Power Tool Safety and Usage

Power Tool Safety and Usage

• Tradespeople working with hand and power tools must have appropriate PPE to protect against hazards like falling objects, flying debris, dust, fumes, and gases.
• Employers and tradespeople must collaborate to ensure establishment of safe working procedures; hazardous situations must be reported immediately.
• Floors around hand tools should be dry and clean to avoid slips.
• Misuse and improper maintenance are primary causes of hand tool accidents.
• Example of misuse is using a screwdriver as a chisel, which can cause the tip to break off; another example includes using a wrench with sprung jaws, which can slip.
• Using impact tools with mushroomed heads is dangerous, as their heads can shatter upon impact.
• Proper tool usage and maintenance is a tradesperson responsibility

Spark Hazards and Non-Sparking Tools

• Iron and steel hand tools can produce dangerous sparks around flammable substances.
• Spark-resistant tools made of materials like brass, plastic, aluminium, or wood should be used in hazardous environments.
• Non-sparking metals include brass, bronze, Monel, copper-aluminium alloys, copper-beryllium alloys, and titanium.
• Non-sparking metals have lower tensile strength, are softer, and wear faster than steel tools.

Power Tool Operation and Maintenance

• Power tools offer enhanced performance but require attention to safety issues and increased operational risks.
• Maintenance personnel must understand tool safety features and follow manufacturer's guidelines and common sense.
• Hazards when using power tools can be prevented by following five basic safety work practices: regular maintenance, using the right tool, examining tools before use, following instructions and using PPE
• Owner/operator manuals are the primary source of information for specific tool procedures.
• Operators must read and understand the owner's manual and labels on the shipping container
• Ground all tools unless they are double insulated
• Power tools should not be used in damp, wet or explosive environments. Vapour or fumes.
• Users must be aware of power lines, electrical circuits, water pipes, and mechanical hazards in the area.
• Wear proper apparel including restrained hair and avoid loose clothing or jewellery; consult tool manuals regarding gloves.
• Improper power tool use can be hazardous; understand potential dangers and safety precautions

Aviation Workshop Power Tool Use

• Aviation workshops use electric, pneumatic, and fixed machine tools.
• Power tools and their power supplies must be handled with care and respect to prevent damage or injury.
• Power tools must be properly maintained for continued serviceability and safety; these tools are expensive
• Precautions for power tool users include: not carrying tools by their cords, keeping cords away from hazards, disconnecting tools when not in use or when changing parts.
• Keep observers at a safe distance from the work area.
• Secure work with clamps or a vice to free both hands.
• Avoid accidental starting by keeping fingers off the switch button when carrying a plugged-in tool.
• Tools should be maintained, kept sharp and clean, with accessories lubricated/changed per the manual.
• Good footing and balance are keys; avoid loose clothing
• Damaged portable electric tools should be tagged "Do Not Use."
• Electrocution, burns, slight shocks, heart failure, and falls are potential dangers

Electrical Safety and Tool Practices

• Low amounts of electric current can cause heart fibrillation or death
• Electric tools must have a three-wire cord with a ground, be grounded, double insulated, or powered by a low-voltage isolation transformer.
• Double insulation uses wire insulation and a non-conductive housing for protection.
• Operate electric tools within design limits. Wear gloves and safety footwear if clear of rotating parts.
• Store tools in a dry place when not in use and never use in damp or wet locations.
• Keep work areas well-lit.
• Exercise caution selecting/using power tool accessories.

Abrasive Wheel Safety

• Only use accessories recommended by the manufacturer, with matching specifications and safety devices intact.
• Unplug tools before installing, adjusting, or changing parts.
• Abrasive wheels can throw off flying fragments.
• Inspect abrasive wheels before mounting; tap gently with a non-metallic instrument, a clear metallic ring signifies safety.
• The wheel must fit freely on the spindle and not be distorted by tightening.
• Follow manufacturer recommendations, and don't exceed abrasive wheel specifications.
• Never stand in front of a wheel during start-up due to disintegration risk.
• Portable grinding tools need safety guards to protect against the moving wheel and flying debris.

