The Safety Manual Thread

[M30]

Hi,

I'm very new to CNC and machining. Recently an opportunity has presented itself to me to utilize a machine shop with a HAAS TM-1 mill, lathe, band saw, drill press, etc. The circumstance is quite unusual, the owner rarely uses the shop anymore and rarely has time to show me how to use the equipment. My day job is completely unrelated so I am basically on my own and in the shop alone after hours.

Since I don't wish to die, I've been reading up on as much safety information as I can before I even touch this equipment. In searching the web, all I can find bits and pieces. In some cases it is simplified as "use common sense". Common sense only works if working with these tools is commonplace for someone - it's not to me.

This safety forum here is a great place to start, but it does not have a well organized or complete list of safety concerns and practices. So, what I would like to try, for the benefit of everyone, is to start a safety thread that concisely lists safety tips.

If there is a fair amount of participation, I will periodically take these tips and compile them in to a Acrobat PDF document. I would like to suggest the following copy-paste template to make that task easier and make the information complete:

Category: <The safety area of concern>

What: <What to do to be safe>

Why: <What could happen if you don't>

Mitigation: <What to do instead or rule of thumb if applicable>

Here are some examples:

Category: Lathes What: Do not allow unsupported stock to protrude excessively past the headstock. Why: The centrifugal forces at high RPM can cause the stock to whip causing severe injury or death. Mitigation: Use a tail stock for lengths more that 2x the diameter of the stock.

(I'm not sure about that 2x rule of thumb, but it's just an example.)

Category: General Safety What: Do not use compressed air to clear away chips or swarf. Why: Metal particles can easily be inhaled or enter the eyes of the operator or bystanders. Particles can also be forced between bearing surfaces of machinery causing premature wearing. Mitigation: Always use a brush or a cloth to remove swarf.

Hopefully this is not too ambitious of a goal... just trying to contribute.

Cheers.

[ToyMaker]

Category: general

What: when working closely with rotating machinery (lathe, mill, drill, grinder, etc.) do not wear loose clothing or jewelry.

Why: clothing (long sleeves, tie?, could get caught and drag you in. a ring caught on a fly cutter could remove a finger.

Mitigation: roll up sleeves, remove jewelry




robotic regards,

Tom
= = = = =
"Fondness makes the heart grow absent."
- - Joseph Salonga

[ImanCarrot]

Category: Lathes.

What: Never ever take your hand off of a chuck key unless it's out of the chuck

Why: Big bit of metal (chuck key) could launch itself at a high velocity at your head.

Mitigation: NA


Category: Mills/ Lathes

What: Even if you've left the machine to only go to the loo, always check fixture and tool holder tightness/ security when you come back.

Why: Tools/ Chuck settings could have been altered by someone else.

Mitigation: NA


Category: Mills/ Lathes

What: Check the E-Stop button at the start of each shift.

Why: THis is your last defence against an accident- if you've ever pressed an E-Stop and... nothing happens you'll know the gut wrenching panic that I wouldn't wish on my worst enemy!

Mitigation: Regular servicing.


Category: Mills/ Lathes

What: Never use a rag/ brush to clean the machine unless it's stopped.

Why: Cloth/ brush could be grabbed by the spindle and drag you in.

Mitigation: NA


Category: Mills/ Lathes.

What: Dry run all software prior to cutting

Why: One X or Z value wrong could plunge the tool at rapid overide anywhere (happened to me and wrecked a germanium dome worth about 9K- it exploded like a grenade!).

Mitigation: NA


Category: General Machine Shop Housekeeping.

What: Flooring- should be raised slats to allow swarf and oil etc to not get under your feet.

Why: Could trip and headbut the rotating lathe/ mill.

Mitigation: NA

[Mickster]

Category: Safety glasses

What: Inspect regularly, scratches are weak points. Following an impact, replace them even if they appear un-damaged

Why: You may not be so lucky the next time...

Mitigation: They are cheap compared to loss of an eye - replace at regular intervals. (Yearly??)




Category: Drill press

What: Clamp workpiece securely to table or in a vise secured to table

Why: Drill bits can grab the work-piece, spin it, remove flesh and shatter before you even realise what is happening.

Mitigation: If drilling a series of holes along the edge/length of a work-piece, clamp a temporary fence to the table



Category: General

What: Do not remove safety guards to enable a larger work-piece to fit into the equipment

Why: The manufacturer has designed the equipment to operate upon stock within safe limits, using the guards as fitted. If your stock won't fit, you need a more capable machine.

Mitigation: N/A





If anyone can offer more suitable/alternative wording to the above, please comment and I will amend as required.

HTH,

Mickster.

[M30]

I should have posted this before, but I thought I could go back and edit my original post. You can find the compiled "manual" here. Work in progress...

General Safety Manual for Machine Shops


Gotta love Google Docs.

[ImanCarrot]

Be aware that humans are falible:

Monday Mornigs and Friday afternoons may cause lapses in concentration.

Lapses in concentration can cause death. Serious.

If I've done 8 pages of A4 maths my brain lags at the end of a shift... you're still thinking about the last nanometre (1E-9) measurement as you press the big green button, an 8 can seem like a G or a 6, a 1 can masquerade as an I or a 7 resulting in a rapid traverse at full velocity in the undesired direction.

Always have your hand over the E-Stop. Always.