Turning machines

• shaping a rotating piece with a cutting tool. This is usually

done with engine lathes, turret lathes and spinning lathe.
Engine lathe
Common hazards
• Having contact with projections
on work, faceplates, chucks or
lathedogs
• being hit by flying metal chips
• hand braking the machine
• leaving the machine unattended
• handling the chips by hand
• callipering the job while the
machine is working
• leaving the chuck wrench in the
chuck
•Catching rings, loose clothing etc
on revolving parts
 mitigation
• Use faceplates and chuck without projections
• Install a simple shield to contour the chuck or the plate to prevent
contact with revolving parts
• Use safety type lathe dogs
• Install chip shield, chip breakers
• Encourage the use of PPEs
• Provide mechanical means for lifting heavy face plates, chucks and
stocks
Turret lathe
It is evolved from conventional lathe
machines with addition of the turret,
which is an indexable tool holder that
allows multiple cutting operations to
be performed with different cutting
tools without the operator to perform
setup tasks in between
hazards
• Operator not moving the turret fully back while changing or
gauging the work
• Keeping hands on turrets slide
• Hand, arm or elbow sticking the cutter while adjusting or
setting up
• High noise levels
Mitigation
• Install splash shields
• Install chip breakers
• Reduce the noise level through engineering methods, if not
viable provide hearing protection equipments
 Spinning lathes
Spinning lathe is a forming tool
rather than cutting tool and requires
specially qualified and skilled
operators
The spinning lathes chuck is usually
made of hardwood shaped exactly
like the finished parts
Hazards
• inserting blanks and removing processed parts while the
machine is working
•Allowing the swarf to build up into long coils
•Failing to fully tighten the tailstocks and thereby risking the
blank to work loose and thereby damaging the stock or tool
•Chucks in the case of necked down operations are made in
sections and held together by locking rings or grooves. If the ring
get worn out the chuck flies apart
 drills
The drilling process is an extensively
used machining operation by which
through or blind holes are cut or
originated in a work piece. The
drilling tool called the “drill is a
multipoint cutting tool
Drill press accidents are more likely to occur during unusual jobs because
special jibs or vises for holding work are not usually provided. The most
common hazards in drilling operation are:
•Contacting the rotating spindle or the tool
•Being struck by broken drill
•Using dull drills
•Being struck by insecurely clamped works
•Catching hair, clothing in revolving parts
•Sweeping chips and removing long spiral chips by hands
•Leaving the key in the chuck
•Being struck by flying metal chips
Mitigation
• Properly clamp the drill’s head and arm and the work piece
prior to cutting metals
• Observe safety precautions and using good operating habits
• To guard an operator from coming in contact with the spindle
use a plastic shield, wire mesh guards or other barriers
• Guard the tool with a telescopic guard that covers the end of
the tool
• Avoid the usage of dull drill bits which may lead to breakage
• Properly select the diameter of the drill
• When deep holes are being drilled frequently remove the drill
and clean out the chips
Boring mills
The process of machining the internal surface of a hole for
enlarging its size. A single point cutting tool used for this
purpose is mounted on a bar called the “ boring bar”. The
common hazards related to boring are:
• Being struck by insecurely clamped work or tool left near the
revolving table
• Catching clothing on revolving parts
• Falling against revolving parts
• Callipering or checking work while the machine is in motion
• Allowing the turnings to build up on the table
• Removing turnings by hand
Boring machines are broadly classified as horizontal boring
machine and vertical boring machine
 Horizontal boring machine
•never try to make measurement,
reach across the table or adjust the
machine or the work while in
operation
•Frequently inspect the clamps and
blockings and avoid makeshift
setups
•Before attempting to raise or
lower the boring mill head make
sure that the clamps on the column
has been loosened
•Before the boring bar is inserted into the spindle the operator should
make sure that the spindle hole and the bars are cleaned from chips
•The operator must not use hammers to drive the bars through the tail
stock bearings
 Vertical boring machines
• Generally used when the length or height of the work piece is
smaller than its diameter
•Provide a metal band guard
around the table rim to protect the
operator from being struck by the
revolving table or projecting work
•Such guards should be hinged so
that the can be easily opened for
setting up and adjusting of the
work piece
•While the machine working the
operator should never attempt to
tighten the work , caliper
milling
• Milling is the process of removing excess material from a work
piece with a rotating cutting tool. The rotating tool called the
milling cutter is a multipoint tool having the shape of a solid
revolution with cutting teeth arranged along the periphery or
on the end face or on both. Used for producing flat,
contoured or helical surfaces, for cutting threads and toothed
gears and for making helical grooves

