GCSE Resistant Materials

GCSE Resistant Materials Topic 2 : Tools, Equipment and Safety Produced by David Bunce Student Workbook 2 Name

Tools, Equipment and Safety It is very important that you are able to identify the different hand tools, power tools, fixed equipment and specialised machinery available for use around the workshop. You should be able to : Name the tool, equipment or machinery Identify what the tool, equipment or machinery is used for. Use the tool, equipment or machinery correctly and safely. As there are over 100 different items in our workshop and you will not be able cover all of the above in one or two lessons. However, during the course of this first year (10) you need to familiarise yourself with all of the tools and equipment available in order to gain the confidence to use these (on your own) at a later date, correctly and safely. Most tools and equipment you see can be placed in one of the following FOUR categories. 1. Hand Held Tools 2. Hand Held Power Tools 3. Fixed Equipment (general purpose) 4. Specialised Machinery 1. Hand Held Tools General Tools (Screwdrivers Spanners, Hammers, Mallets) etc Measuring Tools (Ruler, Measuring Tape, Micrometer, Vernier Caliper) etc Marking Out Tools (Marking Gauge, Scriber, Centre Punch, Tri-Square, Dividers) etc Cutting Tools (Saws, Chisels, Files, Planes, Drills, Tin Snips, Taps and Dies) etc Holding Tools (Vices, Mole Grips, Pliers, G-Clamps) 2. Hand Held (portable) Power Tools Electric Drill, Electric Sander, Electric Grinder, Electric Circular Saw. Electric Jig Saw, Soldering Iron etc 3. Fixed Equipment (general purpose) Guillotine, Vices, Electric Pillar Drill, Electric Sander, Electric Circular Saw, Electric Jig Saw, Electric Band Saw, Electric Polisher etc 4. Specialised Machinery CNC Router, CNC Mill, CNC Lathe, Mig Welding Equipment, Gas Welding Equipment, Vacuum Forming Machine, Laser Cutting Machine, Hot Wire Cutter, Plastic Bending Machine, Wood Turning Lathe etc A great website http://www.thesitebox.com/hand-tools/woodworking-tools.aspx 2

Name of tool, equipment or machine General Tools Ball pein hammer Images Used for A ball pein hammer has a rounded pein on rear face. It s a heavy duty hammer usually used with metal Cross pein hammer A cross pein hammer has a wedge shaped pein on the rear face. Used to hammer small pins and nails. Claw hammer Wooden mallet A claw hammer is a heavy duty hammer used for hammering larger nails into timber. The claw (at the rear) is used to remove nails Wooden mallets are normally made from beech and used with wood chisels or assembling wood joints. Rubber mallet Combination spanner Side cutting pliers Rubber and nylon hammers are the modern version of a wooden mallet. Used for assembling wood joints and bending/shaping some softer metals A combination spanner comes in a large range of sizes and has an open ended spanner at one end and a ring spanner at the other. Use with nuts and bolts Side cutting pliers have a sharp cutting edge and are used to cut and strip electrical wire. 3

Measuring and Marking Out Tools Ruler A steel rule is used for measuring and marking out and is accurate to 1mm Vernier gauge A modern digital vernier gauge is accurate to 0.01mm and is a very useful measuring instrument, that is easy to use. Used for measuring both inside and outside dimensions Micrometer A micrometer is a precision measuring instrument that is accurate to 0.01mm Mortise gauge (marking gauge) A mortise gauge is used for marking parallel lines (in wood), which is ideal when making joints in several pieces of timber Tri-square A tri square is used to ensure that objects have been cut, filed or glued accurately to an angle of 90º 4

Centre punch (dot punch) A centre or dot punch is used to mark where holes need to be drilled in metal objects Scriber A scriber is used when marking out metal objects before cutting and drilling. It has a sharp tip which is used to lightly scribe (scratch) the metal surface Sliding bevel A sliding bevel is used to indicate where wood needs to be cut. It is adjustable and can be set at all angles Dividers Dividers are used for making simple comparisons, but not used as an accurate measuring tool (non-indicating) Odd leg callipers Odd leg callipers are used to mark out lines and can be used in a variety of ways. Most commonly it is used to scribe (scratch) parallel lines 5

Mitre box A mitre block is used to accurately cut wood at exact angles (eg 45 ) for right angle joints. A mitre block is usually made from wood or very hard plastic Sawing Jig A sawing jig also enables timber to be cut at specific angles very accurately, but is larger than a mitre block which enables larger pieces of wood to be cut. 6

