Safe Use of Machinery in Technology Metalwork
VBQU620 Safely operate and maintain metalworking
machines
Contents
Welding .......................................................................................................................................... 3
Filing ............................................................................................................................................. 18
Guillotine ...................................................................................................................................... 38
Grinding Machines ...................................................................................................................... 42
Drilling Machine .......................................................................................................................... 56
Cold Saw....................................................................................................................................... 70
Mill Drill ....................................................................................................................................... 82
Safe Use of Machinery in Technology - Metalwork/Version 1
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Safe Use of Machinery in Technology – Metalwork
VBQU620 Safely operate and maintain metalworking machines
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Understand Metal Shop Safety in the Technology teaching environment and safe operation of
specific metalwork machinery
Learn about preparing metal working machines for use
Learn about operating, maintaining metal working machines
Implement housekeeping procedures in a teaching metal shop
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Safe Use of Machinery in Technology - Metalwork/Version 1
Welding
It is important that every student has knowledge of all types of equipment, materials, and
substances they are to use safely in the metal area. They must have a basic understanding of the
fundamentals required to ensure safe, correct and proper application in the metal area.
The two (2) main gases we are concerned with in this area are oxygen and acetylene.
Oxygen is an odourless gas which can vigorously support and accelerate combustion. Although a
stable element, it is likely to cause unstable substances to explode, therefore certain precautions
must be observed in using it.
It is compressed to a pressure of 12,600 kPa into steel cylinders which are painted black; the
outlet of the cylinder valve is screwed into the cylinder with a right hand thread.
Oily and greasy substances are likely to ignite violently in the presence of oxygen under pressure
so oxygen must not be used a substitute for compressed air.
Acetylene is a highly flammable gas and has a very distinct odour. It is used for welding and
when mixed with oxygen produces the highest known flame temperature of any two (2) gases.
Acetylene has a wide explosive range, commencing from as low as 2% when mixed with air, and
increasing still further when mixed with oxygen.
Acetylene is liable to explode if compressed above the pressure of 105 kPa, therefore to transport
this gas in reasonably large quantities a cylinder filled with a porous mass saturated with liquid
acetone is used.
Acetylene is dissolved under pressure in this acetone. The absorption capacity of acetone for
acetylene is twenty five (25) times its own volume for every atmosphere of pressure applied.
When acetylene is drained from a cylinder, something similar to the reaction of a soft drink
bottle occurs. The gas bubbles out from the soft drink bottle when the pressure is reduced by
removing the bottle cap, the same applies when the acetylene cylinder is opened. Pressure in the
cylinder falls and the acetylene comes away from the liquid acetone.
If the rate of flow from the cylinder is too great while this process is going on the gas does not
have enough time to separate from the liquid and the liquid will flow from the cylinder with the
gas.
Acetone can also be discharged from the acetylene cylinder if the cylinder is left laying on it
side. Acetylene cylinders must always be stored upright and be secured by chains so the will not
fall or be knocked over accidentally.
Safe Use of Machinery in Technology - Metalwork/Version 1
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Oxy-acetylene equipment
Description and use
The oxy-acetylene process produces a high-temperature flame over 3000°C, which is used for
heat-treating metal, brazing, fusion welding, cutting and bending. It is the only gas mixture hot
enough to melt steel. The extremely high temperature of the flame and the explosive nature of
acetylene gas means that extreme care must be taken with oxy-acetylene equipment.
Oxy-acetylene use exposes students to a number of hazards, including toxic fumes, dusts, burns,
fires, explosions, radiation, noise, and heat stress. Only senior students considered responsible
and safety-conscious should be instructed in using oxy-acetylene equipment. Conduct a thorough
induction and training program to teach students of the dangers involved. They must be trained
in the safe way to open, light extinguish, and close down the oxy-acetylene equipment. Provide a
checklist for students to follow. Teachers will still decide whether a trained student will be
allowed to use the equipment for a particular project or in a particular lesson. Skilled adults may
use oxy-acetylene equipment to help primary students in constructing their products (billy carts,
pedal powered vehicles).
Bystanders can be at risk during welding.
Organise a specialist area for oxy-acetylene
welding that protects other students from the
welding process.
Extremely high temperature of flame and heated
material can burn operators.
Students must wear protective clothing while
welding. Lighted torch must always point away
from themselves and others. They must not leave
gas flame unattended. Always light flame with
approved lighter (flint or electronic spark) so that
fingers are not brought close to tip of torch.
Students must wear sturdy leather gloves when
handling materials being welded. All heated work
should be marked with word hot on the metal in
chalk or soapstone.
Extremely high temperature of flame and heated
material can cause fires.
Combustible or flammable materials should not be
near welding. When work cannot be done in a
welding bay, area should be made safe by
removing or protecting combustibles from ignition
sources. Fire extinguishing equipment such as sand
buckets, fire blankets or dry chemical extinguishers
should be readily available.
Dense concrete base or asbestos cement base may
explode when heated.
Benches used for welding should be covered with
firebrick or similar materials.
Toxic fumes created by welded metals are a major
hazard. Metals such as nickel and chromium found
in different grades of steel create fumes that may
cause lung cancer. Tin, copper and galvanised
metal have hazardous coatings.
Students should not weld metals that are considered
hazardous or which have hazardous coatings.
Welding and cuffing should be done in an area with
adequate ventilation that removes and disperses
fumes to outside atmosphere. Local exhaust
ventilation is required for certain metals.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Brazing rods can give off zinc and copper fumes
and some silver solder contains cadmium. Fluxes
can produce hazardous substances when heated.
Welding and cuffing should be done in an area with
adequate ventilation that removes and disperses
fumes to outside atmosphere.
Containers that have held flammable materials can
explode if welded.
Under no circumstances should students weld
drums, barrels, tanks or other containers.
Oxy-acetylene flames are bright, can create sparks
and produce UV rays.
Tinted welding goggles must be worn. The filter
grade to use depends on the intensity of the flame,
which depends on the thickness of metal being
welded. Safety goggles protect eyes from sparks.
Safety glasses are worn when work is being
cleaned.
At a pressure of over 100kPa acetylene 100kPa
becomes unstable and can explode.
Keep acetylene flow pressure below (15p.s.i.). The
pressure for regulator should be set to suit size of
blowpipe tip. Correct tip and pressure must be used
for task being performed.
A backfire (pop or crack) can occur if flame ignites
gases inside nozzle and extinguishes itself.
Avoid holding torch too close to work. Regularly
check nozzles and regulator pressures. If the flame
still burns, valves need to be systematically closed
down and torch relit.
A flashback (shrill hissing) can occur if flame
burns inside torch. Flame can pass back through
torch mixing chamber to the hose.
Flashback can be avoided through correct:
• closing-down procedures
• tip selection
• gas pressure
Also ensure students do not used dirty welding or
cuffing tips. Avoid incorrect gas pressures, which
give too low a gas velocity. If a flashback occurs,
close oxygen blowpipe valve first, then close fuel
gas valve. It is essential to examine torch, hoses
and components and replace if necessary. Arrange
inspection of equipment by qualified personnel
before relighting. Non-return valves filled to hoses
will detect and stop reverse gas flow. A flashback
arrestor is an automatic flame trap device that
quenches flame and prevents it from reaching the
regulator.
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If oxy-acetylene cylinders are not stored outside the classroom, check that the regulator pressure
screw is released, then open cylinder valves gradually. Never open cylinder valves more than
one turn. Keep wrench in place in the acetylene cylinders so that the valve may be shut off
quickly if necessary.
When using oxy-acetylene equipment students will:
• use equipment under close supervision by a suitably trained teacher or adult
• wear suitable protective equipment, including:
- oxy-acetylene goggles when welding and safety goggles when performing other activities
- buttoned-up overalls or similar without cuffs, open pockets, tears or gaps, covering arms
and legs to protect from radiation burns and deflect sparks
- protective gloves
- solid footwear
• use a flint lighter or pilot light to light the blowpipe
• close cylinder valves when work is finished.
Maintenance and Storage
Gases are supplied under high pressure. The colour coding is maroon for acetylene and black for
oxygen. To prevent interchange of fittings between cylinders, oxygen cylinders have a righthand thread and acetylene cylinders have a left-hand thread. Both cylinders are opened by
turning the key or knob anti-clockwise and closed by turning clockwise.
Cylinders should preferably be stored in open air but always in a well-ventilated area, away from
sources of heat, sparks, and other fire risks. The acetylene cylinder should always be stored
upright (refer to 7.6.8 Chemicals used in technology, Gases). Each bottle should be secured to a
wall by a removable chain with fixed lines feeding to the gauges. Oxygen cylinders should be
stored at least three (3) metres from fuel gas cylinders or separated by a 30-minute fire-resistant
barrier in a designated no-smoking area. Sets of gas bottles should not be stored in the school.
One set is enough and it should be replaced as emptied.
Gas supply hoses must be protected from sparks, naked flames, hot metal, and sharp objects.
Moses should be as short as possible. Do not use damaged or frayed hoses.
Check gauges annually and replace every five (5) years. Regulators are sensitive instruments and
should be handled with great care. Teachers should always double-check students’ operation and
setting of regulators.
Blow tips, which should suit the task, must be cleaned regularly with a set of reamers.
Occasionally brush the end of the tip with a fine abrasive cloth. It is important for students to be
taught the maintenance of oxy-acetylene equipment so that they will follow safe practices when
working away from the school.
Oxygen can react violently with oils and grease. Do not use lubricating oils or sealant for the
threads. Cylinder threads should be clean and free from oils and undamaged, especially for
oxygen use. Never grease regulator threads. Use only clean rags to wipe this equipment. Close
cylinder valves before moving cylinders.
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Welding Equipment
Spot Welders (resistance welders)
Description and use
A spot welder is particularly useful for joining sheets of metal. Electrodes convey a flow of
electricity through the metal. The metal is brought close to melting point and the pressure of the
electrode points causes the sheets to join where they meet. Spot welders can be portable or fixed.
Only secondary school students thoroughly instructed in its correct and safe use may use a spot
welder. Primary school students may have a trained adult use a spot welder to help construct
their products.
Hazards
Precautions
Heat generated by electrodes causes metal to
become red hot, creating a burning hazard.
Students must wear sturdy leather gloves when
handling materials being welded.
Too light a pressure causes the welder to spit.
Pressure needs to be correct for the weld to
succeed. By reducing point pressure, more heat
is created.
Machine can be overloaded.
Do not exceed capacity (the number of welds
per minute) of welder.
Maintenance
Keep electrode points clean and in good condition. They must meet exactly and be parallel. Tips
of electrode points need to be machined to a 3mm diameter flat point. Over-size tips will reduce
heating, while small tips will burn the weld.
Check points often for deterioration while in use. A file can be used to shape the tips. A lathe is
used to machine the points if the tips become oversize after constant use and repeated dressing.
Electric Arc Welders
Description and use
An arc welder is used to join metals by creating an electric arc that melts the edges of the joint.
The arc welding electrode acts as a filler rod. Arc welding involves working with electricity,
molten metal and sparks and produces rays extremely dangerous to the eyes. Using the arc
welder improperly can expose the operator to hazards that include toxic fumes, dusts, burns,
fires, explosions, welding flashes, electric shock, radiation, noise, and heat stress. Only students
considered responsible and safety-conscious should be instructed in using arc welding
equipment. In most cases these will be senior students. Conduct a thorough induction and
training program to teach students of the dangers involved. Provide a checklist for students to
follow. Teachers will still decide whether a trained student will be allowed to use the equipment
for a particular project or in a particular lesson.
Safe Use of Machinery in Technology - Metalwork/Version 1
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Hazards
Precautions
Bystanders can be at risk if near welding. Arc
welding creates a flash hazardous to unprotected
bystanders.
Organise a specialist area for electric arc welding
that protects other students from the welding
process The welding area must conform to
AS1485-1983, 12.5 Electric Welding. The walls of
the welding compartment should be non-reflecting
or be finished with a non-reflective surface. Where
portable screens are used, they should be durable
and stable, and constructed of fire resistant
material. The arc welder should be in an area with
adequate ventilation.
The high temperatures created by an arc welder can
cause fire.
Floors must be of a non-combustible material.
Cracks should be filled to prevent sparks and hot
metal from entering. Combustible or flammable
materials should not be near welding activities.
When work cannot be done in a welding bay, the
area should be made safe by removing or protecting
combustibles from ignition sources. Fire
extinguishing equipment such as sand buckets, fire
blankets or dry chemical extinguishers must be
readily available.
Dense concrete base or asbestos cement base may
explode when heated.
Weld only on a firebrick surface.
Extremely high temperature of the heated material
and the sparks created by arc welding can burn
operators.
Students must wear protective clothing while
welding. They must wear sturdy leather gloves
when handling materials being welded.
All heated work should be marked with the word
Hot on the metal in chalk or soap-stone.
Hot metal should be carefully quenched to prevent
steam burns.
Toxic fumes created by welded metals are a major
hazard. Metals such as nickel and chromium found
in different grades of steel create fumes that may
cause lung cancer. Tin, copper and galvanised
metal have hazardous coatings.
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Students should not weld metals considered
hazardous or which have hazardous coatings.
General ventilation may be adequate for welding of
short duration and intermittent. Ventilation must
remove fumes and disperse them to outside
atmosphere. Removal at source (local exhaust
extraction) is the most effective method. The
degree of exposure to fumes depends on welding
position, location, and type and duration of work.
Students must work with their heads away from the
plume. Several students welding at one time create
greater quantities of fumes.
Safe Use of Machinery in Technology - Metalwork/Version 1
Hazards
Precautions
Arc welding electrodes create toxic fumes.
See notes on ventilation above. Choice of welding
rod affects composition and quantity of fume and
gases. A range of welding electrodes is available —
some safer than others. Strictly follow
manufacturer’s instructions for the use of the
welding electrodes.
Welding in confined spaces can create build-up of
toxic fumes.
School students should never work in confined
spaces or enclosed and unventilated areas.
Containers that have held flammable materials can
explode if welded.
Under no circumstances should students weld
drums, barrels, tanks or other containers.
Electric shocks can occur during welding.
When welding is finished, remove electrodes from
the holder. Hang holder where no accidental
contact can occur and disconnect welder from
power source. Position welding cables so that
sparks and molten metal cannot fall on them.
Prevent electric shock hazards such as wet or damp
areas and standing areas made of steel or other
conductive materials. Warn students of these
dangers in case they weld away from the school.
Debris such as electrodes and electrode stubs can
be a slipping hazard.
The welding area must be kept clear of tripping and
slipping hazards.
The flash created by arc welding is extremely
hazardous to eyes.
Warn students always to wear a welding face shield
when welding and never to start weld without it in
place. Never use a helmet with a cracked or broken
filter plate or cover lens.
Slag chipped off welded materials and dust
particles are hazardous to eyes.
Safety goggles must be worn when students are
chipping off slag or cleaning work.
• When using electric arc welding equipment students must follow the following rules:
• Only use the equipment under close supervision by a suitably trained teacher or adult.
• Protect their eyes from the welding flash by wearing an approved face shield fitted with the
correct filter lenses for the welding process used.
• Wear safety goggles when chipping slag or wire brushing the finished bead.
• Wear suitable clothing to protect against heat, ultra-violet rays and sparks. This includes:
- buttoned-up overalls or similar without cuffs, open pockets, tears or gaps, covering arms
and legs to protect from radiation burns and deflect sparks. Clothing should be buttoned
up and gaps avoided
- leather gauntlets to protect arms and hands from UV radiation and spatter burns
- solid shoes with leather spats to prevent hot material entering shoes
- leather apron to protect clothes and body from spatter burns
- flame-proof cap if there is a danger of ignition and tied-back hair.
• Ensure that ventilation systems are working or that the area is well ventilated (this is also the
teachers’ responsibility).
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Maintenance and Storage
Turn off welder when work is being changed. Keep leads, lead terminal, supply leads and plug
and hand-piece insulation in good condition. Check before beginning work. Store arc welder in a
dry area, under cover. Students should report to the teacher if the electrode holder, holder cable
connection, cable terminals at the machine, ground clamp or cable get hot. Make sure circuitbreaker is operating.
Electrodes are coated with flux. Keep them dry by storing in a sealed container.
MIG Welders
Description and use
Metal inert gas (MIG) welding is based on a weld pool formed by a bare wire electrode protected
by gas (helium, argon). It is used in most industries. The heat for welding is produced by
forming an arc between a metal electrode and the work. The electrode melts to form the weld
bead. The wire is continuously fed, so the process is referred to as semiautomatic welding.
Different methods of welding can be used. Terminal connection differs for gasless welding
(steel) and gas shield welding (aluminium and stainless steel).
MIG welders are considered relatively safe compared with other arc and oxy-acetylene welders.
Teachers should refer to the section on arc welders for further precautions when welding.
Hazards
Precautions
Heated material and sparks created by
welding can burn operators.
Students must wear protective clothing while
welding and sturdy leather gloves when handling
materials being welded.
Flash created by MIG welding is hazardous
to eyes.
Warn students always to wear a welding face
shield when welding and never to start the weld
without it in place. Never use a helmet with a
cracked or broken filter plate or cover lens.
Welded metals can create toxic fumes.
Students should not weld metals considered
hazardous or which have hazardous coatings.
General ventilation may be adequate for welding
of short duration and intermittent. Ventilation
must remove fumes and dispersed them to outside
atmosphere. Removal at the source (local exhaust
extraction) is the most effective method.
The shielding gas has a substantial effect on the stability of the arc and metal transfer and the
behaviour of the weld pool. Care in setting voltage and feed of the wire is essential to control
spatter and to perform welds.
Maintenance and storage
Maintain the MIG welder according to the manufacturer’s instructions. Check that controls are
operating correctly before use. Ensure hoses are stored without kinks. Check that they are in
good condition and not perished.
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The purpose of this procedure is to highlight the precautions to be taken when carrying out hot work such
as grinding, oxy cutting, gas or electric welding. Consider the fire risks within a 15m globe from the site
of the hot work and what precautions are required. Hot work is a recognised cause of fires, and on the
available data appears to be the third most common cause at the Steelworks. The hot work procedure is
important as a tool to prevent fires – the next one might be the big one!
HOT WORK
Reference Critical Procedure
When carrying out Hot Work – oxy
cutting, welding, grinding – there is a
real risk of starting a fire.
Precautions must be taken.
Coach
1
1
2
2
Is hot work the best way to do
the job?
If Yes then
Is the work area set aside for
hot work or an SOP in place?
If Yes proceed, if No then
3
3
4
4
5
Fire fighting equipment ready?
If Yes proceed, if No then
Are there flammable materials
within 15m?
If No proceed, if Yes then
Flammable removed or
protected?
If Yes proceed
6
6
Is firewatch or atmosphere
monitoring required?
If No proceed, if Yes then
arrange
If you can’t meet these
requirements; STOP the job and
ask your teacher
Safe Use of Machinery in Technology - Metalwork/Version 1
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Welding – Hazard Control
INTRODUCTION
Welding hazards include electric shock,
burns, fire and explosions, radiation, heat,
noise, fumes and gases. Exposure to any or
all of these can be minimised by using an
effective combination of control measures.
CONTROL MEASURES
The most effective way to reduce exposures
is to eliminate the offending substance or
process. This is not practical, however, in
most instances. Ventilation is the most
common way of controlling exposure to
fumes, gases and heat in welding operations.
There are two types of ventilation - dilution
ventilation or local exhaust ventilation.
GENERAL OR DILUTION
VENTILATION
This type of ventilation relies on diluting
airborne contaminants with fresh air from
open doors, windows or fans. General
ventilation is limited in its usefulness for
controlling welding hazards.
Heat and humidity can usually be controlled
with general ventilation. It is difficult for
this type of ventilation to provide enough air
movement to keep the fumes and gases out
of the welder’s breathing zone.
Exhaust through flexible
ducting. Provide an air
velocity of at least
O.5rn/s (l00ft/min) across
the welding site. Place
hood as close as
practically possible to the
work.
LOCAL EXHAUST VENTILATION
Local exhaust ventilation is much more
effective in controlling welding fumes and
gases because it captures the fumes and
gases close to the source and keeps them
from entering the welders breathing zone.
See examples of local exhaust ventilation for
welding below.
To be effective, local exhaust ventilation
must:
 be close to the welding arc or flame
where the fumes, gases and heat are
generated, and
 have enough velocity to draw away the
contaminants.
PHYSICAL HAZARDS
Injuries can be prevented by following
established procedures and practices.
Safe work practices should exist for all
welding activities including handling and
storage of compressed gas cylinders and
oxy-acetylene or electric arc welding
equipment.
Bench with an open grid as
the work surface. Air is
drawn downward through
the grid, into exhaust
ducting. A speed should be
great enough so that the
fumes and gases do not rise
into your breathing zone.
Workpieces must not be so
large as to cover too much
of the ducting or the exhaust
effect will be lost.
Fumes and gases from
around the welding site are
drawn through the extraction
chamber and into the exhaust
system
Structure with a top and at
least two sides enclosing the
welding or cutting operation.
Fresh air continuously flushes
the enclosure. Provide air
movement at least O.5mIs
(l00ft/min) across the welding
site. Arrange work so that the
fumes and gases are drawn
away from your face.
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SKIN PROTECTION
Head to toe protection is needed to protect
the welder’s skin from hot metal, sparks and
radiation. This includes welding helmets,
caps, work boots, spats and flame-retardant
clothing (long sleeved shirts, long pants and
gloves).
EYE PROTECTION
All welders and other workers in the
welding workplace should wear suitable eye
protection which protect the eyes from
radiation.
For added protection from foreign objects
and radiation, goggles or safety glasses with
side shields should be worn even when other
eye or face protection is worn.
The best way to control noise is at the
source. However, when such control is not
possible, hearing protectors such as ear
muffs or plugs must be worn.
WELDING SCREENS
Welding screens should be provided to
prevent welding flash affecting others.
FURTHER INFORMATION
SafeWork SA
GPO Box 465
ADELAIDE SA 5001
Tel. 1300365255
(If calling from a mobile phone or from interstate
tel. (08) 8303 0400)
website: www.safework.sa.gov.au
HEARING PROTECTION
Welders may be exposed to noise directly
associated with welding processes such as
arc air or plasma arc cutting and gouging.
They may also be exposed to other noise in
the welding workplace such as grinding or
chipping.
Single-use air
purifying respirator
(dust/fumes)
Powered air purifying
respirator
Safe Use of Machinery in Technology - Metalwork/Version 1
Issued August 2000
Air purifying, beltmounted respirator
Supplied air
respirator
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Welding – Electrical Safety
Reducing Electric Shock Hazards
Each year welders die from electric shock.
Below are some safety notes on electric
shock hazards and general welding safety.
1. Servicing and installation must only be
undertaken by a qualified licensed
electrician. Never tamper with electrical
supply circuits or systems. The welder is
only responsible for making connections
in the welding circuit and for setting
external welding machine controls.
2. Equipment should be well maintained and
checked regularly, particularly the
insulation and connections on work
return leads and holders.
4. Electrodes or welding wire should never
be touched with bare hands when in the
holder or welding gun. Holders or
welding guns should never be held under
the armpits. Remember, hot work
increases risk due to the reduced skin
resistance when sweating occurs.
5. Always use Australian Standardsapproved welding helmets and lenses.
6. Welding fumes can be hazardous. Make
sure that there is adequate ventilation.
Further information is available in
AS 1674.2 Safety in welding and allied
processes Part 2:Electrical
3. Wherever possible work should be
performed on a dry insulated floor.
Wooden platforms, rubber mats, or dry
areas provide extra protection especially
in confined spaces.
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Welding and Cutting
TYPES INCLUDE
Welding
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Manual Metal Arc (MMA)
Metal-inert Gas (MIG)
Tungsten-inert Gas (TIG)
Friction
Spot (resistance)
Plasma
Brazing & ‘Silver’ Soldering, Cutting & Gouging
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Gas Cutting
ArcandAirfeed
Oxygen lance
Laser Cuffing
Spark erosion.
HAZARDS (depending on type)
 ARC-EYE (welding flash). A gritty feeling in
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the eye and skin burning can result from
invisible ultraviolet radiation from the arc (or
from oxy flames). The effect is delayed. It is
particularly intense with TIG welding of
aluminium alloy. Retina damage and blindness
can also occur.
FLUORIDE. From the coating on low hydrogen
rods. This can damage the lungs and cause
general poisoning.
Iron Oxide, manganese, nickel and chromium
fume. These can all cause lung disorders. Zinc
fume from galvanised steel can result in chills
and fever. The effect is delayed. In some
applications a cadmium coating has been used.
Cadmium fumes poison the lungs and kidneys.
Copper coatings on rods and materials can also
cause fume fever.
Zinc, lead end chromium fumes from paints or
coatings.
Toxic gases such as ozone, nitrogen dioxide
formed by the arc (the oxy flame also forms
nitrogen dioxide), and carbon monoxide. The
first two attack the lungs (delayed action),
carbon monoxide prevents oxygen reaching the
body cells. Ozone will rot rubber gas tubing.
Laser cuffing requires protection from
accidental eye contact with the beam or beam
reflections, and proper capture of fumes
Properly mount cylinders
Use correct cylinder regulators
Clean cylinder threads (oil-free for oxygen)
Store oxygen and gas separately
Clean blowpipes
Ensure no leaks
Fire extinguisher on hand Proper lighting
Safe Use of Machinery in Technology - Metalwork/Version 1
 Proper earthing of arc-welding equipment
 Protect gas supply tubes from hot metal and
abrasion
 Choose gas tubing which is not rotted by ozone
Eye protection during slag removal (chipping)
 Avoid radiation exposure from weld checking
equipment
 Toxic substances from heated coatings and
paints eg. cyanide, formaldehyde and
isocyanates. Isocyanates can cause chemical
asthma
 Hot metal injury to eyes, skin.
 Brazing uses brass or ‘silver’ solder. Brass can
give off zinc and copper fumes, some silver
solder can give off cadmium fumes (See
Safeguard GS 33 Welding — Metal Fumes).
 Gouging gives off larger quantities of fume and
is extremely noisy. Plasma cutting is also noisy.
PROTECTION
 Prevent burn hazards with proper gloves,
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







