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Machine Shop Safety and Practice

                                               Robin Coope
                                               May 10 2006



UBC Department of Physics and Astronomy / UBC Engineering Physics            Applied Biophysics Laboratory




                  Machine Shop Qualifications

                                                       • Users with the 10 hour course can
                                                       only work under supervision of the
                                                       shop manager Ernest Diamante or a
                                                       qualified Physics 253 Instructor.
                                                       This does NOT extend past the end
                                                       of Physics 253.
                                                       • Users with the 40 hour course
                                                       must work with at least one other
                                                       person in the shop
                                                       • There is a maximum of ten people
                                                       in shop.

      A Qualified Physics 253 Instructor!

UBC Department of Physics and Astronomy / UBC Engineering Physics            Applied Biophysics Laboratory




                                                                                                             1
Machine Shop Safety

           • Safety first! Call 911 for
           emergency and report all injuries to
                                                                                      Long Hair
           shop supervisor.
           • Safety glasses must be worn in
           shop.
           • No bare feet, sandals, slippers or
           open toe shoes are permitted.
           • Minimum foot protection of sneakers
           and socks is required.
           • Tie up/secure long hair and remove
           rings, bracelets etc...                                    Bad Hair
           Do not wear loose fitting clothing.




UBC Department of Physics and Astronomy / UBC Engineering Physics                Applied Biophysics Laboratory




                  Machine Shop Safety
                                                           • Keep your work area free and
                                                           clear of excessive chips and
                                                           clutter.
                                                           • Be careful when using
                                                           compressed air hoses. Do not
                                                           blow chips/ debris towards
                                                           yourself or others.
                                                           • Never touch chips or rotating
                                                           tooling with your bare hands or
                                                           fingers when a machine is
                                                           running.
                                                           • Never leave chuck key or
                                                           wrenches unattended in
                                                           machines.
UBC Department of Physics and Astronomy / UBC Engineering Physics                Applied Biophysics Laboratory




                                                                                                                 2
Machine Shop Safety

                   • Keep the shop doors closed after hours or when
                   supervisor is not present. Do not leave any
                   unauthorized people in the shop. No key, no
                   admittance.
                   • Sign out all tools removed from the shop. Write
                   your name, phone number and room number.
                   Return tools promptly.
                   • If unsure, ask for assistance.
                   • Report damage to tools and machines to the
                   shop supervisor. After hours, leave a note.
                   • Clean up! Dust pans brushes and booms are
                   provided

UBC Department of Physics and Astronomy / UBC Engineering Physics            Applied Biophysics Laboratory




                  Machine Shop Organization


                                                                    • All tools live in
                                                                    specified locations for
                                                                    easy retrieval.
                                                                    • This makes cleanup
                                                                    much easier: just put
                                                                    things back in the
                                                                    proper drawer.




UBC Department of Physics and Astronomy / UBC Engineering Physics            Applied Biophysics Laboratory




                                                                                                             3
Key Hazards


         • Cutting Fingers on Sharp Tools
         • Minor burns from hot parts or chips




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                  Key Hazards

                              One worker one machine!!!




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                                                                                                    4
Tools: Sheet Metal




                                                                            Sheer Bender (brake)


   • Different band saws for steel and Aluminum
   • Blade quality is important for safety
UBC Department of Physics and Astronomy / UBC Engineering Physics                    Applied Biophysics Laboratory




                  More About Band Saws


                                                                    • Lubricate blade with wax
                                                                    block
                                                                    • Fences and Tees do not
                                                                    work very well with sheet
                                                                    stock – cut freehand
                                                                    • Use wood push block to
                                                                    feed work on the band
                                                                    saw.




UBC Department of Physics and Astronomy / UBC Engineering Physics                    Applied Biophysics Laboratory




                                                                                                                     5
More About Band Saws


                                                                    • Clamp round parts
                                                                      in an upside down
                                                                      vise.
                                                                    • Cut steel rod with
                                                                      a hacksaw!




UBC Department of Physics and Astronomy / UBC Engineering Physics              Applied Biophysics Laboratory




                  Tools: Milling Machine

                                                               • Particularly useful
                                                                 for accurate layouts
                                                               • Can mill and drill




UBC Department of Physics and Astronomy / UBC Engineering Physics              Applied Biophysics Laboratory




                                                                                                               6
Tools: Milling Machine




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                  Tools: Milling Machine




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                                                                                                    7
Tools: Lathe




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                  Tools: Lathe




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                                                                                                    8
Tools: Lathe




UBC Department of Physics and Astronomy / UBC Engineering Physics                Applied Biophysics Laboratory




                  Tools: Lathe


                                                                    • Lathes are more
                                                                    dangerous than mills as
                                                                    the spinning parts are
                                                                    larger and heavier.
                                                                    • The SMS lathes are
                                                                    relatively small though.




UBC Department of Physics and Astronomy / UBC Engineering Physics                Applied Biophysics Laboratory




                                                                                                                 9
Tools: Sander/Grinder


                                                                    • Useful for quick
                                                                      material removal on
                                                                      outside surfaces
                                                                    • Parts heat up very
                                                                      quickly and can burn
                                                                    • Use a water bath to
                                                                      cool the part, then
                                                                      dry machine after
                                                                      use.