Cutting Tools (Wasting) Tenon saw Coping saw A tenon saw is a small saw with a brass back which keeps the blade very straight. Ideal for cutting small pieces of wood in a straight line. Most saws cut when they are pushed away from the user. A coping saw cuts when pulled and has a small detachable blade which is easily removed. This saw is ideal for cutting round curves. Hacksaw Ripsaw A hacksaw also has a detachable blade which is easily changed and is used for cutting small metal items. The number of teeth per inch (tpi) depends on the material you are cutting. As a simple rule softer metals like brss and aluminium would have slightly larger teeth than the blades used for steel A rip saw has large teeth like chisels that cut along the grain and is used for cutting large pieces of wood. The blade does flex slightly. Cross cut saw A cross cut saw usually has smaller teeth than a rip saw (cut at 60 ) and is used when cutting across the grain of wood. The blade does flex slightly. 7

Block plane A block plane is used for planning the end grain of a piece of wood Smoothing plane A smoothing plane is used to get a smooth finish on timber before abrasive paper is used for the final smooth finish Spoke shave A spoke shave is used to smooth curved edges Bevel edged chisel (for wood) A bevel edges chisel can be used to cut and trim would where the Mortise chisel (for wood) Mortise chisels are strong withstraight sides and are used for chopping deep holes in timber (eg slots for mortise joints) 8

Gouge chisel (for wood) A gouge chisel has a curved blade for carving Centre bit (drill) A centre bit drill is used to accurately mark the point where drilling needs to be done on a pillar drill or lathe Twist drill Countersink drill Twist drills come in a variety of sizes and are usually used for drilling holes in metal, wood or plastic. Some twist drills are referred to as masonry drills and are used for drilling holes in brick or concrete wall. These drills have a special hardened tip A countersink drill is used to after a hole has been made with a normal twist drill to provide a tapered hole so a countersunk screw head can sit below the surface of the material Chuck Key A chuck key is required to secure a drill bit in place in the chuck of a pillar drill or portable drill 9

Hole Cutter Hole cutters come in a variety of sizes and are used for cutting large diameter holes Taps and Dies Taps and dies come in large sets and are used for cutting threads. Taps are used for cutting internal threads and dies are used for cutting external threads Engineering Files Engineers files come in all shapes and sizes with different size cutting teeth. They are used for shaping and smoothing metal Rasps Rasps look similar to files but have very coarse teeth and are usually used on wood. Tin Snips Tin snips are like very strong scissors that are used for cutting thin tin or steel sheet metal 10

Vices and Cramps (Holding Tools) Woodworking vice A woodworking vice is used to hold wood or plastic while it is being drilled, cut, planed or shaped Engineers vice An engineers vice is used to hold metal objects while it is being drilled, cut or shaped. Soft aluminium inserts can be used (in the vice jaws) to prevent damage to the surface of the metal Machine vice A machine vice is used for holding items securely whilst they are being drilled. G cramp A G cramp is normally used for holding items to a bench whilst gluing, drilling or cutting. Can also be used to hold items together, while inserting screws etc Sash cramp A sash cramp is a large adjustable clamp usually used for holding items together after they have been glued 11

Mole grips (vice grips) Mole grips are used for holding items securely whilst they are being drilled or cut. A variety of jaw shapes enables a wide range of shapes to be held (eg tubing) Engineers pliers Engineers pliers are used for holding all types of small objects. The are very useful for working objects loose (eg bolts, pins etc) that may have become seized. Fixed and Hand Held Equipment (General Purpose) Band saw A band saw is a circular blade that passes vertically through a flat bed. Its ideal for cutting small flat pieces of wood. This machine can be very dangerous Hand held jig saw A hand held jigsaw is used to cut flat wood in straight or curved lines. This machine can be very dangerous Scroll saw A scroll saw has a detachable blade which enables it to be passed through a small hole. It can then cut out small curved shapes quickly and accurately. This machine can be very dangerous. 12

Belt sander Belt sanders can be flat (as shown) or vertically mounted. They are used to sand the edges of wood to to a smooth finish Hand held sanders Belt Sander Orbital sander Hand held sanders are used for finishing timber to a smooth finish prior to applying wood stain or varnish. Bench mounted shears Bench mounted shears are used for cutting sheet metal. These shears can be very dangerous and are often locked. Pillar drill A pillar drill is a large heavy duty machine used for drilling holes. The chuck can enable drill bits to be used that are up to 20mm diameter. Circular saw machine A circular saw machine is a heavy duty how powered machine that is used for cutting up large sheets of timber or man made board in straight lines. This machine can be very dangerous 13

