
Step 7:
Lubrication, period-lubricant Some point will be required to lubricate with gun oiler.

• Headstock – twice a year – SHELL TELLUS 27 OR compatible.

• Compound slides, by gun oiler-daily -, -SHELL TONNA 33 or compatible .
• Apron & carriage-handle pump- daily -, -SHELL TONNA 33 or compatible.
• Tailstock nipple-by gun oiler- daily -, -SHELL TONNA 33 or compatible.
• Change gear nipple- by gun oiler- daily -, -SHELL TONNA 33 or compatible.
• Leadscrew nipple- by gun oiler- daily -, -SHELL TONNA 33 or compatible.
• Bed ways- by gun oiler- daily -, -SHELL TONNA 33 or compatible.
Cont…
• Step 8:
Coolant.
• Check level of coolant, refill is required
• Empty tank and fill up with new coolant every 4 months.
• Avoid contact with coolant during the refilling process, you must wear
rubber gloves.
• Test bottom of coolant tank to verify if there are solids.
• Remove solids and try always to keep coolant tank clean.
• Run the lathe and test coolant is supplied properly.
Cont…
• Step 9:
Electric: Check the main power cable for its conditions. If it is damaged, must be
replaced.
Verify conditions of all external switches.
All switch with damage must be repair or replace it.
Check conditions of all limit switches. They must be strong in position. A loose or
damage limit switch can generate a continuous fault on the machine
• Step 10:
Centre point alignment:
Once a year, depending the precision required would be convenient to verify
alignment of centre tailstock with centre of headstock.
Alignment can be obtain by fitting a total parallel bar between centres, and the with
a dial indicator verify parallelism between centres.
Maintenance of Boring machine
Boring machine General provisions of the cumulative operation of 800h
after the operation of the main one-level maintenance, maintenance
work must be cut off after the power. Below take T68 type horizontal
boring machine As an example, explain the boring machine level
maintenance content and request.
• External maintenance. The main cleaning machine surface dirt, rust,
keep the transmission parts clean. Scrub the surface of machine tool
and cover shell, should have no rust without macular, scrub each
exposed screw, light bar and rack, make up each handle, screw, nut
and so on, keep the machine appearance neat.
Cont…
• Spindle box and feed gearbox maintenance. Open the main shaft box of the dust cover plate,
check the adjustment v-Belt and spindle box clamping lever. Clean the filter and oil tank, check the
balance hammer wire rope fastening condition, scrub the flat disc chute and adjust the insert bar.
• Working table and guideway maintenance. Scrub The work table everywhere, check the
adjustment of iron and insert clearance, check the guide rail is NAP, light burr and scrub guide.
• Post pillar maintenance. After cleaning the bearing seat, guide surface, check the adjustment of
the insert gap.
• Lubrication system maintenance. Clean linoleum, oil tank, keep the oil hole and the circuit
smooth. Clean the cooling pump, filter net and cooling box. Clean the filter to ensure the oil cup is
complete and keep the oil-marked oil window bright.
• Electrical Part maintenance. Clean the electric box and electric motor. Check the position of the
electrical device to ensure that the electrical device is fixed, safe and tidy. Operating system, and
finally cut off the power.
Maintenance of Milling machine
After every use
• Clean the linear milling rails, ball screw, feed screw nut, spindle taper
and the machine in general. Make sure all swarf and turnings have
been cleaned off.
• Lightly oil the milling rails using WD40 (or equivalent). Check the air
filter and lubricator for blockages.
Weekly maintenance tasks
• Grease the gearboxes using a maximum of two strokes.
• Grease the linear bearings using a maximum of two strokes.
Cont…
Quarterly maintenance tasks
• Remove gearbox cap and check bearings and gears for wear. Repair/replace as necessary.
• Grease the main bearings and check for spindle adjustment.
• Grease main drive gears.
Half yearly maintenance tasks
• Check the carriage operation and adjust if necessary.
• Check lead screw backlash.
• Check spindle operation.
Prior to extended duration of storage
• If the machine is to be stored for any length of time clean thoroughly and spray WD40
into the motor inlet and seal. Spray the machine with WD40 or equivalent.
Maintenance of Planning machine
Machines, particularly safety devices and guards, should be adequately maintained
to ensure safety. You should consider how your workers use machinery and have
adequate maintenance arrangements in place to ensure it remains safe. Unless a
bridge guard moves freely (both vertically and horizontally) it is unlikely to be kept
adjusted.
• Lubricate machines regularly.
• Make sure any damage is reported and replace parts as required.
• Change the pads on Shaw guards regularly to suit the size of the workpiece. The
fixing screws need to be in good condition – keep spares available and have the
right tools to hand.
• Inspect and replace the handles on push blocks regularly – they should be secure.
Maintenance of Grinding machine
Portable Grinders
• Air Driven - Measure the speed of governor controlled grinders every 20 hours of actual use or once per week,
whichever comes first. Measure speed of all types of grinders after maintenance or repair, whenever a grinder
is issued from the tool crib and at each wheel change. Several readings should be taken.
• Electric Driven (Hi-Cycle) - Measure monthly and after any maintenance or repair that could affect the speed
of the machine.
All Other Grinders
• Direct Drive (Single Speed) - Measure after any maintenance or repair that could affect the speed of the
machine.
• Belt Driven (Single Speed) - Measure monthly and after any maintenance or repair that could affect the speed
of the machine.
• Variable Speed Machines - Measure once per week and after any maintenance or repair that could affect the
speed of the machine. On variable speed machines, other than semi-automatic snagging grinders, measure
speed whenever a wheel change is made.