Grinder and Drill Usage

• Always use eye protection and turn off the power when the grinder is not in use.
• Never clamp a hand-held grinder in a vice.
• Portable power drills are among the most commonly used power tools.
• Check corded drills for loose connections or cord damage and replace damaged cords immediately.
• Ensure the chuck is tight, remove the chuck key before starting to prevent it from becoming a projectile.
• Use auxiliary handles and insulated surfaces for better control, especially under stalled conditions.
• Brace the drill; if drilling clockwise, brace against anti-clockwise reaction.
• Drill smoothly with enough pressure; forcing it can overheat the motor, damage the bit, and reduce control.
• Bench grinders are mounted with enclosed wheels and require proper metal guards.
• Bench grinders are for small, off-hand jobs.
• User handbooks offer specific grinding wheel information.
• Identifying a wheel that will suit the material is essential for diagnosing common grinding faults

Grinding Wheel Types and Maintenance

• Abrasive or grinding wheels are made from manufactured abrasive grains held together by a suitable material called the bond.
• Abrasive wheels will only perform work satisfactory if the rotating speed and wheel are correct for the work
• Aluminum oxide/Alundum is for high-tensile, tough materials and all steels.
• Silicon carbide/Crystolon is for hard materials like stone, ceramics, and non-ferrous metals.
• Check wheels for flaws such as broken edges, cracks, damaged mounting bushes, and damaged washers.
• Wheels should be dry and free of loose material.
• The maximum safe speed must be marked: do not exceed it or place wheels on the machine where it will
• Running wheel at higher speed than wheel is designed to run can make the wheel fly apart in operation

Grinding Machine Operation

• The work rest must be adjusted, the wheel guard must be fitted and the right machine/wheel combination MUST be used.
• Important is the wheel speed, rotation and abrasives.
• Grinding wheel direction should be towards the work rest to tighten the spindle nuts.
• The left spindle should have a left-hand and the right spindle a right-hand thread.
• Conditions like loading, glazing, and grooving reduce machine effectiveness.
• Loading occurs when material particles embed in the wheel, remedied by wider grain spacing.
• Glazing can be fixed with a softer grade of the bond
• Avoid grinding on the wheel's outside edges to prevent rapid wear.
• Dedicated grinding machines may be tagged.

Abrasive Wheel Care

• Abrasive wheels with loading, glazing, or grooving must be trued or dressed to restore them to operation.
• Dressing removes material from the cutting face to expose new abrasive particles and make it concentric.
• Loading and glazing require dressing while out-of-round wheels require truing.
• Selecting a machine for the work includes floor type pedestal (dressing) and a smaller bench type (tool sharpening)
• Abrasive dust produced by dressing is harmful; use a dust extractor or respirator with goggles.
• Machine suitability checks are wheel, secure wheel guards, and properly adjusted work rest.
• Wear close-fitting, buttoned overalls, safety goggles, a heavy leather apron, safety boots, and leather gloves.
• The area needs to be well lit and free from obstructions
• Off-hand grinding requires comfortable stance and support to prevent slips.

Grinding Techniques and Safety

• Forcing the work against the wheel reduces effectiveness
• Sheet work should be held in a way that eliminates vibration, and the back part of the work should be lifted slightly
• Avoid jamming material between the wheel and the work rest
• Move work across the wheel's face, avoid corners, and only use the side if designed for it
• Grinding generates heat, so hold small articles with pliers, have water nearby and avoid rapid quenching to prevent cracked edges.
• Effective sharpening directs grinding action and airflow to prevent overheating and produce a burr-free surface.
• Avoid heavy pressure/bumping and use a coarser grit wheel if material needs to be removed rapidly

Drilling Machine Essentials

• A basic understanding of the drilling machine's functions is needed to select one for the work
• The common drill press features are belt driven, 13mm shank capacity, spindle speeds ranging from a few hundred to a few thousand rpm, hand feed, machine vice to hold the work
• The upright drill press features are plumbed, bolted to the floor, belt or gear driven, 65 mm shank capacity, wide range of spindle speeds, tilting work table, a separate elevating motor
• Speed calculation errors cause dulling or breakage; efficient drilling depends on material properties, drill press condition, and cutting fluid.
• Type and hardness of material, drill material/diameter, hole depth, drill press.
• Material, cutting fluid and angle of the work should reflect the type of job.
• References describe cutting speed in surface feet per minute
• These speeds are for general cutting and finishing