Hand held circular saw Power hacksaw A hand held saw is also used for cutting timber in straight lines, but has the advantage of portable which is very useful for site work. This machine can be very dangerous and must be used under supervision A power hacksaw is a heavy duty machine design to cut up metal tubing and box section steel. This machine can be very dangerous and must be used under supervision Hand held angle grinder An angle grinder is used to cut through metal or to smooth welded metal joints. It can be very dangerous and needs to be used with extreme care. Hand held drill Hand held portable drill A very popular piece of equipment used for drilling holes. The chuck size usually opens to 10mm diameter. 2 speed settings and a hammer action enable holes to be drilled in masonry with the appropriate drill bit. This is very similar to a normal hand held drill, but is low voltage and far more portable. The main disadvantages are that it has to be recharged and has far less power than a conventional mains powered drill. 14

Specialised Equipment CNC router CNC lathe CNC mill A CNC router is a 3 axis machine (sideways, front to back and up/down) used for cutting out shapes or making holes in wood and soft metal very accurately. It requires a computer and software. The advantage of using CNC is that it enables identical pieces to be manufactured quickly and accurately. A CNC mill is very similar to a router and is also a 3 axis machine (sideways, front to back and up/down) The main difference is that a mill enables far more complex shaped to be machined to a very high degree of accuracy. It requires a computer and software The advantage of using CNC is that it enables identical pieces to be manufactured quickly and accurately. A CNC lathe is also a 3 axis machine (sideways, front to back and up/down) that enables metal or hard plastic (like nylon) to be machined into intricate shapes very accurately. It requires a computer and software. The advantage of using CNC is that it enables identical pieces to be manufactured quickly accurately 15

Laser cutter A laser cutter is a 2 axis machine that only enables cutting in 2 axis (sideways and front to back). It is used to accurately cut plastic and thin wood up to 10mm thick Vacuum former Hot wire cutter (for plastic) A vacuum forming machine is used to manufacture a variety of shapes in plastic. A hard mould is usually produced from a high density fibre board. The plastic is heated until soft and then the mould is forced into the plastic. A vacuum pump ensures that the plastic is formed tightly around the mould to produce a plastic product (shell). A hot wire cutter is used to cut through plastic or foam. It can be used to cut foam quite accurately in lots of different shapes. It is used mainly for modelling products before manufacture. Wood turning lathe A wood turning lathe is used to shape circular or square wood into more ornate round objects like candle holders and table legs. 16

Safety Many of the hand held tools around the workshop have sharp edges (eg saws, chisels, drills, planes etc). If you use these tools incorrectly or handle them carelessly, they can easily cause damage and spoil your work and/or injure yourself or other people. Hand held power tools can be even more dangerous and it is very important that you understand how to use the tools correctly and safely. Using all tools correctly comes with practice in order develop skills and gain confidence. Your teacher will demonstrate the correct operating procedure and highlight all of the safety features that need to be observed. However, there are some very important common safety rules that need to be observed at all times General Safety Rules Always carry sharp tools with the sharp edge facing downwards Never run in the workshop Always wear aprons to protect your clothes Roll up your sleeves Remove your tie (if applicable) Tie back you hair (if applicable) Wear goggle when necessary (eg operating power tools Where a dust mask when necessary (eg operating sanding tools) Wear firm flat shoes Know where the stop buttons are for every machine. Keep your work area clean and tidy Specific Safety Rules Specific safety rules and correct operating procedures apply to almost every single tool and all equipment that you will use in the workshop. Some are very simple (and in most cases very obvious), others are more detailed and specific to that particular piece of equipment. For example, the safety rules for using a screwdriver correctly will be easier to follow than operating a fixed pillar drill or MIG welding machine. In ALL cases you must know these safety rules before you start work. IF IN DOUBT > ASK Safety Signs Around the workshop you will notice a variety of safety signs and notices. These signs are usually colour coded and divided into FOUR categories. RED = Prohibition (Stop/Do Not) YELLOW = Caution (Warning of Danger) BLUE = Mandatory (You must do) GREEN = Information (Go this way) 17