overalls and footwear. Remember, metal can be
hot even though the glow has gone.
Protect eyes with helmet and grade of visor
designed for the type of welding.
Prevent fire with welding blanket, by removing
or covering flammable materials, and proper
distance from flammable substances.
Prevent explosion by checking that tanks and
drums are free of substances which are
flammable or give off flammable substances
when heated, before welding or cuffing
Use proper supports
Ensure that you are comfortable
Ensure protection from fume and gases by
(depending on circumstances) one or a
combination of:
(i) good general ventilation
(ii) use of a booth
(iii) local exhaust ventilation on the handpiece
(iv) air supply to the helmet, and
(v) suitable respirator which fits inside the
helmet.
Protect bystanders by use of screens or proper
welding curtains and blankets
Wear hearing protection if necessary
DO NOT weld near cleaning tanks containing
chlorinated solvents-the heat breaks down the
vapours into very toxic gases
Ensure that ‘0’ rings in oxy/acetylene retractable
hose units are regularly replaced to prevent
leakage.
Page 15
Soldiering Iron
Made of copper because:—
(1) Soft, tough, easily beaten out to a point and readily cleaned and tinned.
(2) Takes in heat quickly.
(3) Gives out heat quickly.
(4) High heat capacity.
Tinning
This consists of coating the surface of the i iron with tin for about 20mm from the tip. The iron
will not pick up the molten solder unless it is properly tinned.
To Tin the Iron
Heat the iron to a dull red heat. File the surface to be tinned quite flat for about 20nm from the
tip. Rub the cleaned faces of the iron with a little solder on a piece •of salammoniac until the
surfaces appear evenly coated with bright shiny tin. Flick off any oxide or dirt from the surfaces,
It must be remembered that during the process of tinning the iron is continually losing its heat,
and therefore it is essential to carry out each operation quickly and decisively. Get everything
ready while the iron is heating up. If it is necessary to draw the end of the iron out by
hammering, care must be taken to remove, by filing, all traces of the tinning from the surfaces
before hammering out. If this is not done the tinning will form an alloy with the copper, and
make the tip of the iron hard and brittle.
Correct Heat
Once the iron is tinned it should ‘1ot be overheated otherwise the tinning will be burnt off. The
iron must be hot enough to freely melt the solder but not so hot that the surface solder attains a
bluish tint. A little practice will soon teach one when the correct heat is obtained.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Care of the Soldering Bit (Iron)
Each time a soldering iron is heated, some scale (copper oxide) is formed. In a small way, the
size of the soldering iron is reduced and after a while the faces of the soldering iron must be filed
and re—tinned, or in severe cases or burning or wear, it must be re—forged to its original shape.
Tinning a Soldering Iron
1. Heat to cherry red.
2. Place the iron in a vice and file faces smooth, first using a coarse file then finish with a smooth
file. Always file to or from the paint, not across the face.
3. Remove burrs from edges of faces.
4. Re—heat to black heat
5. Dip face of iron in dip—pot to clean.
6. Add solder to all faces for 20 mm from tip.
Re-shaping a Damaged Iron
1. Heat to cherry red.
2. Use a heavy hammer and solid bar or anvil. Allow the tip of the iron to overhang the edge of
the bar. Hold iron on slight angle.
3. Strike each face in turn using a drawing action towards the point.
4. Re—heat to cherry red, when heat is lost.
5. When required shape is formed, remove knob of waste from point with a hacksaw.
6. Heat, file and re—tin as before.
Safe Use of Machinery in Technology - Metalwork/Version 1
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Filing
The Grip
For files intended for operation with both hands, the more generally accepted way of gripping
the handle is to allow its end to fit into and bring up against the fleshy part of the palm below the
joint of the little finger, with the thumb lying parallel along the top of the handle and the fingers
upwards towards the face.
The point of the file is usually grasped by the thumb and the first two fingers of the other hand.
The hand is held to bring the ball of the thumb onto the top of the, file, in line with the handle
when heavy strokes are required.
When a light stroke is required and the pressure requirement is less, the thumb and fingers of the
point holding hand may change their direction until the thumb lies at right angles with the length
of the file. These positions can change as needed to meet varying pressure requirements.
When holding the file with one hand, as for filing pins, dies and edged tools not held in a vice,
the forefinger - instead of the thumb - is generally placed on top of the handle and in line with
the file.
How to use a File Correctly
Filing is an industrial art - grip, stroke and pressure may vary to fit the job. It is essential that you
use the correct file for the task at hand.
For normal filing, it is advisable to have the vice at approximately elbow height, however, when
there is a great deal of heavy filing it is better to have the work slightly lower. If the work is of
fine and delicate nature, the work can be raised to eye level.
For work that could become damaged in the vice, through pressure, a pair of protectors made of
zinc, copper or aluminium sheet should be used between the workpiece and vice jaws.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Filing Action:
There are three elemental ways a file can be put to work. They are:
Straight Filing
This consists of pushing the file lengthwise - straight ahead or slightly diagonally - across the
workpiece.
Drawfiling
Drawfiling consists of grasping the file firmly at each end and alternatively pushing and pulling
the file sideways across the work. Since files are made primarily to cut on a longitudinal forward
stroke, a file with a short - angle cut should never be used as it will score and scratch instead of
shaving and shearing. When accomplished properly, drawfiling produces a finer finish than
straight filing.
Normally a standard mill bastard file is used for drawfiling, but when a considerable amount of
stock has to be removed a flat or hand file (double cut) will work faster. However, this roughing
down leaves small ridges which will have to be smoothed by finishing with a single cut mill file.
Keep, the file cutting
One of the quickest ways to ruin a good file is to apply too much pressure - or too little - on the
forward stroke. Different materials of course require different touches; however, in general just
enough pressure should be applied to keep the file cutting. If allowed to slide over the harder
metals the teeth of the file rapidly become dull, and if they are overloaded by too much pressure,
they are likely to chip or clog.
On the reverse stroke it is best to lift the file clear of the workpiece, except on very soft metals.
Even then pressure should be very light — never more than the weight of the file itself.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 19
HAND HACKSAW
Selecting the right blade for the job.
Large Sections of Metal
Use the coarsest teeth possible, so that a minimum of 4 teeth are engaged in the cut. You’ll
remove more metal per stroke without clogging the teeth. Normally 14 teeth per 25 mm.
Small Sections of Metal
A minimum of 4 teeth engaged in the cut at all times will prevent tooth damage. The smaller the
stock, the greater the number of teeth per 25 mm of hacksaw blade.
Tubing, Conduit, Thin Sections
Fine teeth will produce a smooth cut without tearing or roughening the metal. A good rule of
thumb for 18 gauge or thicker - 24 Teeth/25 mm for less than 18 - 32/25 mm.
For Angles, Channels etc.
Never start your cut on a corner or hard edge as this may break or damage the saw teeth. Start
the cut so that as many teeth as possible are engaged.
Tooth Size and Usage
14 Teeth for cutting large and medium solid sections of soft materials.
18 Teeth for cutting medium and small solid sections of both hard and soft materials.
24 Teeth - This is the ideal blade for general use. For cutting hard materials, medium angles,
sheet and heavy tubing and for cutting small solid sections and odd sections between 10 mm and
20 mm thick.
REMEMBER
Sawing too fast will not finish the cut sooner.