Maintenance ofCNC machine
• DAILY CARE AND FEEDING OF YOUR CNC MACHINE
• Check the hydraulic pressure to make sure it’s at 4.5 MPa
• Check the hydraulic fluids to make sure they’re at the right operating level
• Check to make sure the chuck pressure is at the right operating pressure and grease chuck according to
manufacturer's recommendation
• Make sure the way lube level is at the right operating level, and replenish if needed
• If your CNC machine has a cooling system, make sure the cooling unit level is at the right operating level
• Clean the chips out of the chip pan
• Clean off the window of the door and the light so you can see inside your machine
• Wipe down any stainless steel way covers and lubricate them with hydraulic oil so they move smoothly
• On a weekly basis, or every 40 hours, take the filter off the CNC control cabinet and clean it so air will be
able to flow through for cooling.
Cont…
EVERY THREE MONTHS OR 500 HOURS
• Check and grease the chain on the chip conveyor
• Check and clean the filters on the coolant tank
EVERY SIX MONTHS OR 1000 HOURS
• Have the coolant tank cleaned of sludge, chips, and oil
• Have the chuck and jaws taken off the machine and cleaned
• Have the hydraulic tank drained and replace the hydraulic oil with fresh hydraulic oil – also have the line
filter and suction filter changed
• Have the radiator cleaned and make sure the radiator fins are straight
• Have the lubrication unit drained and cleaned out – then add fresh way lube
• If your machine is equipped with a cooling unit, have the unit drained and refilled
• Have the leveling of your machine checked and adjust if necessary
• Have all way wipers inspected for any damage – clean and replace any wipers that are damaged
Cont…
ONCE A YEAR OR EVERY 2000 HOURS
• Have the headstock checked for taper
• Have the spindle checked for radial and end play
• Have the chuck cylinder checked for run out
• Have the tailstock checked for taper
• Have the turret parallelism and inclination checked
• Have your distributor run a backlash program to check the backlash in X
and Z axis and adjust if necessary
• Have your distributor check the X and Z axis gibs and adjust if necessary
Inspections of Turning Machines
• Turning Machine Daily Inspection
• BEFORE POWER ON
• Inspect the oil level of the operating oil tanks (hydraulic unit, central lubrication, spindle gear box lubrication
tank…) and coolant level in tank before starting the operation. If the level in tanks is below standard point,
refill liquid or if oil is discoloured replace. For the correct oil grade refer to the Inspection and maintenance
chapter in the instruction manual
• Check oil skimmer tank and drain if necessary.
• Check strainers in coolant tank. Remove and clean (use compressed air).
• AFTER POWER ON
• After start up machine check pressure gauges for hydraulic unit, ways lubrication unit and compressed air.
• Check fans in electrical cabinet for air flow.
• Check conveyor for smooth movement.
• Return all axes to the reference position.
• Check hydraulic chuck for smooth movement and apply grease.
Cont…
• Check for secure mounting of tool holders and cutting tools
• Lathes with rotary tools
• Check all plugs in turret. Turret should be sealed.
• Open one coolant plug in turret for checking coolant and or chips inside turret head, rotate turret wheel until
open hole is down. Should coolant drip from inside of the turret the leak must be traced and repaired.
• DURING OPERATION
• Check load percentage for all axes and spindle/s in motion (no cutting).
• Check for noise in each part of machine during operation.
• AT THE END OF THE DAY
• Clean remaining chips around spindle, turret, tailstock or sub-spindle and between slide covers. Do not use
compressed air (air gun), recommended brush, rags or coolant
• Check coolant collector (rear of chuck actuator) for chips.
• Check way covers or bellow covers for smooth movement and apply lubrication oil on cover guides.
• Check wipers on way covers for damage
Cont…
• Turning Machine Inspection every three months
• Inspect the following components and keep record of the result. When a problem is found, correct it by repairing or replacing before next
operation.
• Follow daily Inspection first
• Check alignment for headstock, tailstock, turret, Q-setter correct if necessary.
• Check backlash for all axis correct if necessary.
• Check zero position for x-axis and adjust grid shift if necessary.
• Check limit switches for correct reading and clean.
• Check solenoid valves for moisture and or dirt. Clean.
• Open front cover of turret and check for coolant and dust inside the turret.
• Apply suitable amount of grease for live tool gears .
• Check alignment for live tool drive shaft and live tool shaft .
• Check orientation position for live tool drive shaft .
• Inspect and apply grease for ball screws and linear guides if applicable
• Lubricate and grease according to the table of lubrication. Refer to the instruction manual.
• Clean and wash heat exchanger on hydraulic unit .
• Check spindle belts and timing belts for deflection (tool post and spindle encoder) 
Cont…
• Turning Machine Inspection every six months
• Inspect the following components and keep record of the result. When a problem is found, correct it by repairing or replacing before
next operation.
• Follow daily Inspection and inspection every three months first
• Open all covers and clean machine. .
• Replace coolant and oil according to lubrication chart.
• Inspect, clean and / or replace filters (coolant, lubrication, air filters). For details about location and specification please refer to the
Inspection and maintenance chapter in the instruction manual.
• Check the level of machine and adjust if necessary .
• Inspect the accuracy of machine based on the accuracy inspection table.
• Check for broken or damage parts (bellow covers, way covers, door slides and rollers, coolant rotary coupling, limit switches,
conveyor chain links……)
• Lathes with rotary tools. Check rotary drive unit, clean and grease.
• Check electrical terminals and connectors for moisture and dust, check tightness. Check and clean heat sinks for drive units and fans.
• Check for loosening bolts .
• Check battery voltage for NC, servo drives and bar feeder .