Examples of Safety Signs YELLOW = Caution (Warning of Danger) RED = Prohibition (Stop / Do ) BLUE = Mandatory (You must do) GREEN = Information (Go this way) Recognising Hazards and Risks There is a very old saying that prevention is better than cure. This applies to many aspects of life, but is particularly relevant to safety in the workshop. Preparing yourself correctly to start work should ensure that the job is carried out safely. This may involve wearing personal protective equipment (PPE) like goggles or gloves. Ensuring that the work-piece in fixed securely (eg in a vice), checking the tool you are using for signs of wear or damage. This will then be followed by carrying out the task. Again, knowing how to use the tool correctly (before you start) is essential. At a later date, we will look at some statistics of accidents at work and you will be surprised how many accidents happen carrying out the most simple task. Obviously, certain tasks carry a much higher risk (of injury) than other tasks and it is important that you understand how to carry out a RISK ASSESSMENT, in order to understand and appreciate how and why accidents happen with all types of tools and equipment. We will look at risk assessments in more detail at a later date, but there are five principles associated with a risk assessment. 1. Identify potential hazards 2. Decide who might be harmed and how 3. Evaluate the level of risk and decide whether existing precautions are adequate or more should be done. 4. Record the findings of the risk assessment 5. Review and revise the assessment at regular intervals (keep records) 18

Risk Assessment A Risk Assessment is nothing more than a careful examination of what could cause harm to people and whether sufficient safety precautions have been taken. (in simple terms identifying RISK!!) Every employer should take every precaution necessary to prevent injury or illness. Accidents not only ruin individual s lives but can affect their family and friends. Bad accidents can also affect a business, where they may be a temporary or permanent shut down. A bad accident may also result in damage to expensive equipment and machinery which may cost thousands of pounds to repair. In extreme cases an employer could be prosecuted or even given a jail sentence if they have not provide adequate safety training and equipment. Before we start looking more closely at Risk Assessments of the workshop and individual tools and equipment. It is very important to understand that most accidents in the workplace occur due to slips and trips where people have fallen over. Many of these accident could have been prevented if the workplace was kept more tidy and spilt oil or water cleaned up immediately. You should NEVER have the attitude that picking something up of cleaning up some split liquid is somebody else s job. If you are in that workspace IT IS YOUR JOB! You are responsible for the health and safety of your friends and work colleagues as well as yourself. The second highest cause of accidents is NOT wearing adequate personal protective equipment (eg gloves, goggles, work boots etc). Again, it is your responsibility to ensure that you wear googles when using sanding, cutting or grinding. You only have one pair of eyes and a small fragment of metal rotating at 2000 rpm could easily be thrown up and enter your eye at 100 mph. Even if someone else is carrying out a dangerous activity, it is your responsibility to notify that person of the dangers, which could also cause harm to you. Another common cause of accidents is lack of training, where someone operates a piece of equipment incorrectly, before they have carried out adequate set-up or safety checks. Again, a good employer should ensure that you have received adequate training, but it is also important that you DO NOT operate any equipment unless you have been shown how to operate that equipment or tool safely. In the UK the HASAWA (Health and Safety at Work Act) was introduced by the government to raise the standards of health and safety in the workplace. Assessing the risk associated with different workshop tasks comes with experience, but some simple steps can be followed to make the process quite straightforward if the following steps are followed. 19

Carrying out a risk assessment Step 1 Identify potential hazards Who may be exposed to the hazard What control measures are already in place Step 2 Assess the level of risk using a risk graph (see below) Step 3 Evaluate the risk Decide : If existing controls are adequate What action is recommended The time frame to eliminate the risk Review date IT IS VERY IMPORTANT TO KEEP RECORDS OF ANY RISK ASSESSMENTS AND REVIEW THAT THE ACTIONS RECOMMENDED WITHIN THE GIVEN TIME FRAME No Hazard Who might be harmed 1 Using a Operator hot glue gun Hot glue gun tip and hot glue coming into contact with the skin Existing control measures Tools checked for serviceability weekly. Demonstration of correct use by teacher before students are allowed to use this equipment. First aid box checked weekly Level of Risk Medium Future actions required Demonstration of use before each lesson. Emphasise the importance of correct handling of the glue gun and using the stand when not in use. Ensure safety warning is attached to all glue guns l Time frame ONE WEEK This type of risk assessment should be carried out on every piece of equipment in the workshop. Each item should have been given a low, medium or high level of risk. Tools and equipment with high levels of risk, should NOT be used until any safety issues ghave been rectified (eg machine guards fitted etc) 20

The action required and the time frame depends on the LEVEL OF RISK. This risk graph and table will help you establish the level of risk, based on accident likelihood and severity. If it is not possible to carry out the action immediately for high risk activities, that activity should be STOPPED. When you establish the overall level of risk. You need to consider, both : Likelihood of accident Severity of accident Existing Control Measures are also important to consider. As a general rule, if the EXISTING CONTROL MEASURES are very good this should significantly reduce the likelihood of an accident. 21