Lathe Machine

S. No. Hazards Guards / Controls

1 Contact with projections of face Head-stock guard. Chuck guard.
plates and chucks.
2 Contact with projections of the dogs Counter sunk screws.
and projecting set screws.
3 Flying metal chips, long burrs and Enclosure guard, portable perspex screen
tunings. guard, use of chip breaker tool.
4 Hand braking of machines. Foot pedal brake with trip switch, pneumatic
chuck and feeding tools for small jobs.
5 Filling and emerying without a holding Automatic emerying. Emery holder.
device.
6 Gauging the job while machine is in Dial indicators. Tight fitting clothing.
motion.
7 Cleaning chips in motion Safety hook / brush.
8 Projection of the work or stock Tube guard. Bar stock guard.
beyond machine.
9 Flying off the job. Full enclosure guard.
10 Inserting blanks and removing die Spindle jaws, mechanical feeding device and
processed part without stopping. safe fixture.
11 Splashing of coolant resulting in Splash guard, pan and enclosure guard
slipping hazards and dermatitis. mounted on rollers. Floor mats.
12 Flying chips of cast iron, brass and Chip guard. Goggles or face shield.
other non ferrous metals.
13 Pulleys, belts, ears, setscrews. Fixed guards ,Hinged guard.
Turrets & Capstan Lathes :
14 Counter weight falling and bar flying Tube guard. Blank off hole.
through turret head.
Multi spindle Lathe :
15 Collecting component while just martin Wire mesh. Spoon collectors.
off.
16 Parted component comes in between tool and
the first spindle.
1. Revolving cutter Jaw type interlocked or adjustable
guard, or a self closing guard which
automatically close when the job
tables moves backward and opens
when it moves forward for operation.
The guard may be transparent if
visibility is required.
2. Removing chips and swarf Brush, magnetic sweep, cleaning
cleaning by hand and using after stopping the machine. Long
rag to clean oil while it is sleeves to be avoided.
running.
3. Failure to clamp the work Permanent magnetic plate fitted on
properly. the bed.
4 Failure to draw the job back Fixed guard.
to a safe distance while
loading or unloading.
5 Tightening or loosening Use proper spanners. Education
arbor nut and other parts. and training.
6. Power drive pulley, belts, Closed housing or fixed guard and
gears etc. start / stops switch within reach.
 Sr. No. Hazards Guards / Controls
Planners :

1. Bed traveling within short Fixed guard or fencing to prevent

distance from fixed object. entrapping within 45 cm (section 25,
F.A.) All gaps to be guarded.
2. Falling material from the Fixed or self adjusting table guards on
table or bed. sides. Job clamping device.
3. Pulley, belts, drives and Fixed guards, starting and stopping
reversing dogs. device.
4. Flying particles. Aprons, goggles side runway for large
planners.
Shapers :
1 Speed changing and other Fixed or hinged guards.
drives
2. Flying and removing Aprons, goggles, brush.
chips.
3. Flying jobs. Clamping device.
4. Moving ram and tool Transparent shield for tool. A retriever to
the limit of the stroke of ram channel.
5. Reversing dogs. Fixed guard.
6. Other as for planners. As for planners and stated above.
Sr. Hazards Guards / Controls
No.
1. Flying particles, Goggles or face shields. Eye shield attached
Coolant and with the machine frame.
lubricants.
2. Dust generation. Local exhaust ventilation.
3. Bursting of the Protection hood (wheel guard) and protection of
wheel. flanges. Chucks or bands. No over speeding.
Avoid grinding on the side of the wheel.
Compliance of sec. 30, Factories Act.
4 Accidental contact Tool or work rest and its proper adjustment to
with the running avoid contact and trapping.
wheel.
5 Portable grinders. Wheel guard. Electrically earthed and fully safe.
Shock-proof gloves.
6 Belt drive and other Fixed guard
dangerous parts.
Main precautionary measures are as under:
1. Selection of a right wheel for right speed and right diameter.
With the same rpm, peripheral speed increases as wheel
diameter increases and centrifugal force increases as
peripheral speed increases. Due to excessive centrifugal
force, the wheel may break. Therefore peripheral speed (m/
s or f/m) is most important and a grinding wheel should be
selected based on its peripheral speed.
2. Ring test is carried out by a qualified person to check any
crack in the wheel.
3. Speed test before installing wheel. Test speed should be 1.5
x service speed. Testing should be on special stands.
4. The wheel should never be rotated at a higher speed than
that stamped on it.
5. Wheel guard (hood) should be fastened securely to the
grinding head to protect against flying fragments or coolant if
any. An adjustable tongue or a movable wheel guard is
necessary to restrict wheel exposure to 6 mm.
6. Abrasive dust and slurry removal equipment should be in good repair.
Dust generating equipment should be in a separate room.
7. Electrical earthing, bonding and on-off switch in easy reach.
8. Proper storing in dry area . Use special racks, shelves or boxes
according to the shape & size.
9. Proper dressing of the wheel.
10. Use wheel washer and flanges of correct size and equal diameter
(at least 1/3 dia of the wheel).
11. Avoid overtightening or loose tightening. Use proper tool. Proper
mounting to avoid internal stresses. Use mounting blotters supplied
with wheels.
12. Check spindle threads so that the nut is not loosened on revolution.
13. Use spindle of correct diameter.
14. Balance the wheel to avoid vibration. Balance before installation.
15. Apply the work slowly and gently. Do regular lubrication.
16. Avoid side grinding, over speed and cleaning, adjusting or gauging
while the machine is in motion.
17. Wheel exceeding dia 15 cm or speed 50 m/s should have a
strength-test mark.
18. Adjust tool rest properly.
 Milling and Milling Machine
Milling Machines
• The basic components of these machines are as follows:
• Worktable: on which the workpiece is clamped using T-slots.
The table moves longitudinally relative to the saddle.
• Saddle: supports the table and can move in the transverse
direction.
• Knee: supports the saddle and gives the table vertical
movement so that thedepth of cut can be adjusted and
workpieces with various heights can be accommodated.
• Overerarm: used on horizontal machines; it is adjustable to
accommodate different arbor lengths.
• Head: contains the spindle and cutter holders. In vertical
machines, the head may be fixed or can be adjusted vertically,
and it can be swiveled in a vertical plane on the column for
cutting tapered surfaces.
 Column-and-Knee Type Milling Machines