UBC Department of Physics and Astronomy / UBC Engineering Physics                 Applied Biophysics Laboratory




                  Tools: Sander/Grinder


                                                  Grinder for tool steel only!!!!!!
                                                  No Aluminum !!!!!!!!




   The scotch wheel is your
   finishing friend.
   Can semi-polish and deburr
   rapidly and safely
   Much safer than a polishing
   wheel
UBC Department of Physics and Astronomy / UBC Engineering Physics                 Applied Biophysics Laboratory




                                                                                                                  10
Tools: Drill Press




        Careful changing speeds on
        drills and lathes



UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                  Tools: Drill Press




                         • Properly clamp all work in vise on drill
                         presses when ever possible.


UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                                                                                                    11
Tools: Drill Press


                                                                           What is wrong
                                                                           with this picture?




UBC Department of Physics and Astronomy / UBC Engineering Physics                  Applied Biophysics Laboratory




                  Tools: Drill Press and Milling
                  Machine


                                                              Always use specially
                                                              modified drills when drilling
                                                              brass or plastic.




UBC Department of Physics and Astronomy / UBC Engineering Physics                  Applied Biophysics Laboratory




                                                                                                                   12
Hand Working

         • Often faster than machines
         • Many different shapes of files are
           available
         • Use a file card




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                  Remember



             Your three priorities in a machine shop are safety,
                            accuracy and speed.

                                        Never sacrifice safety.




UBC Department of Physics and Astronomy / UBC Engineering Physics   Applied Biophysics Laboratory




                                                                                                    13

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Machine Shop Safety And Practice 2006

  • 1. Machine Shop Safety and Practice Robin Coope May 10 2006 UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Machine Shop Qualifications • Users with the 10 hour course can only work under supervision of the shop manager Ernest Diamante or a qualified Physics 253 Instructor. This does NOT extend past the end of Physics 253. • Users with the 40 hour course must work with at least one other person in the shop • There is a maximum of ten people in shop. A Qualified Physics 253 Instructor! UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 1
  • 2. Machine Shop Safety • Safety first! Call 911 for emergency and report all injuries to Long Hair shop supervisor. • Safety glasses must be worn in shop. • No bare feet, sandals, slippers or open toe shoes are permitted. • Minimum foot protection of sneakers and socks is required. • Tie up/secure long hair and remove rings, bracelets etc... Bad Hair Do not wear loose fitting clothing. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Machine Shop Safety • Keep your work area free and clear of excessive chips and clutter. • Be careful when using compressed air hoses. Do not blow chips/ debris towards yourself or others. • Never touch chips or rotating tooling with your bare hands or fingers when a machine is running. • Never leave chuck key or wrenches unattended in machines. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 2
  • 3. Machine Shop Safety • Keep the shop doors closed after hours or when supervisor is not present. Do not leave any unauthorized people in the shop. No key, no admittance. • Sign out all tools removed from the shop. Write your name, phone number and room number. Return tools promptly. • If unsure, ask for assistance. • Report damage to tools and machines to the shop supervisor. After hours, leave a note. • Clean up! Dust pans brushes and booms are provided UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Machine Shop Organization • All tools live in specified locations for easy retrieval. • This makes cleanup much easier: just put things back in the proper drawer. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 3
  • 4. Key Hazards • Cutting Fingers on Sharp Tools • Minor burns from hot parts or chips UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Key Hazards One worker one machine!!! UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 4
  • 5. Tools: Sheet Metal Sheer Bender (brake) • Different band saws for steel and Aluminum • Blade quality is important for safety UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory More About Band Saws • Lubricate blade with wax block • Fences and Tees do not work very well with sheet stock – cut freehand • Use wood push block to feed work on the band saw. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 5
  • 6. More About Band Saws • Clamp round parts in an upside down vise. • Cut steel rod with a hacksaw! UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Tools: Milling Machine • Particularly useful for accurate layouts • Can mill and drill UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 6
  • 7. Tools: Milling Machine UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Tools: Milling Machine UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 7
  • 8. Tools: Lathe UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Tools: Lathe UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 8
  • 9. Tools: Lathe UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Tools: Lathe • Lathes are more dangerous than mills as the spinning parts are larger and heavier. • The SMS lathes are relatively small though. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 9
  • 10. Tools: Sander/Grinder • Useful for quick material removal on outside surfaces • Parts heat up very quickly and can burn • Use a water bath to cool the part, then dry machine after use. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Tools: Sander/Grinder Grinder for tool steel only!!!!!! No Aluminum !!!!!!!! The scotch wheel is your finishing friend. Can semi-polish and deburr rapidly and safely Much safer than a polishing wheel UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 10
  • 11. Tools: Drill Press Careful changing speeds on drills and lathes UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Tools: Drill Press • Properly clamp all work in vise on drill presses when ever possible. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 11
  • 12. Tools: Drill Press What is wrong with this picture? UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Tools: Drill Press and Milling Machine Always use specially modified drills when drilling brass or plastic. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 12
  • 13. Hand Working • Often faster than machines • Many different shapes of files are available • Use a file card UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory Remember Your three priorities in a machine shop are safety, accuracy and speed. Never sacrifice safety. UBC Department of Physics and Astronomy / UBC Engineering Physics Applied Biophysics Laboratory 13