Excessive pressure dulls teeth and breaks blades.

Insufficient pressure dulls teeth by rubbing.

Ease .pressure on return strokes to prevent dragging.

Never start a new blade in an old cut, this causes breakages.
Stance
As with filing you must observe .the correct stance and holding
positions to gain the maximum affect, so it is with hacksawing.
When Hacksawing you adopt the same stance as you would for
filing.
The correct method of holding a hacksaw is shown.
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COPPER
Copper is found to a limited extent in the free or native condition, but more usually in ores
containing a relatively small proportion of copper-rich minerals distributed in large quantities of
waste rock. In the most important ores, the copper-rich mineral is a mixture of sulphides of iron
and copper, but ores based on carbonates and oxides also occur.
Concentration of the ore is affected by grinding and flotation. The concentrates are then smelted
to a mixture of copper and iron sulphide (40 per cent copper, 35 per cent iron, 25 per cent
sulphur, approximately) which is, in turn converted to crude or blister copper (99 per cent
copper) by blowing with air to oxidize iron and sulphur.
The blister copper is usually refined by the electrolysis process to almost pure copper as with this
method any precious metal that may be present is recovered (mainly silver)
The copper is remelted and cast into various shapes, such as ingots, wirebars, billets, cokes, etc
which are the raw materials for the copper and copper base alloys of industries.
The principal properties which create the great demand for this metal include:
1. Its good conductivity.
2. Its resistance to corrosion.
3. Its good formability properties.
4. Its natural beauty.
5. For all practical purposes copper is non - magnetic.
6. Although copper is expensive, once an article is made, such as a water tank, it never has
to be replaced.
General Information
Copper offers considerable resistance to atmospheric corrosion. The chemical composition of the
atmosphere attacks the outer layers of the metal and a graduse colouring takes place (green
patina) giving a decorative finish to copper work used. on buildings, bronze statues etc.
Copper is readily attacked by some food juices and the inside of cooking utensils should be
silvered or coated with pure tin.
Alloys of copper in general use are:
1. Brass
Copper with zinc of varying proportions
2. Bronze
Copper with tin
3. Cusilman Bronze
Alloy of copper, silicon, manganese
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 21
ALUMINIUM
Aluminium is now produced in such quantity that in terms of volume it ranks second to steel
among the industrial metals. This position appears all the more remarkable when it is recalled
that the metal itself has been known only about 130 years, in fact the aluminium industry did not
begin until 1880.
Production
Aluminium is extracted from an ore called Bauxite. Bauxite consists of aluminium oxide
combined with water and containing impurities in the form of silica (sand) and oxides of steel
and titanium.
Bauxite is mined and then crushed, washed and screened (dressing the Bauxite) before being sent
to the alumina works. At the alumina works the aluminium is chemically refined (Bayer and
Electrolytic Process). Pure aluminium is drawn off into “pigs’ of about 60 kilograms each and
are subsequently re-melted for use in industry.
Deposits
The richest deposits of bauxite found in Australia are at Weipa, York Peninsula, Northern
Queensland.
Properties
(a) Low weight combined with strength.
(b) Resistance to many forms of corrosion.
(c) Good reflectivity of light and. radiant heat.
(d) The non-toxicity of its compound.
Uses
Aluminium can readily be worked into all the usual wrought forms of sheet, strip, foil, wire,
extruded sections, forgings and pressings. Its chief usefulness is in domestic and culinary
articles; in food processing and chemical plant; in containers, and packaging for foods; in
pressings, roofing, mouldings and wall-cladding and other applications where its appearance,
lightness, durability and non-toxicity are to the advantage of the user.
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PLASTIC
Historical
Plastics are man made materials. Nylon, Polythene and other plastic did not exist until they were
made by chemists. They have properties different from that of any natural substance. The first
modern plastic to be manufactured commercially was celluloid. It was first made by an
Englishman called Parks in 1860 by mixing camphor with nitro-cellulose.
A method of welding plastics, using a hot gas blow-pipe was patented by an American called
Reirhardt in 1937.
Plastics are derived mainly from petroleum, coal, salt, air and water. Most plastics are composed
of giant molecules built up mainly from atoms of carbon and hydrogen. There are already
hundreds of thousands of carbon-hydrogen compounds in existence in nature - in trees, plants,
animals and our own bodies. They are called ORGANIC COMPOUNDS. The industry involved
in developing these products is called organic chemistry.
During the post war years plastics have been adopted in every day life and in industry for a
variety of uses. Plastic products range from goods in the home to plumbing, draining, ventilating,
electrical and chemical engineering.
There are 2 main types of Plastics:
i) Thermosetting:
Used for light switches and other electrical fittings, hard plastic,
breakable
ii) Thermoplastic:
Soft, unbreakable plastic utensils such as buckets, perspex, some
toys and kitchen utensils
Safe Use of Machinery in Technology - Metalwork/Version 1
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How to Use the Spot Welding Machine
1. Turn electrical switch on, located on wall next to machine.
2. Turn water tap on 1/4 of a turn.
3. Gently bring points together by depressing pedal.
4. Continue to gently push the pedal down until the bead of spot weld appears.
5. Gently allow the pedal to return to its original position.
6. Complete each weld until job is completed.
7. Turn OFF water and electrical switch.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Bench Vices
The steel bench vines are used to hold metal or
plastic for sawing, filing or just holding material just
so both hands are free to work on your model.
They normally have jaws of hardened steel. These
jaws have a diamond pattern on them for better grip.
It is therefore essential to use soft jaws to protect soft
metals or plastic from becoming marked by the vice
jaws.
The normal size vice will open up large enough to
hold something 100 mm wide securely.
An offset vice is commonly found in the sheetmetal
workshops. This makes it possible to hold long
vertical work with the full width of the jaws.
Vice
Parts of the Vice are:

Main Screw

Body

Slide

Jaw Plates
Offset Vice
Label the drawing of the vice from the list above.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 25
Bench Folder
The bench folder is found in most sheetmetal classrooms. Its main purpose is for folding safety
folds up to 20mm wide. It is also capable of folding sheetmetal at different degrees up to 180
Double safety folds can also be folded up in the bench folder. Maximum thickness of mild steel
sheet this machine will handle is 0.8mm.
“You must never bend wire in this machine”
The parts of this machine are:

Locking Screw

Adjustment Screw

90 steel stop piece

45 steel stop piece

Bevelled steel blade

Gauge bar fingers
Label your drawing of the Bench Folder from the list above.
SAFETY NOTE
Only ONE person should operate the Bench Folder at a time.
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Bar Folder Machine - 1
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Bar Folder Machine – 2
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Bar Folder Machine – 3
Safe Use of Machinery in Technology - Metalwork/Version 1
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Pan Break Folding Machine
The pan break folder as it is commonly known is designed for general folding and bending of
sheet metals. It can be used for forming and bending boxes and cabinets, by taking out different
sections of the folder which are called fingers. The width of these fingers are 70, 75, 80, 90, 95,
100, 110, 115, 120, 130 and 140mm.
“You must never bend wire in this machine”
The Parts of this Machine are:

Top clamping removable fingers

Folding Beam

Folding Beam Handles

Balance Weight
Label your drawing of the Pan Break Folder from the list above.
SAFETY NOTE
Only ONE person should operate the Pan Break Folder at a time.
MAKING A BOX
A drawing of the correct sequence of folding up a box
is shown.
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Standard Hand Brake – 1
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Standard Hand Brake – 2
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Standard Hand Brake – 3
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Curving Rollers
The Curving Rollers are used for curving sheetmetal up to 0.8mm thick. With adjustment the
rollers can turn both parallel and tapered cylinders. Cylinders can be completely formed and then
taken out of the curving rollers by releasing the top roller. This machine also has provision to roll
light gauge wire.
Parts of the Curving Roller are:

Adjusting handles (back roller)

Top roller release handle

Adjusting screws (bottom roller)
SAFETY NOTE
Only ONE person should operate the Curving Rollers at a time.
/
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Slip Roll Forming Machine – 1
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Slip Roll Forming Machine – 2
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Slip Roll Forming Machine – 3
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Guillotine
The guillotine is used to cut all types of sheetmetal up to 0.8mm thick.
“It is never used to cut wire”
Large sheets can be cut to smaller sizes by using the guillotine. By correct positioning against the
side, it is also possible to cut all material square.
Parts of the guillotine are:

Treadle

Tungsten Steel Edged Shear Blades

Safety Gauge

Treadle Springs

Back Gauge
SAFETY NOTE
Only ONE person should operate the guillotine at a time.
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Squaring Shears – 1
Safe Use of Machinery in Technology - Metalwork/Version 1
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Squaring Shears – 2
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Squaring Shears – 3
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Grinding Machines
Bench Grinder
A Bench Grinder is commonly used in Design & Technology for light general purpose grinding
operations and tool sharpening.
Pedestal Grinder
A Pedestal Grinder is primarily used in Design & Technology for heavy general purpose
grinding operations.
Grinding is the process of removing material by the cutting action of the countless hard and
sharp abrasive particles of a revolving grinding wheel as they come in contact with the surface to
be ground.
The grinding wheels are held between
two flanged disks. Usually a roughing or
coarse-grained wheel is mounted on one
end of the spindle and a fine wheel on the
other. A tool rest is provided for each
wheel so that the work piece may be held
or steadied while being ground.
The operator is protected against flying
abrasive particles and ground material by
the wheel guards and spark arrestors,
which are integral parts of a machine.
Safety glass shields are also provided for
additional protection.
WARNING
The main types of injury are caused by:






Page 42
Entanglement of hair or clothing in rotating machinery parts
Fingers being caught between grinder wheel and work rest
Sparks or worn abrasive may be thrown by the grinding action
Body parts coming into contact with abrasive wheel
Ejected material or disintegrated abrasive wheel
Hot metal
Safe Use of Machinery in Technology - Metalwork/Version 1
Grinder Guarding
Machinery must have in place guarding which isolates moving parts and the point of
operation from direct contact with the operator.
Grinding machines must have guarding, which encloses dangerous moving parts by means of
fixed guards.
 The angular exposure of the grinding wheel periphery and sides for guard must not exceed one
quarter of the periphery.
 The exposure must start at a point not be more than 65 above the horizontal plane of the
wheel.
 The guards must cover the spindle ends, nuts
and flange projections.
 The guards must be mounted to ensure proper
alignment with the wheel.
 The guards must be of sufficient mechanical
strength to prevent part of the wheel being
thrown out in the event of a wheel breakage.
 The spark arrestors must be maintained at a
distance of no greater than 6mm from the
grinding wheel face.
 A transparent eye screen, which is sufficiently
large to discourage operators from looking
round it, must be fitted on a grinder used for
hand held work.
 A work rest maintained in good condition and
adjusted as close as possible to the wheel with
a maximum clearance of 1.5mm.
 Additional protection, in the form of an
enclosure, which isolates the remaining work
area from other personnel, may be necessary
depending on the positioning of the machine.
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Purchasing a Bench Grinder
General
A Bench Grinder should:

Meet DECS Standards for Plant and Equipment: Part A

Have spare parts readily available through a local distributor

Be supplied with all tools required for the operation of the machine

Be supplied with detailed instruction/parts manual

Be of robust construction

Be suitable for continuous use, similar to that found in industry

Not exceed noise levels of LAEq 8h of 85 dB(A)

Meet the provisions of the OHS&W Act and OHS&W Regulations 1995 Part 3

Meet the safety requirements of Australian Standard AS4024.1 – 2006 Safeguarding of
machinery Part 1: General principles and Australian Standard AS1788 -1987 Abrasive
Wheels Part 1- Design, Construction, and Safeguarding and Australian Standard AS I788 1987 Abrasive Wheels Part 2 - Selection, Care and Use

Be provided with a risk assessment.
Parameters
A Bench Grinder should:

Be mounted on a robust pedestal

Have a double-ended spindle

Have a stand sufficiently rigid for the grinder to be vibration free and stable when used

Be supplied with wheel guards with exhaust outlets to the rear of the machine, adjustable
spark arrestors, tool rests, 150 x 100 mm clear eye shields (tempered glass or polycarbonate)
and detachable cup of non-corrosive, robust construction

Accommodate a range of work-rest angles leaving no gap between the rest and the wheel
Technical Details
A Bench Grinder should have:

A minimum spindle diameter 19mm

Two wheels: 200mm diameter. X 25.4mm x 19mm, one medium, and one fine

Adjustable tool rests minimum 6mm thick

Preloaded bearings to prevent end float

Either a 3-phase motor: 415V/3/50, 0.75 kW, speed approximately 2800 rpm or a singlephase motor: 240V11/50, 0.75kW, and speed approximately 2800 rpm.
Page 44
Safe Use of Machinery in Technology - Metalwork/Version 1
Purchasing a Pedestal Grinder
General
A Pedestal Grinder should:

Meet DECS Standards for Plant and Equipment: Part A

Have spare parts readily available through a local distributor

Be supplied with all tools required for the operation of the machine

Be supplied with detailed instruction/parts manual

Be of robust construction

Be suitable for continuous use, similar to that found in industry
Parameters
A Pedestal Grinder should:

Be mounted on a robust pedestal

Have a double-ended spindle

Have a stand sufficiently rigid for the grinder to be vibration free and stable when used

Be supplied with wheel guards with exhaust outlets to the rear of the machine, adjustable
spark arrestors, tool rests, 150 x 100mm clear eye shields (tempered glass or polycarbonate)
and detachable cup of non-corrosive, robust construction

Accommodate a range of work-rest angles leaving no gap between the rest and the wheel
Technical Details
A Pedestal Grinder should have:

A minimum spindle diameter 25mm

Two wheels: 250mm diameter. X 40mm x 31.75mm, one medium, and one fine

Adjustable tool rests minimum 6mm thick

Preloaded bearings to prevent end float

A motor 415V/3/50, 1.1 kW, speed approximately 2800 rpm
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Positioning a Grinding Machine
A Bench grinder can weigh approximately 35kg
excluding pedestal. A Pedestal grinder can weigh
approximately 200 Kg.
Most workshop floors should be sufficient to carry
the weight of a Grinding Machine. The machine may
be located on wooden or concrete floors provided
they are in sound condition.
A Grinding Machine is a heavy machine

DO NOT move the machine by yourself
Before moving a Grinding Machine onto a
workshop floor, inspect it carefully to determine
that it will be sufficient to carry the load of the
machine, the device for moving it and its
operators.
WARNING
Assistance and lifting equipment will be
required. Serious personal injury may occur if
safe moving methods are not followed
Ensure a Grinding Machine rests on a suitable foundation.

