Merge pull request #131 from edinburghhacklab/lathe-rewrite

Lathe rewrite

Author: iykdw

syllabuses/Workshop/Bantam Lathe/risk-assessment.md

@@ -1,29 +1,152 @@
 # Bantam Lathe
 
-<!-- Each thing below becomes a row in the table - copy it for each risk that's been identified.
-     Please delete all the comments from the final document -->
+## Injuries from tools or workpiece
+
+### Severity
+
+H
+
+### Likelihood
+
+M
+
+### Who may be harmed & how
+User - the user may receive cuts from tools while handling or sharpening them. They may also be cut by sharp edges on the workpiece. Long swarf can wrap around the workpiece causing unexpected sharp edges.
+
+### Control measures
+- Training - user should not touch cutting surfaces at any time, and should be aware of potential sharp edges on the workpiece. Workpieces should be sanded where appropriate before being considered "finished."
+- Training - swarf cleanup should be done with shop vac or dustpan and brush, not by hand.
+- Equipment - an emergency stop button is installed. A first aid kit is available.
 
-## A thing that might go wrong
+
+## Injuries from improper setup
 
 ### Severity
 
-<!-- How bad it is if the thing happens. H, M, or L. -->
 H
 
 ### Likelihood
 
-<!-- How likely something is, *after* the control measures listed below. H, M, or L. -->
+L
+
+### Who may be harmed & how
+- User - the user may be hurt if the workpiece comes loose, a tool is improperly secured and is ejected from the machine, or if the chuck key is left in the lathe.
+- Bystanders and other users of the room - other users in the room may similarly be hurt if the workpiece, tool, or chuck key are ejected from the machine.
+
+### Control measures
+- Training - user should ensure workpieces and tools are secured and the chuck key is removed before starting the machine.
+- Awareness - user must inform all users of the room that they are using the lathe.
+- Equipment - anyone in the room while the lathe is being used should be wearing appropriate PPE (eye protection, ear protection, and closed-toe shoes). An emergency stop button is installed, and first aid it is available.
+
+
+## Entanglement in moving parts
+
+### Severity
+
 H
 
+### Likelihood
+
+L
+
 ### Who may be harmed & how
+- User - the user is most at risk from loose clothing, jewellery, or hair being caught in the spindle or leadscrews. Theymay also be entangled while holding a file or other tool in contact with the workpiece.
+- Bystander - anyone standing close by the lathe while it is in operation may become entangled if they have loose clothing, jewellery, or long loose hair.
+
+### Control measures
+- Training - user must ensure that they and anyone nearby have removed secured clothing, removed jewellery, and tied hair back. User should avoid holding files and must not hold sandpaper or emery paper in their hand. If sanding using the lathe is required, the sanding medium should be glued to a piece of wood. In all cases, tools held againt the workpiece must be held with a very loose grip, and should be released immediately in the event of unexpected force.
+- Awareness - user must inform all users of the room that they are using the lathe.
+- Dual Working - user should not use the lathe if they are the only person in earshot. Where possible, the user should inform other lab users that they are using the lathe, and give an estimate of how long for. User should - at minimum - have a mobile phone capable of calling 999 easily accessible about their person.
+- Equipment - an emergency stop button is installed.
+
+## Crushing in moving axis
+
+### Severity
+
+M
+
+### Likelihood
+
+L
 
-<!-- Usually some combination of:
-       User
-       Bystander
-       Users of the room
-       The space
-       Following user -->
+### Who may be harmed & how
+- User - the user's extremities may be crushed by the table and slide as they are movin, particularly if power feed is being used.
 
 ### Control measures
+- Equipment - the power feed will disengage if significant resistance to movement is encountered. A first aid kit is available. An emergency stop button is installed.
+- Training - user should be aware of crushing risk when performing movement or cutting operations, and ensure that they are clear of potential crush zones.
+
+## Injury from flying swarf
+
+### Severity
+
+M
+
+### Likelihood
+
+M
 