•Peripheral or horizontal milling:

Here the finished surface is
parallel to the axis of the cutter
and is machined by cutter teeth
located on the periphery of the
cutter.
Face or vertical milling: The finished
surface is at right angle with the axis of
the cutter and it is obtained by the
teeth on the periphery and the flat end
of the cutter.

• Milling process involves the rotary motion of the cutter and

the linear motion of the work piece. And depending on the
relative motion of the cutter and the work piece they are
classifies as:
1. Conventional (UP) milling : the direction of the feed of the
work table is opposite to the direction of rotation of the
cutter
2. Climb (down) milling: the direction of the fee of the work
table is same as that of the direction of rotation of the cutter
Hazards in milling
Many hazards occurs when operator unload or make adjustments. Other
main causes are:
• Using jigs and vises that prevents close adjustments
• Leaving the cutter exposed after the job has been done
• Leaving hand tools on work table
• Failing to securely clamp the work
• Reaching around the cutter to remove chips when the machine is in
motion
• Removing swarf cuttings with hand instead of using brush
• Adjusting coolant flow while the cutter is running
• Calipering the work while the machine is working
• Using incorrectly dressed cutters
• Using rags to clean excess oil while the machine is working
• Incorrectly storing the cutters
• Striking the cutter with hand while setting up or adjusting the stopped
machine
• Misjudging the clearance between the arbor or other parts
• Cleaning the machine in motion
mitigation
• Self closing guard for the milling machine cutter
• Install splash guards and pans for catching thrown cutting
lubricants and lubricants running from the tools
• When possible make all the cuts into the direction on the
travel of the table
• Mount hand adjusting wheels on the shaft either by clutches
or ratchet device so that the wheel will not revolve when
automatic feed is used
 EDM
• edm is used to make simple or
complex machining possible through
hole boring or cavity sinking in any
electrically conductive work material
•The work piece is normally clamped
to a table and an electrode is
fastened to the vertical ram platen
above the work piece.
•The electrode is then brought near the work piece so an accurately
controlled electrical discharge takes place between the electrode
and the work piece.
•As the metal is removed the electrode tool is fed to the work piece
and held in correct cutting relationship by electro hydraulic servo
control
•A dielectric fluid should completely cover the work piece in the
work tank
Hazards and precautions
• In order to prevent the Operator from accidently coming in
contact with the live electrodes install safety shields
• Edm is a heat producing process hence install EDM machines
only where there is adequate ventilation and maintain the oil
level above the highest portion of the workpiece ‘s working
gap
• EDM machines produces discharge gases which are
flammable. Allow discharge gases to escape without being
trapped in a close area. Turn off the electrical power to stop
additional gas or hot metal particles from forming to
extinguish flame
• Operator and maintenance personnel should read and
understand al the precautions before operating, setting up,
running or performing maintenance
Shapers, planners and sloters
• The main function of these machines is the machining of flat
surfaces by means of straight line reciprocating single pint
cutting tool. The surfaces produced may be horizontal vertical
or inclines at an angle.
Hazards in shapers and planer
Accidents are caused by unsafe practices cause by inadequate
training and supervision such as:
• Placing hand or finger between the tool and the work piece
• Running bare hand over sharp metal edges
• Measuring the job while the machine is running
• Failing to properly clamp the work piece
• Having insufficient clearance for the work piece
• Coming in contact with reverse feed dogs
• Unsafely adjusting the tool holder
• Failing to turn on the power supply when magnetic chucks are
used
• Contact with the projections on the work piece or with
projecting bolts or brackets
• Failure in properly locating the stops and dogs
mitigation
• to avoid these accidents install guards
• Cover the reversing feed dogs
• Construct a guard so that it will not cause accident when the
bed is extended
• Self adjusting planer table guards
• Rigidly bolt the stops to the table especially on heavy jobs