On a floor or other support that ensures the plant is stable and secure against movement.

A Grinding Machine must be securely fixed into position using ‘Dynabolts’ or similar for
concrete floors or coach screws for wooden floors.

Where a Grinding Machine is fixed to wooden floors, consider either securing the machine
on a concrete plinth or fit anti-vibration rubber mounts to the base of the machine.
Extraction plant may be used with Grinding Machines and this may well affect the options when
siting these machines.
The installation, spacing, services and foothold around grinding machines must be such as to
ensure:

Sufficient space for safe access to the machine for supervision, operation, cleaning,
maintenance, inspection and emergency evacuation

The installation is plumb

The plane of operation is not in line with doorways, passageways, entrances or where
students regularly work

There is adequate space for handling materials and parts to and from the machine and for
work in progress.

Grinding sparks will not damage glazed surfaces or cause a fire hazard.

All operators are afforded a good view of the point of operation of the equipment.

A low stand should be considered to suit the operational requirements of the shorter student.
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Spatial Allowances for Grinding Machines
The following graphic indicates the recommended spatial
allowances for a Grinding Machine and operator.

Only a single operator may use a Grinding Machine.

The measurements displayed are considered
minimum requirements.

Sufficient space should be provided around
machines to handle the material with the least
possible interference from or to other operators.

WARNING
ONE PERSON ONLY MAY
OPERATE THIS MACHINE
Operator zones must be clearly marked with 50mm.
wide yellow or yellow/black line.
Secondary School Code 580.27
Technology and Applied Studies Educational Specification
Government of New South Wales
CROWN COPYRIGHT STATE OF NEW SOUTH WALES
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Grinding Machine Safe Work Procedure
Complementary equipment and the application of appropriate work practices and procedures are
fundamental to the safe operation of the grinding machines.
•
Operators must be properly instructed in the safe operation and the characteristics of the
machine and materials involved.
- The safe handling of the workpiece when grinding and the position of the hands relative
to the work piece.
- Hands may be trapped between workpiece support and abrasive wheel.
- This machine has the capacity to grab workpiece.
- Beware of the rotating abrasive wheels, which can cause entanglement and abrasions.
•
Ensure the abrasive wheels meet with and are operated according to the manufacturer’s
recommendation
- The wheel must not be operated at a speed in excess of the safe working speed
recommended by the manufacturer.
•
Never use a wheel that has been dropped or received a heavy blow, even if there is no
apparent damage.
•
The grinding wheels must be properly mounted.
•
Before using a new wheel, let it a run a few seconds at full speed to make sure it is balanced.
•
Periodically check grinder wheels for soundness.
- Suspend the wheel on a string and tap it. If the wheel rings, it is probably sound.
•
Ensure that no combustible or flammable materials are nearby that sparks from the grinder
wheel can ignite.
•
Ensure that a guard covers at least 2700 of the grinding wheel.
•
Maintain the upper spark arrestor not more than 6mm above the grinding wheel for bench or
pedestal grinders.
•
Maintain the work rest at 1.5mm from wheel.
•
The face of the wheel should dressed and maintained in good condition
- The wheel dresser should be equipped with a guard over the top of the cutters to protect
the operator from flying particles.
•
Approved hearing protection must be worn.
- The machine is capable of producing noise levels in excess of lOOdB(A). This can
rapidly cause hearing loss if the ears are unprotected.
•
The removal of waste must only occur when the machine is in a safe rest position and the
wheels have stopped rotating.
•
Ensure that any body parts do not get near the abrasive wheels.
•
Allow the grinder to develop full operating speed before commencing the grinding operation.
•
Do not stand directly in front of a grinding wheel when it is first started.
•
Do not use a wheel that vibrates.
Page 48
Safe Use of Machinery in Technology - Metalwork/Version 1
Grinding Machine Safe Operation
Only operators who have been authorized as properly trained and competent are allowed to
operate machines.
1. Adequate instruction and supervision are essential.
2. The pedestal grinder must not be used to perform tasks
beyond its design specification.
3. One person only must operate this machine at anytime.
4. Ensure workspace is clear before operating machine.
WARNING
• Foreign materials may cause poor footing.
Guards must be in place and
function correctly.
5. Operators must wear the appropriate Personal Protective
Equipment.
• Eye protection is mandatory.
• Operators must wear close fitting protective clothing.
 Ties, shirtsleeves and other loose items of clothing
may become entangled in moving machine parts.
• Dust mask must be worn in an extremely contaminated
or dusty environment.
WARNING
• Hearing protection is required.
Gloves must not be worn
when operating this machine
• Sturdy Footwear to be worn at all times in work areas.
6. Long and loose hair must be contained.
7. Rings, watches, jewellery must not be worn.
• Medic alert identity (if worn) must be taped.
8. Use proper type of grinding wheel for the material being
processed.
• Do not grind nonferrous materials.
9. The work rest must be set at 1.5mm away from the
WARNING
abrasive wheel.
Grinding soft, ductile
10. Ensure wheels are in a serviceable condition before use.
materials such as aluminium
11. Allow the machine to develop full speed before grinding.
or copper leads to wheel
12. Never force the workpiece against a cold wheel.
loading
13. Slowly move workpiece across the face of wheel in a
uniform manner
• This will keep the wheel sound.
14. Grinding on the side of the wheel must not occur unless a suitable wheel designed for this
purpose is fitted.
15. Do not allow the machine to run unattended.
16. The workpiece must never be held with a cloth, apron or any form of pliers.
• If necessary a hand vice or similar lock grip can be used
17. Bring the machine to a complete standstill and isolate the machine from power before
cleaning or making adjustments.
18. Coolant spilt on the floor should be immediately absorbed and absorbent material suitably
disposed.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 49
Safety Hazards of Grinding Machines
Point of operation
•
Contact with the grinding wheel may occur during operation.
•
Operator’s fingers may be trapped between work stop and abrasive wheel.
•
Burns and burrs from the workpiece as a result of the grinding process.
- The operator must be aware of the position of their hands and fingers in relation to the
grinding wheels at all times.
Kickbacks
•
Operators must be aware of the potential of being hit by pieces of the machine or workpiece
being flung off.
- A workpiece can be ejected from the machine after being caught by the grinding wheels.
In-running nip points
•
Clothing, hair or hands may be caught by and pulled into the wheels.
- Under no circumstances should an operator bend down near this machine whilst it is
operating.
- The operator must be aware of the position of their hands and fingers in relation to the
grinding wheels at all times.
Flying particles and material
•
Flying particles can be thrown up into the operators face by the action of the abrasive wheels
leading to eye injuries.
- Grinders generate significant quantities of airborne particulates and grinding residue,
which may create health problems.
- Adequate extraction is necessary and appropriate PPE may be needed for some
operations.
Page 50
Safe Use of Machinery in Technology - Metalwork/Version 1
Grinding Machine Maintenance
A documented Pedestal Grinder maintenance schedule or
Bench Grinder maintenance schedule must be developed and
time should be allocated specifically for this purpose.
•
The procedure outlined in the maintenance schedule is
indicative and may require changes to meet the needs of the
school and manufacturer’s recommendations for the
specific machine.
WARNING
Isolation procedures must
be implemented when
cleaning and when
maintenance tasks are
carried out on machinery
•
The only criteria being that regular maintenance
requirements are identified, actioned and documented along
with any repair work undertaken.
•
Refer to information supplied with the machine for specific
maintenance requirements for this machine.
•
Manufacturers and suppliers must supply adequate information for the correct maintenance
of the machine including tool changing, adjustment, cleaning and lubrication instructions.
Grinders are relatively low maintenance machines.
•
The tool rest needs to be regularly checked and maintained at maximum distance of 1.5 mm.
from the work face of the wheel.
•
The grinding wheel face must be regularly dressed and maintained in good condition.
•
Discard abrasive wheels:
- When the diameter of the grinding wheel approaches that of the driving flanges.
- When the work rest can no longer be correctly adjusted to the wheel diameter.
- When the grinding wheel no longer cuts efficiently because of reduced peripheral speed.
Dressing a Grinding Wheel
Dressing is the process of restoring the sharpness of the
grinding wheel by breaking away the dulled abrasive
crystals or by removing the glazed or loaded surface of
the wheel. This procedure provides new sharp cutting
edges of the abrasive grains.
•
•
•
•
•
Adjust the work rest away from the wheel so that the
dresser is supported on the work rest and the heel of
the dresser is hooked over the work rest.
The point of contact should be slightly above the centre, and with the handle tilted upward at
an angle.
Slowly press the dresser against the face of the revolving wheel until it ‘bites’.
Move the dresser back and forth to obtain a straight surface, and at the same time, hold the
dresser rigidly enough on the work rest to maintain trueness while dressing.
Once completed adjust the work rest to 1.5 mm. from the work face of the wheel.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 51
Mounting a grinding wheel
•
•
•
•
•
•
•
•
•
•
•
•
Wheels must be closely inspected prior to mounting
and rung’ to ensure that they are not damaged.
The spindle speed of the machine must be checked
to ensure that it does not exceed the maximum
operating speed marked on the wheel.
he grinder spindle has a right-hand thread on the
right end and a left-hand thread on the other as a
safeguard against the wheel loosening. Each wheel
is mounted directly on the spindle and is held
between a pair of flanged collars by either the rightor left-hand spindle nut.
Great care must be used when mounting wheels so
that no undue strains are set up, which might cause
the wheel to break.
Grinding wheels must fit freely on the spindle.
Clearance between the wheel hole and the machine
spindle is necessary to prevent excessive pressure
arising from mounting pressure and spindle
expansion. A wheel that fits tightly should never be
forced on the spindle. Instead, the bushed hole
should be scraped to make it fit freely.
Bushing, where used, must not interfere with seating
of the flanges nor affect the balance of the wheel.
Blotters of soft compressible material covering the
entire contact area of the flanges are always placed
between the side of the wheel and the flanged collars. This
lessens the danger of setting up strains in the wheel,
causing it to crack.
The clamping nut should be drawn only tight enough
against the flanged collar to prevent the wheel from
turning on the spindle.
Flanges must be maintained in good condition. Where the
bearing surface has been warped or damaged they must be
replaced.
After mounting, the wheel must be checked for trueness
and balance.
When starting the grinder with a newly mounted wheel
for the first time, always stand to the side of the wheel
and allow it to run for one minute before starting to
grind.
This will guard against any injury in the event the wheel
is faulty and should break apart.
Page 52
WARNING
Replace all guards before
starting the Grinder
Safe Use of Machinery in Technology - Metalwork/Version 1
Decommissioning a Grinding Machine
A risk assessment using the Risk Assessment Process
Part A and Part B proformas must be undertaken before
decommissioning to ensure that there is no likely health
and safety risk to personnel carrying out the
decommissioning of the machine.
•
Retain risk assessment as a record.
Where plant is to be dismantled and/or stored as part of
decommissioning:
WARNING
Because of the size and weight of a
Grinding Machine it is strongly
recommended that only properly
equipped and experienced
personnel attempt the removal or
relocation of the machine.
•
Ensure relevant health and safety information
supplied by the designer or manufacturer is provided
to the person who dismantles or stores the machine.
•
A competent person must carry out dismantling.
•
Ensure steps are in place to minimize the potential for injury due to corrosion, machinery
fatigue or hazardous substances.
Prior to the removal or relocation of a Grinding Machine the following processes must be
completed:
1.
2.
3.
4.
5.
6.
7.
The machine must be tagged barring use.
A licensed electrician must disconnect hard-wired equipment.
Tape the mains cable/plug to the grinder.
The machine should be in a clean condition.
Secure any ancillary equipment to the Grinder.
Any fixings securing the equipment to its bed should be removed.
If the machine is on a pedestal carefully move the machine so that it lies lengthwise along the
ground.
• Observe correct manual handling procedures and ensure the machine neither does nor
create a trip hazard.
• A competent person to facilitate convenient handling may dismantle the Grinder from the
pedestal.
8. All original documentation should be placed in a plastic bag, which is then securely taped to
the unit.
9. School records and electrical testing databases must be amended
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 53
Grinding Machine Glossary
Arbor
A spindle or shaft for holding cutting tools.
Blotters
Soft compressible material, which is always placed between the side
of the grinding wheel and the flanges. Blotters must cover the entire
contact area of wheel flanges. This reduces the danger of setting up
strains in the wheel, causing it to crack.
Danger zone
Any zone within or around machinery in which any person is
subject to a risk to health or safety.
“dB(A)”
Means decibels of A-weighted sound pressure level. ‘A weighted’
means the measuring instrument has been adjusted to mimic the
hearing characteristics of the human ear.
Direct-on-line-starter
Starter that connects the line voltage across the motor terminals in
one step.
Dressing
Dressing is the process of restoring the sharpness of the grinding
wheel by breaking away the dulled abrasive crystals or by removing
the glazed or loaded surface of the wheel, thus presenting new sharp
cutting edges of the abrasive grains.
Flanges
Collars, discs or plates between which grinding wheels are
mounted.
Grinding
Grinding is the process of removing material by the cutting action
of the countless hard and sharp abrasive particles of a revolving
grinding wheel as they come in contact with the surface to be
ground.
Grinding Face
The surface of the grinding wheel upon which grinding is carried
out.
Grinding Wheel
A revolving cutting tool made up of abrasive particles that are held
together by a glue-like material called the bond. Almost all grinding
wheels made for pedestal grinders are made with artificial abrasives,
namely silicon carbide and aluminium oxide.
Guard
An enclosure designed to retain the pieces of the abrasive wheel
should it be broken during operation.
Hard Wired
A method of electrical connection, which is permanent as against
the normal plug and socket method of supplying electrical power.
Hard-wired equipment must be connected and disconnected by a
licensed electrician.
Hazard
A situation at the workplace capable of potential harm.
Loading
A condition caused by grinding the wrong material with a grinding
wheel or using too heavy a grinding action.
Lock
A keyed padlock, which will secure a control device in the “off’
position and prevent it from being reactivated. Combination locks or
locks using magnetic keys or bars are not acceptable.
Page 54
Safe Use of Machinery in Technology - Metalwork/Version 1
Lux
A unit of illuminance.
Reducing Bush
Inserts used to reduce the size of the hole in a grinding wheel so that
it can be correctly mounted on a smaller diameter spindle.
Ringing
A procedure for determining the soundness of a grinding wheel. The
wheel is suspended on one finger or with a piece of string. A sound
wheel, when tapped gently with a light non-metallic instrument,
such as the handle of a screwdriver, will ring.
Risk
The probability that the potential harm may become a reality.
Spindle
A rotating device widely used in machine tools, such as lathes,
milling machines, drill presses, and so forth, to hold the cutting
tools or the work, and to give them their rotation.
Spark Arrestor
A thin, coated metal strip secured to the inside top of the wheel
guard to deflect abrasive from the operator. Spark arrestors must be
regularly adjusted to maintain efficiency.
Starter
Combination of all the switching means necessary to start and stop a
motor in combination with suitable overload protection.
Three Phase Power
A system of electrical generation and distribution which enables
significant economies in industrial applications. Most commonly
used in heavy-duty machinery.
Truing
Truing is restoring the wheel’s concentricity or reforming its cutting
face to a desired shape by means of a wheel dresser.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 55
Drilling Machine
A Drilling Machine is primarily used in Design &
Technology for accurate drilling of holes.
Mortising can be carried out on this machine with
the aid of various attachments.
A Drilling Machine consists of a base that supports
a column that in turn supports a table. Work can be
supported on the table with a vice or hold down
clamps, or the table can be swivelled out of the way
to allow tall work to be supported directly on the
base.
The table height can be adjusted with a table lift
crank then locked in place with a table lock. The
column also supports a head containing a motor.
The motor turns the spindle at a speed controlled
by a series of stepped pulleys. The spindle holds a
drill chuck to hold cutting tools (twist drills,
forstener bits, spade bits, hole saws etc). The quill
is moved up and down with a lever or capstan
wheel.
WARNING
The main types of injury are caused by:
 Entanglement of hair or clothing in rotating machinery
parts
 The operator attempting to hold the workpiece by hand

