WORKSHOP TECHNOLOGY

1.0 SAFETY AND HEALTH

 This topic is an introduction to the safety and

health of machining and welding processes as
related safety aspects.
SAFETY IN MACHINE SHOP

 Health and Safety in a workshop is very

important. If a pupil/student uses equipment,
tools and machinery, he/she should have
received safety training. This should ensure
that he/she feels confident in the use of
machines and can operate them without
having an accident or causing an accident to
other people.
 SAFETY IN MACHINE SHOP
 Before you can use equipment and machines or attempt
practical work in a workshop you must understand basic
safety rules. These rules will help keep you and others
safe in the workshop.
 Safe Ed (left) always thinks about working safely. On the
other hand, Ed the Handyman (right) never considers
safety. Not only is he at risk of having an accident but so
are those who work near him. They could have an
accident because of his reckless behaviour.
SAFETY IN MACHINE SHOP
Read the safety rules carefully. If you fully understand them you should
be able to work safely in a workshop. Do not be like Ed the Handyman !!!!

1. Always listen carefully to the teacher and follow instructions.

2. Do not run in the workshop, you could ‘bump’ into another student and
cause an accident.
3. Know where the emergency stop buttons are positioned in the
workshop. If you see an accident at the other side of the workshop you
can use the emergency stop button to turn off all electrical power to
machines.
4. Always wear an apron as it will protect your clothes and hold lose
clothing such as ties in place.
5. Wear good strong shoes. training shoes are not suitable.
6. When attempting practical work all stools should be put away.
7. Bags should not be brought into a workshop as people can trip over
them.
SAFETY IN MACHINE SHOP
8. When learning how to use a machine, listen very carefully to all the
instructions given by the teacher. Ask questions, especially if you do
not fully understand.
9. Do not use a machine if you have not been shown how to operate it
safely by the teacher.
10. Always be patient, never rush in the workshop.
11. Always use a guard when working on a machine.
12. Keep hands away from moving/rotating machinery.
13. Use hand tools carefully, keeping both hands behind the cutting edge.
14. Report any damage to machines/equipment as this could cause an
accident.
SAFETY - VERTICAL MILLING MACHINES

 The vertical milling machine is very dangerous if

used by someone who has not been trained to
use it safely. Never use a machine like this
unless you have received precise operating
instructions by the teacher. This machine can cut
through steel and so it will quickly cut through
flesh and bones with great ease. Also, the
teacher should be next to you when you use it
for the first few times.
SAFETY - VERTICAL MILLING MACHINES
 Safe Ed has followed the instructions given to
him by the teacher.
 He has set up the material to be cut in a large
machine vice which is bolted to the milling
machine table.
 Guards have been paced around the work so
that small pieces that fly off the surface do
not hit the machine operator.
 Safe Ed has set up the automatic feed so that
the cutting tool removes the excess metal
very slowly.
 He watches the machine at all times, never
moving away from it.
 He also wears the correct protective clothing
including safety goggles.
 His hands are safely a way from the rotating
cutter.
SAFETY - VERTICAL MILLING MACHINES

 However, Ed the Handyman has

decided to start the vertical miller,
ignoring the training he has been
given.
 As the cutting tool spins round at
high speed he plays with the
machine vice handle and pulls down
the cutting tool onto the metal.

 QUESTIONS:
Ed the Handyman shows a total
disregard for safety in other ways.
Can you list what else he is doing
that is wrong?
HOW ED the HANDYMAN USES A HAMMER

 A variety of hammers are used regularly when working in a workshop. Special

hammers are available for use with different materials such as plastics, steels,
woods and other groups of materials. Which ever hammer is selected they all
need to be used with care.

 Ed the Handyman is irresponsible. He smashes

two hammers together because he likes the noise.
He is unaware of how dangerous this can be. The
hammer heads are made from cast steel and they
are specially hardened. When the hammer heads
smash together they can spark and even smash
breaking into many small dangerous pieces. The
small pieces fly off at high speed and damage
anything they hit.
Hammers should be stored carefully and used
properly.
HOW ED the HANDYMAN USES A HAMMER

 Ed the Handyman has started to use a hammer

without considering safety. As he raises the hammer
he hits himself in the face.

 Ed the Handyman tries a second time to use the

hammer. Again he is careless. He holds the nail in his
hand but misses with the hammer, hitting his hand
with the full force.
 Hammer heads are normally fixed to the handle
by a wedge. If the wedge becomes loose this will
eventually lead to the hammer head flying off
when the hammer is used. The head will fly off at
great speed which means that it will inevitably hit
something or someone. If it hits a person it can
cause serious injury. Always check the hammer
head before using it and report damage
immediately to the teacher. Ed the Handyman
thinks he knows best and his brother gets hurt as a
result.
CORDED HAMMER DRILLS
 Corded Hammer Drills have a wide range of uses.
Corded drills are powered directly by plugging into
the main electricity supply and this means that extra
care must taken regarding safety.

