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Safety for Metal Cutting 115

Metal Cutting Training

Class Information

Tooling U classes are offered at the beginner, intermediate, and advanced levels. The typical class consists of 12 to 25 lessons and typically requires at least two hours of instruction time.

Class Name:	Safety for Metal Cutting 115
Description:	This class identifies the safety hazards associated with cutting operations and the precautions you must take to avoid injury.
Prerequisites:	none
Difficulty:	Beginner
Number of Lessons:	15

Class Outline
Objectives The Importance of Cutting Safety What Is OSHA? Personal Protective Equipment (PPE) Fire Hazards Point of Operation Hazards Machine Guarding: Manual Lathe Machine Guarding: Manual Mill CNC Machine Guarding Cutting Fluid Safety Chip Control Lifting Safety Tool Handling Safety Worksite Organization Summary

Class Objectives

Identify common hazards during metal cutting.
Describe the purpose of OSHA.
Describe the PPE required for cutting operations.
Identify common fire hazards for cutting operations.
Identify common point of operation hazards.
Describe common safety hazards on the manual lathe.
Describe common safety hazards on the manual mill.
Describe machine guarding methods for CNC machines.
Describe common safety hazards associated with cutting fluids.
Describe methods to protect yourself from contact with chips.
Describe safe lifting practices for cutting operations.
Describe safe tool handling practices for cutting operations.
Describe the characteristics of a well-organized worksite.

Class Vocabulary
auger	A rotating shaft with a helical blade that removes chips from the machine.
bore	The internal surface of a cylinder. Bore surfaces are often accurately ground to accommodate a retaining ring with minimum friction.
chip	An unwanted piece of metal that is removed from a workpiece. Chips are formed when a tool cuts or grinds metal.
chip guard	A plastic shield that covers the point of operation and prevents flying chips from contacting the operator.
chuck	A device that holds a workpiece in place as it rotates. The chuck commonly has three or four jaws that can be adjusted to fit various sizes of parts.
chuck key	A device used to loosen the bolts or cam-locks on the chuck.
CNC machine	A machine controlled by a computer that runs special programs driven by numerical data. CNC machines are very rigid and are capable of fast cutting speeds.
conveyor belt	A moveable belt that helps to remove chips from the machine.
coolant	A cutting fluid used to decrease the temperature of the tool and workpiece.
cutting	A machining process that uses a tool to create chips and remove metal from a workpiece.
cutting fluid	A fluid used during cutting operations to reduce heat and friction between the cutting tool and the workpiece.
dolly	A low, two- or four-wheeled cart or platform used for transporting objects.
drill	A multi-point cutting tool used to make round holes.
drill chuck	A type of toolholder that holds drill bits on the mill. Drill chucks allow for quick installation and removal of drill bits for various drilling operations.
drill press	A machine tool that rotates a cutting tool with enough force to cause it to penetrate the surface of the workpiece and make a round hole to a certain depth.
earplugs	Ear wear that is inserted into the inner ear to protect hearing.
eye wash station	A designated station in an easily accessible area in which employees may flush their faces with water in the event of an emergency.
face shield	A rigid, transparent plastic sheet that covers the worker's entire face to protect against dust or splashes. Because face shields do not protect against impacts, they are often worn with goggles.
fixed guard	A machine guard that is attached to the machine with screws or other devices that require a tool for removal. Fixed guards are generally safer than other types because they are harder to remove.
goggles	Tight-fitting eye protection that completely covers the eyes, the sockets, and the surrounding facial area. Goggles offer protection from impact, dust, chips, and splashes.
hand truck	A small hand-propelled vehicle used for transporting small loads.
hand wash station	A designated station in an easily accessible area in which employees may wash their hands.
interlock switch	A switch that shuts off or disengages the power whenever the CNC door is opened or pushed out of position.
lathe	A machine tool commonly used to create cylindrical parts. A lathe holds a cylindrical workpiece on one or both ends. The cutting tool is gradually passed along the surface of the rotating part.
leadscrew	The long threaded device that controls the precise movement of the carriage on a lathe.
machine guarding	A method of preventing worker injury by keeping body parts from entering hazardous areas of the machine or by keeping flying debris from exiting the machine.
machine tool	A power-driven machine that uses a cutting tool to create chips and remove metal from a workpiece.
mill	A machine tool used to either horizontally or vertically remove metal from the surface of a workpiece.
mill	A multi-point cutting tool that is used to remove metal from the surface of a workpiece.
multi-point tool	A cutting tool that has two or more cutting edges.
Occupational Safety and Health Administration	A government agency under the U.S. Dept. of Labor that helps employers reduce injuries, illnesses, and deaths in the workplace.
OSHA	The abbreviation for the Occupational Safety and Health Administration.
overhead crane	A crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure.
personal protective equipment	Any example of various safety equipment that workers wear or use to prevent injury in the workplace. Safety glasses are common personal protective equipment (PPE).
point of operation	The area where the work actually takes place. It is the place where the tool and the workpiece meet.
safety glasses	Protective eyewear, usually made of thick plastic, that shields the eyes from flying debris. Safety glasses with side shields or safety goggles must be worn in any work area.
saw	A multi-point cutting tool that is used to rough cut a part to a certain length.
single-point tool	A cutting tool that has a single cutting edge.
soluble oil	A cutting fluid that is composed of lubricant-based oil, emulsifiers, and other additives. Soluble oil is obtained as a concentrate and is then mixed with water.
spindle	The component of a tool that spins. For safety, spindles must be properly tightened and able to move freely without obstruction.
splash guard	A plastic shield that covers the point of operation and protects the operator from contact with cutting fluids.
straight oil	A cutting fluid that is composed of mineral oil or vegetable oil and is mainly used as a lubricant. Straight oil is not intended to be mixed with water.
tailstock	The component located at the end of a lathe opposite the headstock that supports the end of longer workpieces.
tool crib	A designated area where extra tools and accessories are kept. The tool crib is also typically where tools can be serviced or repaired.
toolholder	A mechanism used to rigidly hold a cutting tool in place during machining.
ventilation system	A means of cleaning or re-circulating contaminated air. Ventilation systems are necessary to prevent cutting fluid inhalation.
vise	A workholding device with one fixed jaw and one moveable jaw. Vises are often used to hold simple rectangular or cubic workpieces on a mill or machining center.