Page 56
while drilling. When the drill enters the work, it can catch
and twist the workpiece from the operator, which results
in an uncontrolled rotating piece of material.
Chips or swarf may be thrown by the drilling action.
Safe Use of Machinery in Technology - Metalwork/Version 1
Drilling Machine Guarding
Machinery must have in place guarding which isolates moving parts and the point of
operation from direct contact with the operator.
A Drilling Machine must be guarded in the following ways:
•
All pulleys and drive belts must be completely shrouded by guarding to prohibit access.
•
Where the belts or pulleys are accessed on an operational basis in order to change the drill
speed then the guard must be equipped with an electrical interlocking guard, preventing the
machine from being operated while the guard is not in place.
•
An adjustable drill chuck guard must also be utilised to protect the operator from the rotating
chuck.
•
The chuck guard should also protect the operator from broken twist drills and swarf, which
may be ejected with considerable force from the point of operation.
•
When lowered the drill chuck guard should eliminate the possibility of the chuck key (where
keyless chucks are not employed) being left in the chuck.
Drilling Machine Guards should:
•
Be strong and rigid
•
Be rigid to prevent them touching revolving spindles and
chucks
•
Be robust so those accidental knocks will not displace or
bend them
•
Constructed so that it is not easily deflected, which would
expose moving machine parts
•
Be designed so that access to moving parts that may still be
moving after the power is turned off, is prevented until
motion ceases
•
Be firmly fixed in such a manner that a tool is required to
remove
•
Be difficult to by-pass or disable
•
Cause minimum obstruction to the view of the process
•
Restrict access during normal operation yet allow for servicing, maintenance, installation and
repair of moving parts to be undertaken only with the aid of a tool or key
•
Be easy to adjust so that they can be set correctly
•
Be regularly maintained to keep them easy to adjust
•
Not introduce any other risks
•
Cover dangerous moving parts such as motor, belts, gear trains, pulleys and shafts
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 57
Purchasing a Drilling Machine Floor Mounted Pillar
Type
General
A Floor Mounted Type Drilling machine should:









Meet DECS Standards for Plant and Equipment: Part A
Have spare parts readily available through a local distributor
Be supplied with all tools required for the operation of the machine
Be supplied with detailed instruction/parts manual
Be of robust construction
Be suitable for continuous use, similar to that found in industry
Produce less than 85 dB(A) at the point of operation
Meet the safety requirements of Australian Standard AS4024.1 — 2006 Safeguarding of
machinery Part 1: General principles
Be provided with a risk assessment
Parameters
A Floor Mounted Type Drilling Machine should:







Consist of a machine slotted base and round upright pillar
Have a table that is slatted to allow the fixing of a drill vice or clamps
Be provided with a table holding mechanism that will rotate 360 degrees around the pillar
shaft
Have a rack and pinion table height adjustment
Be provided with a depth stop to limit the drilling depth
Have a quick acting belt tensioning release to allow for safe changing of speed
Be provided with an easily accessible guard with positive closing and fitted with an
electrical interlock
Technical Details
A Floor Mounted Type Drilling Machine should have:













Page 58
A maximum drilling capacity of 32mm
An alloy steel ground spindle shaft with a No 3 Morse taper end
A minimum spindle travel of 100mm with adjustable depth gauge
An overall height not exceeding 1750mm
Rotatable table approximately 300mm x 300mm
Minimum column diameter of 60mm
Working distance range: spindle to table 0mm to 800mm
Minimum throat distance 195mm
Chuck 13mm minimum, keyless to suit Morse taper
A clear chuck guard
No. 1, No. 2 and No.3 Morse taper sleeve
Speeds 10 speeds approximately 150 to 3000 rpm
A 415V/3/50 - 0.75kW minimum electric motor or a 240 V/1/5O —0.75 motor
Safe Use of Machinery in Technology - Metalwork/Version 1
Purchasing a Drilling Machine - l3mm Bench Type
General
A 13mm Bench Type Drilling machine —should:







Meet DECS Standards for Plant and Equipment: Part A
Have spare parts readily available through a local distributor.
Be supplied with all tools required for the operation of the machine.
Be supplied with detailed instruction/parts manual.
Be of robust construction.
Be suitable for continuous use, similar to that found in industry.
Produce less than 85 dB(A) at the point of operation.
Parameters
A 13mm Bench Type Drilling Machine should:







Consist of a machined base and round upright pillar.
Be provided with a table holding mechanism that will rotate 360 degrees around the pillar
shaft.
Have a table that rotates and is slotted to allow the fixing of a drill vice or clamps to the
table.
Have a rack and pinion table height adjustment.
Have a quick acting belt tensioning release to allow for safe changing of speed.
Be provided with a depth stop to limit the drilling depth.
Be provided with an easily accessible guard with positive closing and fitted with an
electrical interlock.
Technical Details
A 13mm Bench Type Drilling Machine should have:












A table size of 300mm. x 500mm. (approximately)
A base working surface 300mm. x 250mm. (approximately)
A throat depth of 200mm (approximately)
Minimum column diameter of 60mm
A minimum spindle travel 120mm
Minimum throat distance 195mm
Chuck 13mm minimum, keyless to suit Morse taper
A clear chuck guard
No. ‘I No. 2 and No.3 Morse taper sleeve
Speeds 4 speeds minimum - approximately 500 to 4000 rpm
A machine vice — 100 mm minimum
A 41 5V/3/50 - 0.75kW minimum electric motor or a 240V/1/50 —0.75 motor
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 59
Positioning a Drifting Machine
A Drilling Machine - Floor Mounted Type depending on the
brand and model can weigh approximately 150 Kg.
A Drilling Machine — Bench Mounted Type depending on the
brand and model can weigh approximately 90 Kg.
Most workshop floors should be sufficient to carry the weight
of a Drilling Machine. A Drilling machine may be located on
wooden or concrete floors provided they are in sound
condition.

Before moving a Drilling Machine onto a workshop
floor, inspect it carefully to determine that it will be
sufficient to carry the load of the machine, the device for
moving it and its operators.
WARNING
A Drilling Machine is a heave
machine.
DO NOT move the machine by
yourself.
Assistance and lifting equipment
will be required. Serious personal
injury may occur if safe moving
methods are not followed.
Ensure the machine rests on a suitable foundation, for example, on a floor or other support that
ensures the plant is stable and secure against movement.
•
A Drilling Machine — Bench Type can be installed on a sturdy bench top.
- Bench mounted plant should be bolted through the bench top.
A Drilling Machine — Floor Mounted type must be securely fixed into position using
‘Dynabolts’ or similar for concrete floors or coach screws for wooden floors
•
Where a Drilling Machine is bolted to wooden floors, consider either securing the machine
on a concrete plinth or fit anti-vibration rubber mounts to the base of the machine
The installation, spacing, services and foothold around a Drilling Machine must be such as to
ensure:






Page 60
Sufficient space for safe access to the machine for supervision, operation, cleaning,
maintenance, inspection and emergency evacuation
The installation is plumb
The plane of operation is not in line with doorways, passageways, entrances or where
students regularly work
There is adequate space for handling materials and parts to and from the machine and for
work in progress
All operators are afforded a good view of the point of operation of the equipment
Sufficient task and general lighting
Safe Use of Machinery in Technology - Metalwork/Version 1
Spatial Allowances for a Drilling Machine
The following graphic indicates the recommended spatial
allowances for a Drilling Machine and operator.




Only a single operator may use a Drilling Machine.
The measurements displayed are considered minimum
requirements.
Sufficient space should be provided around machines
to handle the material with the least possible
interference from or to other operators.
Operator zones must be clearly marked with 50mm.
wide yellow or yellow/black line.
Safe Use of Machinery in Technology - Metalwork/Version 1
WARNING
ONE PERSON ONLY MAY
OPERATE THIS MACHINE
Page 61
Commissioning a Drilling Machine
A Drilling Machine must not be used until the following checks have been completed according
to the manufacturer’s recommendation and necessary adjustments have been made.
1. Ensure the machine is in a clean condition.
• The unpainted surfaces are coated with a waxy oil to protect
them from corrosion during shipment.
• Remove this protective coating with a solvent cleaner or
citrus-based degreaser.
• To clean thoroughly, some parts may need to be removed.
• For optimum machine performance, clean all moving parts or
sliding contact surfaces that are coated.
• Avoid chlorine-based solvents as they may damage painted
surfaces should they come in contact.
WARNING
Isolation procedures must
be implemented when
cleaning and when
maintenance tasks are
carried out on machinery
2. A Drilling Machine must be securely fixed to the floor or bench
depending on the type of the machine.
• Under no circumstances must a machine be left to stand
unsecured
3. All nuts, bolts and grub screws must be in place and tight.
4. Belt drives must be checked for pulley alignment, serviceability
and correct tensioning.
• Ensure the belt profiles match the pulley type.
5. Machines employing a rack and pinion type table height
adjustment must have an adequate locking mechanism, which
allows operators to easily secure the table.
WARNING
Use care when disposing of
cleaning cloth/rag to be sure
they do not create fire or
environmental hazards
6. The mains cable and plug (if any) should be visually checked for
flaws and then electrically tested.
7. A licensed electrician must install hard-wired equipment.
8. When electrical connection has been made, an authorised person
must confirm the direction of spindle rotation.
• Switch on and at the same time switch off to view direction.
•
The spindle must run in a clockwise direction when viewed
from the front of the machine.
•
If required an electrician must make any alterations to correct
the direction of rotation.
•
Failure to carry out a direction test may result in serious
operator injury and damage to the machine.
9. Lubrication points should be serviced.
10. Attach Drill Press Safe Ocerating Procedures.
Page 62
WARNING
Guards musts be in place and
function correctly
WARNING
The Drilling Machine should
run smoothly, with little or no
vibration or rubbing noises.
Strange or unnatural noises
should be investigated and
corrected before operating
machine further
Safe Use of Machinery in Technology - Metalwork/Version 1
11. Ancillary equipment such as machine vices, clamps, twist drills, hole saws etc. should be
located in close proximity to the machine
12. Appropriate Personal Protective Equipment must be sited in close proximity to the machine.
13. File machine documentation supplied from manufacturer/ supplier to ensure ready
availability.
14. Warranties must be processed and forwarded to the appropriate parties.
15. The details of the machine must be entered in the school’s record and in the Drilling Machine
Maintenance Schedule.
16. Conduct a risk assessment using the Risk Assessment Process Part A and Part B proformas
to ensure that there is no likely health and safety risk to personnel.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 63
Drilling Machine Safe Work Procedure
Complementary equipment and the application of appropriate work procedures and practices are
fundamental to the safe operation of a Drilling Machine.
•
Operators must be properly instructed in the safe operation and the characteristics of the
machine and materials involved.
- The safe handling of the workpiece when drilling and the position of the hands relative to
the work piece.
- A Drilling Machine has the capacity to grab workpiece if not securely held.
- Beware of the rotating chuck and cuffing tools, which can cause entanglements.
•
A Drilling Machine must not be modified to perform tasks beyond its design specification.
- It must not be used for drum sanding, moulding or milling operations all of which can be
undertaken more safely and efficiently with purpose built machinery.
•
Ensure the Drilling Machine is operated according to the manufacturer’s recommendation.
•
Although the Drill Press is a relatively quiet machine some operations can be noisy
necessitating hearing protection.
•
A drill chuck guard must be used at all times as a protective measure.
•
Chuck key (if used) must be removed immediately after tightening the chuck.
•
Never place a taper shank tool, such as large diameter drill or tapered shank reamers in drill
chuck.
- Only straight shank tool such as standard drills can be clamped in chucks.
•
Ensure drill speed matches cutting tool diameter.
- Hard materials and large diameter drills require slower speeds.
•
Use a correct ground drill bit for the material being drilled.
- Sheet metal, acrylic and other brittle plastics can be difficult to drill.
•
Workpiece must be securely held with a drill vice or clamped to the table.
- Jigs and work holding devices must be used when drilling.
•
Cutting tools must be regularly checked to ensure their operational suitability.
•
Strip material or non-ferrous material should not be drilled unless securely clamped.
•
Under no circumstances should an operator bend down near this machine whilst it is
operating.
•
Ease up on drilling as the drill starts to break through the bottom of the material.
•
Properly designed drifts must be used to remove taper drills or chucks from spindle
Page 64
Safe Use of Machinery in Technology - Metalwork/Version 1
Drilling Machine Safe Operation
1. Only operators who have been authorized as properly trained
and competent are allowed to operate machines.
2. Adequate instructions and supervision are essential.
3. Operators must wear the appropriate Personal Protective
Equipment.
4. Eye protection is mandatory.
5. Some operations can be noisy necessitating ear protection.
6. Operators must wear close fitting protective clothing. Ties,
shirt sleeves and other loose items of clothing may become
entangled in moving machine parts.
WARNING
This machine has the capacity
to grab workpiece if not
securely held using correct
clamping procedures
7. Sturdy Footwear to be worn at all times in work areas.
8. Long and loose hair must be contained.
9. Rings, watches, jewellery must not be worn. Medic alert
identity (if worn) must be taped.
WARNING
Gloves, apron or any other
10. Twist drills, forstener bits, spade bits, hole saws or other culling
fabric must not be used to hold
tools must be sharp and in sound condition.
workpiece when drilling
11. It is vital that the workpiece is securely held.
12. In the case of thin material such as sheet metal a hand vice should be employed.
13. More substantial work pieces may require the use of a drill vice, vee-blocks and clamps or a
combination of each.
14. When the drill enters the work, it can catch and twist the workpiece from the operator, which
results in an uncontrolled rotating piece of material.
15. Run drill at correct RPM for diameter of twist drill and material.
16. See drill speed chart and move the belt to the correct position for that speed.
17. Do not drill with excessive pressure.
18. Ease up on drilling as the drill starts to break through the bottom of the material.
19. If the drill binds in a hole, stop the machine and turn the spindle backwards by hand to
release the bit.
20. Long workpieces must be supported by appropriate supports and must not obstruct
passageways or create a trip hazard.
21. Barricades must be erected should the work piece extend beyond the work area.
22. Let the spindle stop of its own accord after turning the power off.
23. Never try to stop the spindle with your hands.
24. Do not leave machine running unattended.
25. Use a brush to remove swarf and never by hand or with a rag.
26. Completely stop the machine before removing swarf from a choked twist drill.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 65
Safety Hazards of Drilling Machines
Point of operation
•
One of the most common causes of accidents that occur on a Drilling Machine is poor
operator judgment such as the operator attempting to hold the workpiece by hand while
drilling.
- When the drill enters the work, it can catch and twist the workpiece from the
operator, which results in an uncontrolled rotating piece of material.
•
Other point-of-operation hazards include the rotating drill and hot chip generation when
drilling metal.
In-running nip points
•
Clothing, hair or hands may be caught by and pulled into unprotected chucks and spindles.
- Under no circumstances should an operator bend down near this machine whilst it is
operating.
- The operator must be aware of the position of their hands and fingers in relation to
the chuck at all times.
Flying chips and material
•
Chips and swan can be thrown up into the operator’s face by the cuffing action of the cuffing
toll resulting in eye injuries.
- Certain types of dust may cause allergic reactions.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Drilling Machine Maintenance
A documented Drilling Machine maintenance schedule must
be developed for should be allocated specifically for
maintenance purposes.
•
The procedure outlined in the maintenance schedule is
indicative and may require changes to meet the needs of the
school and manufacturer’s recommendations for the
specific machine.
WARNING
Isolation procedures must be
implemented when cleaning
and when maintenance tasks
are carried out on machinery
•
The only criteria being that regular maintenance
requirements are identified, actioned and documented
along with any repair work undertaken.
•
Refer to information supplied with the machine for specific maintenance requirements for
this machine.
•
Manufacturers and suppliers must supply adequate information for the correct maintenance
of the machine including tool changing, adjustment, cleaning and lubrication instructions.
A Drilling Machine is a low maintenance machine.
•
Routine maintenance, cleaning and lubrication is required to ensure a Drilling Machine and
its safeguards operate properly
- The rack and pinion of the able raising mechanism often become dusty, which
impedes free running
- Ensure the drive belt guarding operates correctly
- Ensure drill chuck guard is in place and operates effectively
- The chuck guard may need to be replaced if operator’s view is restricted due a
scratched screen
•
Ensure table lock and table safety collar are in sound condition
Safe Use of Machinery in Technology - Metalwork/Version 1
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Decommissioning a Drilling Machine
A risk assessment using the Risk Assessment Process Part A and Part B
proformas must be undertaken before decommissioning to ensure that
there is no likely health and safety risk to personnel carrying out the
decommissioning of the machine.