Drill Operation and Safety

• The cutting speed depends on the materials of the drill and the work piece
• Small drills require faster speeds than large drills when cutting the same metal.
• Cutting soft metals = faster drill; hard metals = slower drill.
• Exceeding speeds overheats/damages drill bits; too-slow speeds cause breakage.
• Power needs to be switched off and the safety guard removed before the work starts. The tension bolts must be loosened and replaced.
• Move V-belt to the speed based on the speed table
• Table must be horizontal at each end; slanted belts can be damaged
• Small drills require slow metal-feed speeds to prevent breakage.
• Sharp, cool, and lubricated drills are more effective
• Soluble oil is best for mild and high-carbon steel, kerosene is an option for copper and brass, and best worked dry = cast iron Aluminum can be filed withe kerosene.

Drilling Procedures and Checks

• Use the steps when drilling a part - select the right size drill, check the size, secure the work, check the drill hole, feed the drill slowly
• Multiple checks ensure safety: wear eye-protection, 1 operator per press drill, don't hold the part, pilot hole if over 10mm in diameter
• Lubricants such as soluble oil work best
• Inspect electrical cords, tool, and hoses for damage,
• The operator must understand the company's damage policy
• Electric tools include drills, saws, and buffers; cordless tools are battery powered
• Electric drills come in a variety of sizes, power, and chuck to suit all applications
• Use a power screwdriver for installing screwdriver bits

Bandsaw Operation and Hand Grinders

• Bandsaws must have the correct blade and guard, with hands kept clear.
• Radially or axially-cut roundstock must be clamped in a V-section jig
• Eye protection is a must, and power should be isolated before any adjustments
• Hand grinders can be air or electrically powered/use safety precautions
• Three types: angle, straight, and die (aka pencil) grinders
• Electric buffers. Jigsaws = metal.

Pneumatic Tools and Safety

• Compressed air powers nailers, drills, etc
• Dangers come from tool attachment failure
• Eye and face protection when attachments break
• Pneumatic power are compact tools
• Faster speeds makes them very versatile
• Pneumatic power is less prone to static and electrical discharge
• Pneumatic tools can be diamond saws, grinders etc.
• High-speed pneumatic grinders are used for large items.
• Use filters for cleaning and painting with air
• Air-line filters help to adjust air pressure when using air hoses
• Hose connections must be designed for air pressure
• Secure pneumatic tools to prevent disconnection
• Install safety clips and retainers to prevent tools shooting off
• Do not exceed the safe amount of pressure for what the manufacturer set
• Working with hazardous materials requires hearing protection

Pneumatic Tools: Precautions

• A short wire serves as added safeguard
• A safety clip or retainer to add attachments is added safety (Chisels and hammers are prime examples
• Ensure that there are screens around workers in the event of things breaking
• Pointing compressed air tools at anyone is never right
• The most common problem is water in air hoses; the contamination stems from cold air or humidity
• Most humidity is condensed
• Condensed parts cause slow actions
• Lubricants washing, tools freezing, and other issues

Pneumatic Tools: Precautions and Riveting

• Distinguish air pipes from other pipes
• Clear any dirt from any nipple before connecting and check equipment, hoses and casing for damage
• Avoid dragging these parts and running them over
• Don't use tools with parts that are not fully operational
• Eye and rubber protection when cleaning with the air hose
• Connect the tools before powering them on
• Riveting guns combine with a set or snap to suit head shapes.
• The setting will snap suited the head shape
• Pressing the trigger creates rapid vibrations to attach objects effectively.
• Avoid pointing at any person
• Bucking bars and rivets are formed when the set is operated
• Use of dollies is important to set the right size
• Soft-made riveters are air pressured and form the head of the job
• Dollies are versatile and adjustable

Soldering Guidelines

• Soldering may be referred to as hard or soft, the temp is very crucial, the higher the temp, the higher the process
• Soft soldering combines sponge to iron for tip cleaning
• A soldering combines the parts into a single source.
• Each time the tip is varied, pinpoint matching is required.