Schematic illustration of (a) a horizontal-spindle column-and-

knee type milling machine and (b) vertical-spindle column-and-
knee type milling machine.
 Bed-type Milling Machine

FIGURE 24.16 Schematic illustration of a bed-type milling machine.

 CNC Vertical-Spindle Milling Machine

A computer numerical-control (CNC) vertical-spindle milling

machine. This machine is one of the most versatile machine tools.
 Five-Axis Profile Milling Machine

Schematic illustration of a five-axis profile milling machine. Note

that there are three principal linear and two angular movements of
machine components.
 Chapter 24
Machining Processes Used to Produce
Various Shapes: Milling
 Parts Made with Machining Processes

Typical parts and shapes that can be produced with the machining
processes described in this chapter.
 Cutters

a. Straddle: more cutters are

used to machine two parallel
surfaces on the workpiece

b. Form milling produces

curved profiles using cutters
that have specially shaped
teeth

C & D Slotting and

slitting operations are
performed with
circular cutters. [T-slot
cutters,
Cutters for (a) straddle milling, (b) form milling, (c) slotting, and
(d) slitting with a milling cutter.
The intelligent milling operator will study and observe the
following safe working operations when operating the
machines.
(a) Learn how to operate the controls before using the
machine.
(b) Fasten the work securely in the vice or to the table.
(c) Don’t change the spindle speed of any machine while the
machine is running.
(d) Be sure to keep your finger clear of the arbor bearing
when setting the support arm position.
(e) Make sure that the cutter is clear of the work.
(f) Never remove or tighten a milling machine arbor with the
power on.
(g) Support arm is always in position when the arbor is being
removed or tightened.
(h) Keep hands away from revolving cutters. Never reach over
a revolving arbor to make any adjustment.
(i) Don’t check work or measure while the cutter is
revolving shut the machine off first.

(j) Don’t remove guard from the machine.

(k) Stop the machine and use a suitable brush to clean the
chips from the cutter or vice. Rag and wastes not to be
used near rotating cutters.

(l) Don’t lift the machine’s heavy attachments alone .ask

some one to help you or use a crane.

(m) Don’t walk away from the machine while the cuter is
revolving. Shut off the motor. Never permit another person
to start or stop the machine for you.
(n) When removing end mills and face milling cutters, always hold a rag over
the sharp edges of the cutting teeth. This will prevent the painful cuts.

(o) Keep the floor around your machine clean and free from object that may
cause one to slip and fall.

(p) Wear snugly fitting cloth. Loose garments, flapping ties are easily caught in
machines.

(q) Release all auto feed when you have finished using the machine. Keep
your mind on the job.

(r) Don’t lean on the machine. Keep both feet on the floor.

(s) If you are not sure of correct and safe methods or procedure, ask your
supervisor.