WARNING
Retain risk assessment as a record
Where plant is to be dismantled and/or stored as part of
decommissioning:
Because of the size and
weight of a Drilling Machine
it is strongly recommended
that only properly equipped
and experienced personnel
attempt the removal or
relocation of the machine

Ensure relevant health and safety information supplied by the
designer or manufacturer is provided to the person who
dismantles or stores the machine.

A competent person must carry out dismantling

Ensure steps are in place to minimize the potential for injury due to corrosion, machinery
fatigue or hazardous substances.
Prior to the removal or relocation of a Drill Press the following processes must be completed:
1. The machine must be tagged barring use.
2. A licensed electrician must disconnect hard-wired equipment.
3. Tape the mains cable/plug to the machine.
4. The machine should be in a clean condition.
5. Secure any ancillary equipment such as chuck key (if used) to the machine.
6. Any fixings securing the equipment to its bed should be removed.
7. Any belt drives should be freed from tension.
8. Protect any machined surface with a suitable corrosive preventative.
9. Carefully move Floor Mounted Type Drilling Machine so that it lies lengthwise along the
ground.
•
Observe manual handling procedures and ensure the machine neither does nor create a
trip hazard.
•
To facilitate handling a Drilling Machine may be dismantled by a competent person.
10. All original documentation should be placed in a plastic bag, which is then securely taped to
the unit.
11. School records and electrical testing databases must be amended.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Drilling Machine glossary
Arbor
A spindle or shaft for holding cutting tools.
Belt Profile
The shape of the cross-section of a power transmission belt. Common
examples are’ v’, multi-’ v’, flat and round belts. The belt profile must
suit the pulley type.
Drill chuck
A device used to grip parallel shank drills and attach them to a rotating
spindle.
Danger zone
Any zone within or around machinery in which any person is subject to
a risk to health or safety.
Drift
Tapered tool made of hardened steel used to eject taper shank drills
from quill.
Flute
A straight or helical groove machined into a cutting tool to provide
cutting edges and clearance for chips of metal to escape.
Guard
A physical barrier that prevents or reduces access to a danger point or
area.
Hard Wired
A method of electrical connection, which is permanent as against the
normal plug and socket method of supplying electrical power. Hardwired equipment must be connected and disconnected by a licensed
electrician.
Hazard
A situation at the workplace capable of potential harm.
Jig
A device for holding a workpiece.
Lux
A unit of measurement relating to light.
Lock
A keyed padlock, which will secure a control device in the “off position
and prevent it from being reactivated. Combination locks or locks using
magnetic keys or bars are not acceptable.
Morse taper
A self-holding standard taper largely used on small cutting tools such as
drills, end mills, and reamers, and, on some machines, spindles in which
these tools are used.
Quill
Rotating part of a drill, which holds the chuck.
Risk
The probability that the potential harm may become a reality.
Shank
The part by which a cuffing tool is held.
Safety collar
Prevents the table from accidentally sliding down the column when the
table- locking lever is released.
Taper
A wedge shape increasing uniformly in width, or diameter, along its
length.
Three Phase Power
A system of electrical generation and distribution which enables
significant economies in industrial applications. Most commonly used in
heavy-duty machinery.
Twist drill
A commonly used parallel shank metal-cutting drill, usually made with
two flutes running around the body.
Safe Use of Machinery in Technology - Metalwork/Version 1
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Cold Saw
A Cold Saw is used in Design and Technology to:
•
Crosscut metal tube, rod, bar and sections to length.
•
Cut mitres and bevel cuts.
- The saw arm can be swung from side to side
to adjust the horizontal angle of the cut.
Cold Saws are multi-purpose circular saws that use a
High Speed Steel (FISS) blade that cuts above the
material. During the cross cutting operation the stock to
be cut is firmly clamped underneath the blade in a
machine vice. The operator pulls down on a handle to
move the blade, which is flooded with cuffing fluid,
through the workpiece being cut so that the material can
be pushed away from the operator.
A Cold Saw’s blade is fixed and does not walk or wander. Cold sawing produces square or
perpendicular cuts and minimal or no burrs.
Because it is a cold cutting process, cold sawing does not work harden the workpiece, which can
be a benefit for a workpiece that requires subsequent finishing with cutting tools.
Cold sawing is suitable for culling smaller-diameter or thin-walled material that requires tight
tolerances. While some Cold Saws can handle round tube up to 85mm diameter and round solid
up to 50mm diameter they are most effective at Cutting stock with a maximum OD of 44mm.
WARNING
COLD SAWS ARE DANGEROUS MACHINES
 Amputations may occur if the operator’s hands and
fingers come into contact with the saw blade
 Eye injuries can occur due to flying metal chips
 Entanglement of hair and clothing may occur if contact is
made with the revolving saw blade if the blade is not
completely guarded
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Safe Use of Machinery in Technology - Metalwork/Version 1
Cold Saw Guarding
Machinery must have in place guarding which isolates moving parts and the point of
operation from direct contact with the operator.
A Cold Saw must be guarded in these ways:
1. A fixed (hood) guard to enclose the non-cuffing part of the saw blade
• The upper guard must protect the operator from flying metal, swan and broken saw teeth.
• This guard should extend at least as far down as the saw spindle.
2. Side guards that cover at least the outside edge of the exposed saw teeth. These can be:
• Self-closing side guards
 Rise and open on contact with the workpiece.
 A ‘clamshell guard’ that covers the saw blade with a scissor opening action as the cut
is made.
 In the at-rest position, the sides of the lower exposed part of the blade must be
guarded from the tips of the teeth inward radially with no gullet exposure.
 There should be no access to the saw blade of any design when in the rest position.
 The guard must not inhibit the intended use of the saw.
3. Machines should be fitted with:
• An operating automatic return device, so that the saw returns to its safe rest position
above the workpiece when the saw is released.
• An automatic brake that stops the rotation of the saw spindle within 10 seconds or less.
4. A workpiece vice that is high enough to support the workpiece must be provided so that it
can be moved either side of the cuffing line.
5. Adequate workpiece support is essential for alt crosscutting operations.
• Large workpieces should be supported using extension tables or roller supports at either
side of the table.
Cold Saw Guards should:
•
Be strong and rigid.
•
Be rigid to prevent them touching the revolving blades.
•
Made from a material such as aluminium or similar, so that in the event of contact with the
blade, neither the guard nor the blade will disintegrate.
•
Be robust so those accidental knocks will not displace or bend them.
•
Constructed so that it is not easily deflected, which would expose the blade.
•
Be designed so that access to moving parts that may still be moving after the power is turned
off, is prevented until motion ceases.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 71
•
Be difficult to by-pass or disable.
•
Cause minimum obstruction to the view of the process.
•
Restrict access during normal operation yet allow for servicing, maintenance, installation and
repair of moving parts to be undertaken only with the aid of a tool or key.
•
Be easy to adjust so that they can be set correctly.
•
Be regularly maintained to keep them easy to adjust.
•
Not introduce any other risks.
•
Cover dangerous moving parts such as motor and shafts.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Purchasing a Cold Saw
General
A Cold Saw should:
•
•
•
Meet DECS Standards for Plant and Equipment: Part A.
Have spare parts readily available through a local distributor.
Be supplied with detailed instruction/parts manual and all tools required for the operation of
the machine.
• Be of robust construction and suitable for continuous use, similar to that found in industry.
• Produce less than 85 dB(A) at the point of operation.
• Be supplied with a risk assessment.
Parameters
A Cold Saw should:
•
•
•
•
•
•
•
Have a stand sufficiently rigid for the Cold Saw to be vibration free and stable when used.
Have a fully integrated automatic coolant system.
Be supplied with a serviceable coolant pump with coolant held in the machine base
Be capable of two-speed operation for the cutting of ferrous and non-ferrous materials.
Have gear type drive with adjustable backlash
Have switching controls in an easy to reach location.
Cut by manual operation.
Technical Details
A Cold Saw should have:
• An upper blade guard that completely encloses the blade down to a point that includes the
end of the saw arbor
- The upper guard must protect the operator from flying metal, swarf and broken saw
blade.
- In the at-rest position, the sides of the lower exposed part of the blade must be
guarded from the tips of the teeth inward radially with no gullet exposure.
- The guard must not inhibit the intended use of the saw.
• A self-adjusting, floating guard that rises and falls and automatically adjusts to the thickness
of the workpiece
• A return device, so that the saw returns to its safe rest position when the saw is released
• A three-phase, self-braking motor with overload protection: 240V/3/50, 2.2kW minimum
capacity.
• Two blade speeds 42/85 rpm
• Blade diameter 300mm. x 2.5mm. x 40mm. bore diameter
• A minimum cutting capacity at 90°— 85mm. diameter
• An angle cutting capability at 45° left and right
• A capacity to perform adjustable angle cuts by 10 increments
• A cam lock machine vice capable of moving to either side of the saw blade
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 73
Positioning a Cold Saw
A Cold Saw depending on the brand and model weighs
approximately 170 Kg.
Most workshop floors should be sufficient to carry the
weight of a Cold Saw. The machine may be located on
wooden or concrete floors provided they are in sound
condition.
•
WARNING
A Cold Saw is a heavy machine.
Before moving a Cold Saw onto a workshop floor,
inspect it carefully to determine that it will be sufficient
to carry the load of the machine, the device for moving it
and its operators.
DO NOT move the machine by
yourself.
Assistance and lifting equipment
will be required. Serious personal
injury may occur if safe moving
methods are not followed.
Ensure a Cold Saw rests on a suitable foundation
•
On a floor or other support that ensures the plant is stable and secure against movement
•
A Cold Saw must be securely fixed into position using ‘Dynabolts’ or similar for concrete
floors or coach screws for wooden floors.
•
Where a Cold Saw is bolted to wooden floors, consider either securing the machine on a
concrete plinth or fit anti-vibration rubber mounts to the base of the machine.
It is recommended that a Cold Saw form part of the materials handling infrastructure and, as
such, be best positioned in the materials store.
•
A Cold Saw is normally positioned close to a wall with an integrated extended bench
designed to support long work-pieces.
The installation, spacing, services and foothold around a Cold Saw must be such as to ensure:
•
Sufficient space for safe access to the machine for supervision, operation, cleaning,
maintenance, inspection and emergency evacuation
•
The installation is plumb
•
The plane of operation is not in line with doorways, passageways, entrances or where
students regularly work
•
There is adequate space for handling materials and parts to and from the machine and for
work in progress
•
All operators are afforded a good view of the point of operation of the equipment
•
Sufficient lighting
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Safe Use of Machinery in Technology - Metalwork/Version 1
Spatial allowances for a Cold Saw
The following graphic indicates the recommended spatial allowances for a Cold Saw and
operator.

Only a single operator may use a Cold Saw.

The measurements displayed are considered minimum
requirements.

Sufficient space should be provided around machines to
handle the material with the least possible interference
from or to other operators.

