7)Operational Safety Precautions

There are two kind of milling machine that we using in workshop during our practical class, the first one is Vertical Milling Machine, and another one is Horizontal Milling Machine. All milling machines contain hazards from rotating parts, belts and pulleys, high voltage electricity, noise, and compressed air. When using CNC machines and their components, basic safety precautions must always be followed to reduce the risk of personal injury and mechanical damage.

Horizontal and Vertical Milling Machine Safety Guidelines
The Horizontal Mill is use for boring, drilling, face milling, tapping, and similar operations. The principle hazards associated with the operation of horizontal machine are :
· Tools or materials dropped on the feet and toes.
· Flying chips or scale from boring and facing operations and flying fragments from a broken tool. · Contact with unguarded moving parts or with pinch point between a tool and a work.Work pieces thrown from the worktable if they are not secured properly

1. Always keep safety in mind. Accidents on milling machines usually occur when the operator loads or unload or makes adjustments to the milling operation. The major hazard is injury to hands, arms or fingers by contact with the cutter, other sharp object, or by pinching. Unsafe can be due to :
· Lack of essential guarding.
· Unsafe work practices.
· Failure to withdraw the job to a safe distance from the cutter while loading or unloading the machine, measuring the parts or checking the finish.
· Attempting to remove chips by hand.
· Adjusting coolant while cutters are revolving.
· Using wipes or rags near revolving cutters.
· Wearing gloves or loose clothing near revolving cutters or machine parts.
· Unsafe workplace.
· Poor housekeeping around machine (wet or slippery floor).

1. Before starting the machine, the operator will make certain that conditions are such that neither she/he nor a fellow worker will be injured by the operation of the machine. Among the items to be checked are :
· All guard are in good condition and in place.
· Proper cutting tool , correctly sharpened , is used.
· Tool is securely fastened.
· Machine has been properly lubricated.
· Work has been properly secured in place, and bolts and other holding devices are such that they will not be caught or come into contact with moving parts of the machine.
· Table feeds, proper cutting speed and all machine attachments are correctly set and in proper working order.
· Tools or other loose objects are not lying about where they may fall or be caught n thrown ,injury to the operator or other or with damage to the machine or to the work.



2. Before leaving the machine for any reason, the operator is to make sure the machine is stopped and the power shut off.



3. Wear eye protection and safety shoes at all times.



4. Do not wear neckties, wristwatches, rings, jewelry, gloves, etc. When operating the machine. Long sleeve shirts will be rolled above the elbows. Do not wear loose clothing.



5. The area around the machine should be free of oil or coolant spills (avoid a slippery floor) and as free as possible from obstructions. Keep the area clean at all times.



6. Do not use compressed air to blow chips from the spindle or table machine surfaces, cabinets, controls, or the floor around the machine.



7. For normal lifting, use leg, not back muscles. For heavy lifting, use a hoist.



8. Illuminating lamps should be adjusted so light is not directed into operator’s eyes.



9. When work platforms are used around the machine, they should be extremely sturdy, safe, and with anti-slip surfaces.



10. Wrenches, tools, and other miscellaneous equipment should be kept off all moving units of the machine.



11. Be mentally alert on the job, always sober, and never dulled by the influence of drugs, prescribed or otherwise.



12. Use the proper hand tools for each job.



13. Only qualified personnel should perform maintenance repair work.



14. Report any unsafe conditions to yr supervisor.



15. Keep machinery clean.



16. Clean machine and area after each use.



17. Before starting clear area and table of obstructions.



18. Use appreciate lifting device for fixtures, rotary tables, angle plates and large work pieces.



19. Always remember to remove wrench after tightening bolt for collets and arbors.



20. Use soft hammer (plastic or rawhide) to loosen collets, not a wrench or steel hammer.



21. Always pay attention and never walk away when machine is in use.



22. Make sure all changeable tooling is properly secured.



23. Remove levers, handles, and cranks before engaging feed or rapid traverse.



24. Stop spindle when removing chips, changing or measuring parts or adjusting setups.



25. Use a magnetic shield when necessary.



26. To check workpiece – shut machine off & move cutter away from workpiece, do not check
workpiece while spindle is moving.



27. Use appreciate PPE for the job.



28. Do not operate under restrictive medications or use of alcohol or drugs.



29. Report any safety discrepancies to the shop supervisor.


Do’s and Don’ts
1.DO get thoroughly familiar with the STOP lever or button.
2.DO make sure that the work is held securely before engaging the cutter with it.
3. DO make sure that all tools and machine parts are clear of the cutter before starting the machine.
4.DO keep your hands away from the revolving items (cutters, spindles, work pieces, etc)
5.DO handle all cutters carefully to guard against injury to yourself and others.
6.DON’T under any circumstances attempt to operate any machine unless you are thoroughly familiar with it.
7.DON’T move any lever unless you know exactly what is going to happen when it is moved.
8.DON’T play around with the lever of any machine.
9.DON’T go away, even a moment, and leave the machine running.
10.DON’T try to operate the machine and engage fellow workers in conversation at the same time. Keep your mind on your work and let the other fellow do the same.
11.DON’T attempt to oil the machine while it is in operation.


The Cautions and Symbol
1. Do not operate without proper training.
2.Always wear safety goggles.
3.Never place your hand on the tool in the spindle and press ATC FWD, ATC REV,
4.NEXT TOOL, or cause a tool change cycle. The tool changer will move in and crush your and.
5.To avoid tool changer damage, ensure that tools are properly aligned with the spindle drive lugs when loading tools.
6.The electrical power must meet the specifications in this manual. Attempting to run the machine from any other source can cause severe damage and will void the warranty.
7.DO NOT press POWER UP/RESTART on the control panel until after the installation is complete.
8.DO NOT attempt to operate the machine before all of the installation instructions have been completed.
9.NEVER service the machine with the power connected.
10.Improperly clamped parts machined at high speeds/feeds may be ejected and puncture the safety door. Machining oversized or marginally clamped parts is not safe.
11.Windows must be replaced if damaged or severely scratched - Replace damaged windows immediately.
12.Do not process toxic or flammable material. Deadly fumes can be present. Consult material manufacturer for safe handling of material by-products before processing.
13.The spindle head can drop without notice. Personnel must avoid the area directly under the spindle head.