(t) A moment’s thought may prevent hours of pain; you have eight fingers and
two thumbs; keep them safe.
 Safety Precautions Regarding Operators
1.No alteration or adjustment should be done on the machine parts
while the machine is running

2.Clamps holding the work should not be adjusted while the machine is
in running

3.The machine is to be stopped before cleaning the metal

4.The sharp edges of the work should be handled with care

5.The measuring of the work should be done only after the machine is
switched

6.The operator should not seek the assistance of others for starting and
stopping the machine.

7.Machining of precise parts and internal surfaces of the workpiece are

to be carried out with great care and
8.The operator should stay away from direction of the ram
 Safety Hints Regarding the Shaping Machine

1.The workpiece is to be positioned in such a way that the ram will

not hit the workpiece while performing the forward

2.Stroke length of the ram and the position of stroke are to be set
correctly before performing the operation.

3.Proper holding of the work should be Work holding devices like

clamps and vice jaws should not come in the way of the
reciprocating tool.

4.We have to ensure that the tool or the tool post or the ram will
not hit the job or the job holding clamps or the vice

5.The machine should be stopped before making any adjustment

to the stroke length, position of stroke, apron and tool
Precautions for Power Shearing

Following are the precautions to be observed while working on

Power shearing machine:
(a) The machine should be faultless and have safety devices.

(b) There should be clearance between cutting members.

(c) The cutting tool must be sharp.

(d) Machine should be rigid and robust.

(e) There should be good arrangement for holding and setting

the heavy sheets and plates.

(f) Machine should be well lubricated.

(g) The stroke should be set according to the requirement.

Safety Precautions in Sheet Metal Work

Accidents in sheet metal shop are due to negligence when

handling sheets the cuts are observed on fingers. Following
safety precautions are suggested to avoid injury:

(a) Use hand gloves before handling a sheet metal.

(b) Do not try to lift the cut portion of the sheet at the time of
cutting or shearing.

(c) Do not try to test the quality of cut edge with naked hand.

(d) Place the sheets in such manner that there is no danger of

their fall.

(e) Do not try to bend or perform other operations on the sheet

without tools.
In metalworking, rolling is a metal forming process in which metal stock is
passed through one or more pairs of rolls to reduce the thickness and to make
the thickness uniform. The concept is similar to the rolling of dough. Rolling is
classified according to the temperature of the metal rolled.

In metalworking, rolling is a metal forming process in which metal stock is

passed through one or more pairs of rolls to reduce the thickness and to make
the thickness uniform. Rolling is classified according to the temperature of the
metal rolled.

Hot rolling is a mill process which involves rolling the steel at a high
temperature (typically at a temperature over 1700° F), which is above
the steel's recrystallization temperature.

Surface defects may occur due to scale, rust or impurities. Scale is produced
when the hot surface is oxidized by air. This mill scale can reduce corrosion if
steel is exposed to air over short periods, however, the corrosion increases if
exposed for long periods. Large amounts of mill scale also cause severe
pitting corrosion if the surface is in contact with water.
Scale on the surface is usually removed mechanically, using water under high
pressure or acid pickling and then oiling to reduce rusting.
Hazards in Rolling .
1. Hazards in handling of raw material , scrap .
2. Melting furnace hazards.
3. Handling of ladle with liquid metal / red hot ingots.
4. Burn injuries due to contact with hot metal.
5. Contact with unguarded driving drives on rolling
conveyors.
6. Shearing machine hazards. / hazards in gas cutting
7. Poor housekeeping.
8. Material handling.
Wire Drawing:
A wire is a circular, small diameter flexible rod. Wire drawing is
an cold working process. It is an operation to produce wire
of various sizes within certain specific tolerances. This
process involves reducing diameter of thick wire by passing it
through a series of wire drawing dies with successive die
having smaller diameter than the preceding one. Mostly die
are made by chilled cast iron, tungsten carbide, diamond or
other tool material. The maximum reduction in area of wire is
less than 45% in one pass.
CNC Machine Safety & Maintenance :

Many tools are fitted in an auto tool changer which operates suddenly as per
the programme. Therefore all moving mechanism of a CNC machine should be
totally enclosed in a plastic cover to afford safety and visibility. Such covers
should be so interlocked that inner parts will not start till the cover is closed and
will not open till the inner parts are stopped. Limited openings for the job
insertion, machined part ejection and scrap removal are permitted. Any manual
control, if required, should be remote. Machine should not start inadvertently.
Necessary trips and locks are provided for built-in safety. Electrical double
earthing, start-stop switches in easy reach, sound foundation to eliminate vibration,
automatic lubrication system, mono-rail and chain pulley block to handle heavy
machine part or the job, numerical display system, sufficient surrounding space for
work and maintenance and protection of computer system are basic safety
requirements. Tool magazine operating at a height as in case of steel plant, are
considered safe by position. Machine operators should be qualified and well
trained for the operation of machine and the job.