Operator zones must be clearly marked with 50mm. wide
yellow or yellow/black line.
Safe Use of Machinery in Technology - Metalwork/Version 1
WARNING
ONE PERSON ONLY MAY
OPERATE THIS MACHINE
Page 75
Cold Saw Safe Work Procedures
Complementary equipment and the application of appropriate work procedures and practices are
fundamental to the safe operation of a Cold Saw.
•
Operators must be properly instructed in the safe operation and the characteristics of the
machine and materials involved
- The safe handling of the workpiece when sawing and the position of the hands
relative to the work piece
- This machine has the capacity to break blades when forced into the workpiece
- Attention must be paid to unusual noises and visual indicators of improper operation
•
Ensure the saw blade meets with and is operated according to the manufacturer’s
recommendation
•
Blades must be kept sharp
- A blunt blade requires more feeding pressure, which can be dangerous
•
Metal must be securely fastened in the work vice
- When a mitre or angle cut is to be undertaken the machine must be set up with the
metal secured in the vice, which is firmly locked in position
- Do not cut free hand
•
Approved Hearing protection must be worn
- The machine is capable of producing noise levels in excess of l00dB(A). This can
rapidly cause hearing loss if the ears are unprotected
•
The removal of off cuts must only occur when the saw blade is in a safe rest position and the
saw blade has stopped rotating
- It is good practice to use a stick rather than hands to remove off cuts
•
Accidents can occur when operators cross their arms during cutting.
- For example, they pull a workpiece along the backstop, from right to left, using the
left hand instead of correctly pushing it along with the right
- Avoid reaching across the saw line
- Left-handed Operators may require specific training
•
Make sure that the saw is fully retracted by positive pressure with the hand at the end of the
cutting cycle
•
When loading moving or unloading workpiece ensure that the hands do not get near the blade
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Safe Use of Machinery in Technology - Metalwork/Version 1
Cold Saw Safe Operation
1. Only operators who have been authorized as properly
trained and competent are allowed to operate machines
2. Adequate instruction and supervision are essential
3. A Cold Saw must not be used to perform tasks beyond its
design specification.
WARNING
4. Ensure workspace is clear before operating machine
• Foreign materials may cause poor footing
Keep guards in place and in
working order
5. Operators must wear the appropriate Personal Protective
Equipment
• Eye protection is mandatory
• Operators must wear close filling protective clothing
 Ties, shirtsleeves and other loose items of clothing
may become entangled in moving machine parts
WARNING
• Approved Hearing protection is required
• Sturdy Footwear to be worn at all times in work areas
6. Long and loose hair must be contained
Immediately absorb any spilt
coolant and safely dispose the
absorbent material
7. Rings, watches, jewellery must not be worn
• Medic alert identity (if worn) must be taped
8. Check condition of the blade
9. Ensure all locks are tightened before operating
10. Ensure workpiece is securely held in workpiece vice
11. Do not start the machine with the workpiece against the blade
12. Allow the machine to develop full speed before sawing
13. Allow the blade to do the work without forcing the saw
14. The maximum cut must not be exceeded
15. Do not reach over the blade for any reason
16. Return the cutting head completely to the top of the saw after each cut
• Release the operator switch
• Do not remove hand from the operating handle unless the cuffing head completely above
the workpiece
17. Avoid the accumulation of swarf, waste or stock on the machine table or on the floor
18. Ensure that long and heavy pieces of metal are properly supported
19. Bring the machine to a complete standstill and Isolate the machine from power before
cleaning or making adjustments
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 77
Safety Hazards of a Cold Saw
Point of operation
•
Contact with the blade may occur.
- Lacerations or amputations from rotating blade.
In-running nip points
•
The rotation of the blade means that if something were to be caught then it would be
“wound’ down on to the blade or guard very quickly.
- Under no circumstances should an operator bend down near this machine whilst it is
operating.
- The operator must be aware of the position of their hands and fingers in relation to
the blade at all times.
Flying debris
•
Metal swarf, fines, can be thrown up into the operator’s face by the action of the blade.
- A workpiece can be ejected from the machine after being caught by the blade.
- Broken blade can be ejected from the machine.
- Certain coolants may cause an allergic reaction in people.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Cold Saw Maintenance
A documented Cold Saw maintenance sehedide must be
developed and time should be allocated specifically for
maintenance purposes.
The procedure outlined in the maintenance schedule is indicative
and may require changes to meet the needs of the school and
manufacturer’s recommendations for the specific machine,
•
The only criteria being that regular maintenance requirements
are identified, actioned and documented along with any repair
work undertaken.
•
Refer to information supplied with the machine for specific
maintenance requirements for this machine.
•
Manufacturers and suppliers must supply adequate
information for the correct maintenance of the machine
including tool changing, adjustment, cleaning and lubrication
instructions.
A Cold Saw is not in itself a high maintenance machine.
•
Using sharp saw blades contributes significantly to the safe
operation of a Cold Saw
- Keep blades sharp, properly set and firmly secured so
that they will cut freely without having to force the
blade against the work piece
WARNING
Isolation procedures must be
implemented when cleaning
and when maintenance tasks
are carried out on machinery.
WARNING
Take care to avoid laceration
when carrying and installing
saw blades.
- Obtain and follow instructions from supplier for correct maintenance on saw blades
•
Routine maintenance, cleaning and lubrication is required to ensure the saw and its
safeguards operate properly
- The slides, runways, pivots and bearings of a Cold Saw often become clogged with
fines, which impedes free running
- Ensure the guarding on the lower portion of blade operates correctly and the return
device is fully functional
•
Ensure coolant delivery system is checked and adjusted to provide sufficient flow to the
point of operation
- The coolant delivery system often becomes clogged with fines, which impedes
coolant flow
- Coolant flow should be sufficient to wash swarf away during the sawing operation
- Coolant (suds) must be completely changed at the end of each tem and disposed
according to the MSDS
- Ensure correct levels of coolant contain the proper levels of PH according to main
specifications
Safe Use of Machinery in Technology - Metalwork/Version 1
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Decommissioning a Cold Saw
A risk assessment using the Risk Assessment Process Part A and
Part B proformas must be undertaken before decommissioning to
ensure that there is no likely health and safety risk to personnel
carrying out the decommissioning of the machine.
•
Retain risk assessment as a record.
WARNING
Where plant is to be dismantled and/or stored as part of
decommissioning:
Because of the size and
weight of a Cold Saw it is
strongly recommended that
only properly equipped and
experienced personnel
attempt the removal or
relocation of the machine
•
Ensure relevant health and safety information supplied by the
designer or manufacturer is provided to the person who
dismantles or stores the machine
•
A competent person must carry out dismantling
•
Ensure steps are in place to minimize the potential for injury due to corrosion, machinery
fatigue or hazardous substances
Prior to the removal or relocation of a Cold Saw the following processes must be completed:
1. The machine must be tagged barring use.
2. A licensed electrician must disconnect hard-wired equipment.
3. Tape the mains cable/plug to the machine.
4. The machine should be in a clean condition.
5. Secure any ancillary equipment such as spanners, Allen keys, workpiece vice etc. to the
machine.
6. Any fixings securing the equipment to its bed should be removed.
7. Remove saw blade to prevent lacerations.
8. Protect any machined surface with a suitable corrosive preventative.
9. Carefully move the Cold Saw so that the machine does not create a hazard.
•
Observe manual handling procedures when moving the machine.
10. All original documentation should be placed in a plastic bag, which is then securely taped to
the unit.
11. School records and electrical testing databases must be amended.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Cold Saw Glossary
Backstop
A fixed fence that enables quick, easy and secure location of the
work-piece.
Bevel
Any surface that is not at right angles to another surface.
Chamfer
The surface produced by planing off the two adjacent surfaces at an
angle of 45.
Danger zone
Any zone within or around machinery in which any person is subject
to a risk to health or safety.
Feed rate
The rate of movement of the tool into the work
Fence
An adjustable guiding device fitted to a machine.
Guard
A physical barrier that prevents or reduces access to a danger point or
area.
Hazard
A situation at the workplace capable of potential harm.
Kickback
Unexpected movement of the work piece opposite to the direction of
feed.
Lux
A unit of measurement relating to light.
Risk
The probability that the potential harm may become a reality.
Spindle
The Spindle is the actual moving part of the machine and is powered
from the motor.
Suds
A liquid coolant which is used to facilitate machining operations.
Swarf
Waste material generated by the machining of metal.
Three Phase Power
A system of electrical generation and distribution which enables
significant economies in industrial applications. Most commonly
used in heavy-duty machinery.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 81
Mill Drill
A Mill Drill is used in Design and Technology for
precise removal of machineable metals and nonmetals such as wood and plastic by feeding it into a
rotating cutting tool.
A Mill Drill is similar to a robust drill press in which
the axis of the spindle is vertical. The spindle is the
main rotating shaft in which cutting tools are
mounted. The machine is supplemented by a
worktable, which can be moved side-to-side and
front-to- back very accurately.
In operation, the workpiece is securely clamped to the
worktable or is held in a machine vice which in turn is
clamped to the worktable. A culling tool rotates much
like a twist drill, and the work is advanced past the
cutting tool by means of the hand wheels that move
the table. As culling progresses, the head can be
lowered in precise increments until the desired depth
of cut is achieved.
By making a series of horizontal cuts across the
surface of a workpiece, the end mill removes layers of material at a depth than can be accurately
controlled to about one one-hundredth of a millimetre.
The most common cutting tool used with a Mill Drill is an end- mill. This looks like a stubby
twist drill with a flattened end instead of a point. An end mill can cut into a workpiece either
vertically, like a drill, or horizontally using the side of the end mill to do the culling. This
horizontal culling operation imposes heavy lateral forces on the tool and the mill, so both must
be rigidly constructed.
WARNING
 Severe lacerations may occur if the operator’s hands and
fingers come into contact with cutters
 Eye injuries can occur due to flying metal chips
 Entanglement of hair and clothing may occur if contact is
made with the revolving cutters power feed
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Safe Use of Machinery in Technology - Metalwork/Version 1
Mill Drill Guarding
Machinery must have in place guarding which isolates moving parts and the point of
operation from direct contact with the operator.
A Mill Drill must be guarded in these ways:
1. All pulleys, spindles and drive belts must be completely shrouded by guarding.
• Where the belts or pulleys are accessed on an operational basis in order to change the
speed then the guard must be equipped with an electrical interlocking guard, preventing
the machine from being operated while the guard is not in place.
2. An adjustable chuck guard must be utilised to protect the operator from the rotating chuck.
• The chuck guard should also protect the operator from broken milling cutters and swarf,
which may be ejected with considerable force from the point of operation.
3. A workpiece vice that is high enough to support the workpiece must be provided so that it
can be moved either side of the culling line.
4. Have a run down time of lO seconds or less.
5. Emergency Stop device/s in addition to the ON/OF Direct On Line (DOL) starter must be
fitted to a Mill Drill
• The Emergency Stop device/s must be immediately accessible to the operator when using
the machine.
Mill Drill Guards should:
•
Be strong and rigid to prevent them touching revolving spindles and chucks
•
Be robust so those accidental knocks will not displace or bend them
•
Constructed so that it is not easily deflected, which would expose moving machine parts
•
Be designed so that access to moving parts that may still be moving after the power is turned
off, is prevented until motion ceases
•
Be difficult to by-pass or disable
•
Cause minimum obstruction to the view of the process
•
Restrict access during normal operation yet allow for servicing, maintenance, installation and
repair of moving parts to be undertaken only with the aid of a tool or key
•
Be easy to adjust so that they can be set correctly
•
Be regularly maintained to keep them easy to adjust
•
Not introduce any other risks
•
Cover dangerous moving parts such as motor, belts, gear trains, pulleys and shafts
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 83
Purchasing a Mill Drill
General
A Mill Drill should:
•
•
•
Meet DECS Standards for Plant and Equipment Part A.
Have spare parts available through a local distributor.
Be supplied with detailed instruction/parts manual and all tools required for the operation of
the machine.
• Be of robust construction and suitable for heavy-duty use, similar to that found in industry.
• Produce less than 85 dB(A) at the point of operation.
• Be supplied with a risk assessment.
Parameters
A Mill Drill should:
•
•
•
•
•
•
•
Have a stand including coolant tray sufficiently rigid for the Mill Drill to be vibration free
and stable when used.
Have a fully integrated automatic coolant system.
Be capable of multi-speed operation for the cutting of ferrous and non-ferrous materials.
A run down time of lO seconds or less.
Have gear type drive with adjustable backlash
Have switching controls in an easy to reach location.
Cut by manual operation.
Technical Details
A Mill Drill should have:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Milling head located to column by ground key-way with adjustment to ensure consistent
accuracy and alignment throughout the vertical travel
Drilling capacity 25mm
Column diameter of 78mm
Maximum distance spindle to table - 350mm approximately
Spindle speeds (6) - 110/160/310/510/880/1600 rpm approximately
Spindle stroke - 45mm. approximately
Spindle taper -2 Morse
Quill diameter of 65mm
Head swivel - 360
Head tilt left & right calibrate - 45 0° 45°
Throat depth —175 mm approximately
Longitudinal travel - 635mm. approximately
Cross travel - 165mm. approximately
Table size - 590 x 160mm approximately with 3 tee slots
Either a 3-phase TEFC induction motor: 415V/3/50, .55 kW minimum capacity, or a singlephase TEFC induction motor:240V/1/50, .55 kW minimum capacity
Maximum overall height- 1010mm approximately
Maximum overall width - 890mm approximately
A 75mm swivel milling vice
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Positioning a Mill Drill
A Mill Drill depending on the brand and model weighs
approximately 150 kg.
Most workshop floors should be sufficient to carry the
weight of a Mill Drill and stand. The machine may be
located on wooden or concrete floors provided they are in
sound condition.
•
Before moving a Mill Drill onto a workshop floor,
inspect it carefully to determine that it will be
sufficient to carry the load of the machine, the device
for moving it and its operators
WARNING
A Mill Drill is a heavy machine.
DO NOT move the machine by
yourself.
Assistance and lifting equipment
will be required. Serious personal
injury may occur if safe moving
methods are not followed
Ensure a Mill Drill rests on a suitable foundation.
•
On a floor or other support that ensures the plant is stable and secure against movement
•
A Mill Drill must be securely fixed into position using ‘Dynabolts’ or similar for concrete
floors, or coach screws for wooden floors
•
Where a Mill Drill is bolted to wooden floors, consider either securing the machine on a
concrete plinth or fit anti-vibration rubber mounts to the base of the machine
The installation, spacing, services and foothold around a Mill Drill must be such as to ensure:
•
Sufficient space for safe access to the machine for supervision, operation, cleaning,
maintenance, inspection and emergency evacuation
•
The installation is plumb
•
The plane of operation is not in line with doorways, passageways, entrances or where
students regularly work
•
There is adequate space for handling materials and parts to and from the machine and for
work in progress
•
All operators are afforded a good view of the point of operation of the equipment
Safe Use of Machinery in Technology - Metalwork/Version 1
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Spatial allowances for a Mill Drill
The following graphic indicates the recommended spatial allowances for a Mill Drill and
operator.
•
Only a single operator may use a Mill Drill.
•
The measurements displayed are considered
minimum requirements.
•
Sufficient space should be provided around machines
to handle the material with the least possible
interference from or to other operators.
•
Operator zones must be clearly marked with 50mm.
wide yellow or yellow/black line
Page 86
WARNING
ONE PERSON ONLY MAY
OPERATE THIS MACHINE
Safe Use of Machinery in Technology - Metalwork/Version 1
Commissioning a Mill Drill
A Mill Drill must not be used until the following checks have been completed according to the
manufacturer’s recommendation and necessary adjustments have
been made.
1. Ensure the machine is in a clean condition.
• The unpainted surfaces are coated with a waxy oil to protect
them from corrosion during shipment.
WARNING
• Remove this protective coating with a solvent cleaner or
Do not use petroleum-based
citrus-based degreaser.
solvents for cleaning. They
have low flash points that
• To clean thoroughly, some parts may need to be removed.
make them extremely
• For optimum machine performance, clean all moving parts or
flammable. A risk of
sliding contact surfaces that are coated.
explosion and burning exists
• Avoid chlorine-based solvents as they may damage painted
if these products are used
surfaces should they come in contact.
2. A Mill Drill must be securely fixed to the floor.
• Under no circumstances must a machine be left to stand
unsecured.