1. The cord is carefully laid out so that it cannot trip the person using the drill.
2. It is good practice to use a circuit breaker. This will cut power if any electrical fault
in the drill occurs.
3. Always wear safety goggles to protect the eyes. Never operate equipment like
this without eye protection.
4. When using a corded drill hold both the normal handle and front handle securely.
This will help steady the drill as it vibrates during use. It also allows the user to
put pressure against the drill as it is used to drill holes in difficult materials.
5. The person using the drill should space their feet apart. This helps the person
balance and lean into the drill, applying his/her weight safely.
6. Always check that electrical wires or water pipes are not in the area of intended
drilling. Drilling through an electrical wire can be extremely dangerous.
7. Always seek instruction / training from an appropriately qualified instructor
before using any tools, especially power tools.
 JIGSAWS
 Jigsaws are general cutting and shaping tools. They are provided with a
selection of blades suitable for cutting and shaping a range of materials. They
are ideal for cutting thin manmade boards such as plywood and MDF (Medium-
density fibreboard) and they are capable of cutting detailed curves. They can
also be used to cut kitchen tops and quite thick material. Thin material (4mm to
6mm) can be cut quite quickly but great care must be taken when cutting thicker
material (6mm upwards).

Safety and use of jigsaws are outlined below. Remember, before operating any
power tools you must receive training from a suitably qualified instructor.
JIGSAWS
1. Always plug power tools into a RCB (Residual-current device - circuit breaker)
as a safety measure against electrical faults.
2. Wear goggles to protect eyes from dust/chippings and a face/dust mask to
prevent breathing in dangerous dust particles.
3. Always read the manufacturers instructions very carefully and follow them.
4. Always seek instruction / training from an appropriately qualified instructor
before using any tools, especially power tools.
5. Make sure that the mains cable cannot be tripped over or that it causes a
hazard in anyway.
6. G Cramp the material to be cut/shaped to a firm workbench before starting.
7. Fit an extraction bag to the jigsaw. This will collect most of the dust.
8. Use the guard at all times.
WORKSHOP MACHINERY - MACHINE DRILLS
 There are two types of machine drill, the bench drill and the pillar drill. The
bench drill is used for drilling holes through materials including a range of
woods, plastics and metals. It is normally bolted to a bench so that it cannot be
pushed over and that larger pieces of material can be drilled safely.

 The larger version of the machine drill is called the pillar drill. This has a long
column which stands on the floor. This can do exactly the same work as the
bench drill but because of its larger size it is capable of being used to drill larger
pieces of materials and produce larger holes.

PILLAR DRILL

BENCH DRILL
WORKSHOP MACHINERY - MACHINE DRILLS

SAFETY

1. Always use the guard.

2. Wear goggles when drilling materials.
3. Clamp the materials down or use a machine
vice.
4. Never hold materials by hand while drilling.
5. Always allow the ‘chippings’ to clear the drill
by drilling a small amount at a time.
6. Follow all teacher instructions carefully.
 THE CENTRE LATHE
 The Centre Lathe is used to
manufacture cylindrical shapes
from a range of materials
including; steels and plastics. Many
of the components that go together
to make an engine work have
been manufactured using lathes.
These may be lathes operated
directly by people (manual lathes)
or computer controlled lathes (CNC
machines) that have been
programmed to carry out a
particular task. A basic manual
centre lathe is shown. This type of
lathe is controlled by a person
turning the various handles on the
top slide and cross slide in order to
make a product / part.
THE CENTRE LATHE
SAFETY

1. Do not use a machine if you have not been shown

how to operate it safely by the teacher.
2. Always use a guard when working on a machine.
3. Keep hands away from moving/rotating
machinery.
4. Report any damage to machines/equipment as
this could cause an accident.
5. Follow all teacher instructions carefully.
 WORKSHOP EQUIPMENT - HAND DRILLS
HAND DRILL

 In the workshop you probably use a ‘hand drill’ and

a ‘ratchet brace’ as part of practical work. These are
used for drilling a range of sizes of hole and they are
very useful especially if machine drills are not
available. The hand drill generally holds drill sizes
from 1mm to 9mm whilst the brace will hold larger
drill bits called ‘forstner bits’ and ‘auger bits’. These
larger bits can be used to drill ‘blind holes’ (holes that
do not go the entire way through material).

 When using these drills, always hold them so that

they are vertical and turn the handles in a clockwise
direction. The common mistake is to turn the handles
anticlockwise as this makes it almost impossible to
drill even the smallest holes. Also, put scrap material
underneath the material to be drilled so that the
bench is not damaged by the bit as it ‘bursts through
the other side.
RATCHET BRACE
WORKSHOP EQUIPMENT - HAND DRILLS
SAFETY

1. Clamp down the work to be drilled.

2. Hold the brace or hand drill vertically.
3. Turn the handle clockwise
4. Place scrap material underneath the material to be drilled.
5. If you feel it is necessary - wear goggles.
6. Do not drill too quickly, take your time.
G CRAMPS
 G Cramps are an essential tool in the workshop
and they come in a range of sizes and are
generally used for clamping work securely to a
surface/workbench top. They can also be used to
hold parts together whilst glue is drying.
The clamp is tightened by turning the small
Tommy bar which turns the threaded rod.

 Some G Cramps have a wing nut in place of the

bar making it easier to turn by hand. However, if
a Tommy bar is used more pressure can be
applied to the thread in order to tighten the
clamp.

 The thread of a G Cramp is made from hardened

and tempered steel which means it is quite
resistant to wear. The frame is normally made
from drop-forged steel.
 G CRAMPS

 Diagram 1 shows how a piece of material is

clamped down using a G Cramp during drilling.
Material should never be held in the hand
because it can spin at high speed if the drill bit
jams . The G Cramp holds the material down
safely.

 Diagram 2 shows a G Cramp used to secure a

piece of wood to a bench so that a chisel can
be used on it. This is essential as chisels are
very sharp and if the wood were to move the
chisel could slip, causing a serious accident.