3. All nuts, bolts and grub screws must be in place and tight.
4. The mains cable and plug (if any) should be visually checked for
WARNING
flaws and then electrically tested.
5. Ensure there is adequate local and general lighting available.
Use care when disposing of
6. A licensed electrician must install hard-wired equipment.
cleaning cloth/rag to be sure
they do not create fire or
7. When electrical connection has been made, an authorised person
environmental hazards
must confirm the direction of the spindle rotation.
• Switch on and at the same time switch off to view direction.
• The spindle must run in a clockwise direction when viewed
from the front of the machine.
• If required an electrician must make any alterations to correct
the direction of rotation.
• Failure to carry out a spindle direction test may result in
WARNING
serious operator injury and damage to the machine.
Guards musts be in place and
8. Lubrication points should be serviced and all moving parts
function correctly
should move freely but with little slop or backlash.
9. Attach Mill Drill Safety Operating Procedures.
10. Mark in the machine operator zone.
11. Appropriate Personal Protective Equipment must be sited in close
proximity to the machine.
12. Associated housekeeping equipment should be installed in a
suitable nearby location.
WARNING
13. File machine documentation supplied from manufacturer!
supplier to ensure ready availability.
The Mill Drill should run
smoothly, with little or no
14. Warranties must be processed and forwarded to the appropriate
vibration or rubbing noises.
parties.
Strange
or unnatural noises
15. The details of the machine must be entered in the school’s record
should be investigated and
and in the Mill Drill Maintenance Schedule.
corrected before operating
16. Conduct a risk assessment using the Risk Assessment Process
machine further
Part A and Part B proformas to ensure that there is no likely
health and safety risk to personnel.
Safe Use of Machinery in Technology - Metalwork/Version 1
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Mill Drill Safe Work Procedures
Complementary equipment and the application of appropriate
work procedures and practices are fundamental to the safe
operation of a Mill Drill.
•
Operators must be property instructed in the safe
operation and the characteristics of the machine and
materials involved
- The safe handling of the workpiece when milling
and the position of the hands relative to the work
piece
Clamping Kit
- This machine has the capacity to break cutters when forced into the workpiece
- Attention must be paid to unusual noises and visual indicators of improper operation
•
Ensure the machine is operated according to the manufacturer’s recommendation
•
Cutters must be kept sharp
- A blunt cutter requires more feeding pressure, which can be dangerous
•
Workpiece must be securely fastened to the table by means of a milling vice, angle plate or
clamping kit
- Do not cut ‘free hand’
•
It is usually regarded as standard practice to feed the workpiece against the milling cutter
•
Approved hearing protection must be worn
- The machine is capable of producing noise levels in excess of lOOdB(A). This can
rapidly cause hearing toss if the ears are unprotected.
•
The removal of swarf must only occur when the cutter is in a safe rest position and the cutter
has stopped rotating
- It is good practice to use a stick rather than hands to remove off cuts
- Never use rag or hands to remove swarf
•
When loading, moving or unloading workpiece ensure that hands do not get near the cutter
•
Remove milling cutters from machine when not in use
•
Gloves must not be worn when operating the machine
•
Use recommended cutting oil
- In general, a simple coolant is all that is required for roughing
- Finishing requires cutting oil with good lubricating properties to help produce a good
finish on the workpiece
- Plastics and cast iron are almost always machined dry
- Refer to MSDS when handling lubricants and coolants
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Mill Drill Safe Operation
1. Only operators who have been authorized as properly
trained and competent are allowed to operate machines.
2. Adequate instruction and supervision are essential.
3. A Mill Drill must not be used to perform tasks beyond its
design specification.
4. Ensure workspace is clear before operating machine.
• Foreign materials may cause poor footing.
5. Operators must wear the appropriate Personal Protective
Equipment.
• Eye protection is mandatory.
• Operators must wear close fitting protective clothing.
• Ties, shirtsleeves and other loose items of clothing
may become entangled in moving machine parts.
• Hearing protection is required.
• Sturdy Footwear to be worn at all times in work areas.
6. Long and loose hair must be contained.
7. Rings, watches, jewellery must not be worn.
• Medic alert identity (if worn) must be taped.
8. Ensure milling cutter is appropriate for the material and
task.
• Check condition of the milling cutter.
9. Ensure all locks are tightened before operating.
10. Ensure workpiece is securely held to the table.
• Observe correct clamping procedures.
• Set up every job as close to the milling machine
spindle as circumstances will permit.
11. Ensure guarding is in place.
12. Set the correct speed to suit the cutter diameter, the depth
of cut and the material.
• The maximum cut must not be exceeded.
13. Do not start the machine with the workpiece against the
cutter.
14. Allow the machine to develop full speed before milling.
15. Allow the cutter to do the work without forcing the cutter.
16. Do not reach over the cutter for any reason.
17. Do not leave the machine running unattended.
18. Avoid the accumulation of swarf, waste or stock on the
machine table or on the floor.
19. Ensure that long and heavy pieces of material are properly
supported.
20. Bring the machine to a complete standstill and Isolate the
machine from power before cleaning or making
adjustments.
Safe Use of Machinery in Technology - Metalwork/Version 1
WARNING
Guards must be in place and
function correctly.
WARNING
DO NOT make adjustments while
the machine is running. Ensure
that the switch is off, power is
isolated and moving parts have
stopped before making
adjustments.
WARNING
Before running machines fitted
with power feed by certain that
there is sufficient running
clearance between the table
spindle, vice clamps and/or parts.
Be aware all these can become
pinch points.
WARNING
Immediately absorb any spilt
coolant and safely dispose the
absorbent material.
WARNING
Operating this machine has the
potential to propel debris that can
cause eye injury.
Page 89
Safety Hazards of a Mill Drill
Point of operation
•
Contact with the cutter may occur
- Lacerations or amputations from rotating cutter
- Lacerations from a stationery cutter during maintenance or cleaning operations
In-running nip points
•
The rotation of the cutter or chuck means that if something were to be caught then it would
be “wound” down on to the cutter very quickly
- Under no circumstances should an operator bend down near this machine whilst it is
operating
- The operator must be aware of the position of their hands and fingers in relation to
the chuck and cutter at all times
Flying debris
•
Swarf, fines, etc. can be thrown up into the operator’s face by the action of the rotating cutter
- A workpiece can be ejected from the machine after being caught by the cutter
- Broken cutter can be ejected from the machine
- Certain coolants may cause an allergic reaction in people
- Guarding must be in place
- PPE must be worn
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MIII Drill maintenance
A documented MIII Drill maintenance schedule must be developed
and time should be allocated specifically for maintenance purposes.
The procedure outlined in the maintenance schedule is indicative
and may require changes to meet the needs of the school and
manufacturer’s recommendations for the specific machine.
•
The only criteria being that regular maintenance requirements
are identified, actioned and documented along with any repair
work undertaken
•
Refer to information supplied with the machine for specific
maintenance requirements for this machine
•
Manufacturers and suppliers must supply adequate information
for the correct maintenance of the machine including tool
changing, adjustment, cleaning and lubrication instructions
A Mill Drill is not in itself a high maintenance machine
•
Using sharp milling cutters contributes significantly to the safe
operation of a Mill Drill
- Keep cutters sharp, properly set and firmly secured so
that they will cut freely without having to force the
cutter against the work piece
WARNING
Isolation procedures must be
implemented when cleaning
and when maintenance tasks
are carried out on machinery.
WARNING
Take care to avoid laceration
when carrying and installing
milling cutters.
- Obtain and follow instructions from supplier for correct maintenance on milling
cutters
•
Routine maintenance, cleaning and lubrication is required to ensure the Mill Drill and its
safeguards operate properly
- The slides, runways, pivots and bearings of a Mill Drill often become clogged with
fines, which impedes free running
- Ensure the guarding operates correctly and the return device is fully functional
•
Ensure coolant delivery system (if filled) is checked and adjusted to provide sufficient flow
to the point of operation
- The coolant delivery system often becomes clogged with fines, which impedes
coolant flow
- Coolant flow should be sufficient to wash swarf away during the sawing operation
- Coolant (suds) must be completely changed at the end of each term and disposed
according to the MSDS
Safe Use of Machinery in Technology - Metalwork/Version 1
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Decommissioning a MiII Drill
A risk assessment using the Risk Assessment Process Part A and
Part B proformas must be undertaken before decommissioning to
ensure that there is no likely health and safety risk to personnel
carrying out the decommissioning of the machine.
•
Retain risk assessment as a record.
WARNING
Where plant is to be dismantled and/or stored as part of
decommissioning:
Because of the size and
weight of a Mill Drill it is
strongly recommended that
only properly equipped and
experienced personnel
attempt the removal or
relocation of the machine.
•
Ensure relevant health and safety information supplied by the
designer or manufacturer is provided to the person who
dismantles or stores the machine.
•
A competent person must carry out dismantling.
•
Ensure steps are in place to minimize the potential for injury due to corrosion, machinery
fatigue or hazardous substances.
Prior to the removal or relocation of a Mill Drill the following processes must be completed:
1. The machine must be tagged barring use.
2. A licensed electrician must disconnect hard-wired equipment.
3. Tape the mains cable/plug to the machine.
4. The machine should be in a clean condition.
5. Secure any ancillary equipment such as spanners, Allen keys, workpiece vice etc. to the
machine.
6. Any fixings securing the equipment to its bed should be removed.
7. Remove milling cutters to prevent lacerations.
8. Protect any machined surface with a suitable corrosive preventative.
9. Carefully move the Mill Drill so that the machine does not create a hazard.
•
Observe manual handling procedures when moving the machine.
10. All original documentation should be placed in a plastic bag, which is then securely taped to
the unit.
11. School records and electrical testing databases must be amended.
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Safe Use of Machinery in Technology - Metalwork/Version 1
Mill Drill glossary
Angle plate
Precision holding device made of cast iron or steel. The two principal
faces are at right angles and may be slotted for holding the work or
clamping to a table.
Arbor
A shaft or spindle for holding cutting tools most usually on a milling
machine.
Backlash
The lost motion or looseness (play) between the faces of meshing gears or
threads.
Bed
One of the principal parts of a machine tool, having accurately machined
ways or bearing surfaces for supporting and aligning other parts of the
machine.
Bevel
Any surface that is not at right angles to another surface.
Burr
The sharp edge left on metal after cutting.
Chamfer
The surface produced by planing off the two adjacent surfaces at an angle
of 45°.
Chuck
A device on a machine tool to hold the workpiece or a cutting tool.
Collet
A precision work holding chuck which centres finished round stock
automatically when tightened.
Coolant
A common term given to the numerous cutting fluids or compounds used
with cutting tools to increase the tool life and to improve surface finish on
the material.
Cutting fluid
A liquid used to cool and lubricate the cutting to improve the work
surface finish.
Cutting tool
A hardened piece of metal (tool steel) or High Speed Steel that is
machined and ground so that it has the shape and cuffing edges
appropriate for the operation for which it is to be used.
Feed rate
The rate of movement of the tool into the work
Fence
An adjustable guiding device fitted to a machine.
Gib
A tapered strip of metal placed between the bearing surface of two
machine parts to ensure a precision fit and provide an adjustment for
wear.
Guard
A physical barrier that prevents or reduces access to a danger point or
area. Jacobs chuck Common term for the drill chuck used in either the
headstock spindle or in the tailstock for holding straight-shank drills, taps,
reamers, or small diameter workpieces.
Kickback
Unexpected movement of the work piece opposite to the direction of
feed.
Machine tool
A power-driven machine designed to bore, cut, drill, or grind metal or
other materials.
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 93
Milling
The process of machining flat, curved, or irregular surfaces by feeding
the workpiece against a rotating cutter containing a number of cutting
edges.
Morse taper
A self-holding standard taper largely used on small cutting tools such as
drills, end mills, and reamers, and, on some machines, spindles in which
these tools are used.
Rack
An array of gears spaced on a straight bar.
Spindle
The spindle is the actual moving part of the machine and is powered from
the motor.
Suds
A liquid coolant which is used to facilitate machining operations.
Swarf
Waste material generated by the machining of metal.
T-bolt
Tern for the bolts inserted in the T-slots of a worktable to fasten the
workpiece or work-holding device to the table.
T-slot
The slots made in the tables of machine tools for the square-head bolts
used to clamp the workpiece, attachments, or work-holding fixtures in
position for performing the machining operations.
Ways
The flat or V-shaped bearing surfaces on a machining tool that guide and
align the parts that they support.
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Reference Tool
Hot Work – are precautions in place?
Audit
YES
NO
YES
NO
Is fire fighting equipment in place?
Extinguished (minimum is 1, get one if not present)
Other equipment
Flammable materials protected?
Are there within 15m radius?
(eg. drains, pits, liquid leaks, gas leaks, pipeline
residuals, rubbish)
Flammables removed?
Are screens and covers in place?
Is all movement in the area controlled?
People?
Vehicles?
Product?
Fire watch
Is fire watch needed?
If so, for how long after work complete? Hours
Fire watch arranged
Atmosphere considered
No fume generation/adequate ventilation
Is monitoring needed – use Hazardous
Work Clearance?
Name:
Department:
Date:
Audited by:
Safe Use of Machinery in Technology - Metalwork/Version 1
SCORE
Page 95
SAFETY OPERATING PROCEDURES
Oxy-Fuel Gas Welding
DO NOT use this equipment unless a teacher has instructed
you in its safe use and operation and has given permission.
PRE-OPERATIONAL SAFETY CHECKS
1. Ensure no slip/trip hazards are present in workspaces and walkways.
2. Keep area clean and free of grease, oil and other flammable material.
3. Gas hoses must be in good condition and not create a tripping hazard.
4. Before lighting up make a visual inspection of all equipment for damage.
5. Check that the area is well ventilated and flame extraction unit is on.
6. Faulty equipment must not be used. Immediately report suspect equipment.
PRESSURE SETTING
1. Check that the oxygen and acetylene regulator adjusting knobs are loose.
2. Check that both blowpipe valves are closed.
3. Slowly open the cylinder valves on each cylinder for half a turn only.
4. Screw in the regulator adjusting knobs slowly until the delivery pressure gauges register
7OkPa.
5. Purge and check for constant oxygen gas flow.
• Open the oxygen blowpipe for 2 seconds valve and check the delivery gauge.
• If necessary re-adjust the oxygen regulator to achieve a 7OkPa pressure.
• Close the oxygen blowpipe valve.
6. Purge and check for constant acetylene gas flow.
7. Open the acetylene blowpipe valve for 2 seconds and check the delivery gauge.
8. If necessary re-adjust the acetylene regulator to achieve a 7OkPa pressure.
9. Close the acetylene blowpipe valve.
LIGHTING UP
1. Open the acetylene blowpipe valve slightly and light the blowpipe with a flint lighter.
2. Continue to slowly open the acetylene valve until the flame no longer produces soot.
3. Slowly open the oxygen blowpipe valve until a neutral flame is produced.
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Safe Use of Machinery in Technology - Metalwork/Version 1
SAFETY OPERATING PROCEDURES
Oxy-Fuel Gas Welding
DO NOT use this equipment unless a teacher has instructed
you in its safe use and operation and has given permission.
SHUTTING OFF BLOWPIPE
1. Close the acetylene blowpipe valve first.
2. Then close the oxygen blowpipe valve.
CLOSING DOWN
1. Close down both cylinder valves.
2. Open oxygen blowpipe valve to allow the gas to drain out.
3. When oxygen gauges read zero, unscrew regulator-adjusting knob.
4. Close oxygen blowpipe valve.
5. Turn off acetylene cylinder valve.
6. Open acetylene blowpipe valve and release gas.
7. When acetylene gauges read zero, release regulator adjusting knob.
8. Close acetylene blowpipe valve.
HOUSEKEEPING
1. Hang up welding blowpipe and hoses.
2. Turn off flume extraction.
3. Leave the work area in a safe, clean and tidy state.
POTENTIAL HAZARDS
• Bums
• Flying sparks
• Fumes
• Flashbacks
• Radiation damage to eyes
• Explosion by gas leakage
FORBIDDEN
• Lighting blowpipe with matches or lighters
• Using oil, grease or other hydrocarbons
• Using oxygen as a substitute for compressed air
Safe Use of Machinery in Technology - Metalwork/Version 1
Page 97
Resourced Material
Australian/New Zealand Standard 4024-2006 Safeguarding of Machinery
Australian/New Zealand Standard 1473-1991 Guarding and Safe use of Woodworking
Machinery
Australian/New Zealand Standard 1473.2-2001 Wood processing machinery- Safety-Finishing
machinery- Common Requirements
Australian/New Zealand Standard 1473.3-2001 Wood processing machinery-Safety-Finishing
machinery- Circular sawing machines
Australian/New Zealand Standard 1473.4-2001 Wood processing machinery-Safety-Finishing
machinery- Bandsawing Machines
Australian/New Zealand Standard 1716:2003 Respiratory protective devices
Australian/New Zealand Standard 1715:1994 Selection, use and maintenance of respiratory
protective devices
Australian/New Zealand Standard 1337:1992 Eye protectors for industrial applications
Australian/New Zealand Standard 1269.3-2005 Occupational noise management- Hearing
protector program
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