-<!-- Anything that's in here should also be in the syllabus somewhere, to ensure it's actually practised. -->
+### Who may be harmed & how
+- User - the user may experience harm if swarf is ejected from the workpiece.
+- Bystanders and other users of the room - though less likely, swarf ejected during cutting may injure other users in the room.
+
+### Control measures
+- Training - user should perform cuts at appropriate feeds and speeds to ensure swarf is an appropriate size. User should stop the machine immediately if swarf is being ejected violently or is too big or too small.
+- Equipment - user and other users of the room should wear eye protection, ear protection, closed toed shoes, and long sleeves. A first aid kit is available. An emergency stop button and footbrake are installed.
+
+
+## Crushing from chuck
+
+### Severity
+
+M
+
+### Likelihood
+
+L
+
+### Who may be harmed & how
+- User - the chucks are heavy and hard to grip, and require movement to unergonomic positions during changing. Dropping a chuck could cause a crushing injury to hands or feet.
+- The space - the lathe may also be damaged if a chuck is dropped on it.
+
+### Control measures
+- Training - the user should ensure plentiful space around the chuck is cleared before attempting to change the chuck.
+- Equipment - appropriate shoes, preferably with steel toecaps, should be worn during chuck changes. A first aid kit is available.
+
+
+## Burns from tools or workpieces
+
+### Severity
+
+M
+
+### Likelihood
+
+L
+
+### Who may be harmed & how
+- User - the workpiece and tools can become hot due to friction while cutting and could cause burns.
+
+### Control measures
+- Training - the user should use coolant during cut operations where appropriate. The user should be aware that workpiece and tools should not be touched immediately after a cut is finished.
+- Equipment - a first aid kit is available.
+
+
+## Fire
+
+### Severity
+
+H
+
+### Likelihood
+
+L
+
+### Who may be harmed & how
+- User - the user may sustain burns or eye damage if the material or swarf catches fire.
+- The space - a fire in the workshop could damage the tools and the building as a whole.
+- Next user - if flammable swarf is left on the machine, the next user could (inadvertently and blamelessly) be burned or sustain eye damage if it catches fire.
+
+### Control measures
+- Training - user must use coolant for flammable metals. User must ensure all flammable swarf (metals and wood) are removed from the machine after operation and that a thorough cleanup is performed. Wood should not be turned on this machine. Flammable metals must be turned with extreme care and preparation, and after consultation with qualified users if there is any uncertainty.
+- Equipment - a fire extinguisher is available. If turning flammable materials, the user should ensure it is within easy reach and is in-date.

syllabuses/Workshop/Bantam Lathe/syllabus.md

@@ -1,12 +1,13 @@
 # Bantam Lathe
 
-<!-- There is no prescribed structure, but here is a suggestion: -->
-
 ## Safety
 
 ### PPE
 - Safety glasses required.
-- Hearing protection optional.
+- Closed toe shoes required.
+- Hearing protection recommended.
+- Long-sleeved shoes recommended.
+- Respirator optional, based on material.
 
 ### Risks
 
@@ -15,37 +16,46 @@
 - No loose jewellery (i.e. rings, watches) or accessories (i.e. cables).
 - No gloves.
 - Long hair must be tied back.
+- No holding emery paper or sandpaper against the workpiece.
 
 #### Stock, swarf and chip risks
 - Wood or flammable metals (magnesium, titanium) dust and swarf must be immediately cleaned up.
 - Sharp chips may fly.
-- Stock, workpieces, and tools may all have sharp edges.
-- Stock and workpiece may become very hot during cutting.
+- Stock, workpieces, swarf and tools may all have sharp edges.
+- Workpiece and tools may become very hot during cutting.
 
-<!-- Usually, all of the control measures in the risk assessment should be mentioned here -->
 ## Anatomy of the lathe
 - Headstock is where the part is turned from.
-- Bed is the portion which moves when you turn the big wheel.
-    - Slides are mounted on the bed and controlled by little wheels.
-- Tailstock is the piece at the far end, used for securing work or for drilling.
-- Z axis is parallel to the work.
-- X axis is perpendicular to the work.
+- Carriage is the portion which moves when you turn the big wheel. It moves parallel to the rotation axis of the workpiece.
+    - The cross slide is mounted on the carriage, and moves radially in and out from the workpiece.
+    - The compound slide is mounted on the cross slide and can be used for fine control cuts, or rotated to cut tapers into the workpiece or bore the centre.
+    - The toolpost is mounted on the compound slide.
+- Tailstock is the piece at the far end, and can be used for securing work or for drilling.
 - Autofeed knob
 - Fwd/reverse knob
 - Thread-cutting levers
     - TODO: Document how these actually work
         - TODO: Figure out how these work.
 
 ## Startup checks
-### Surrounding area cleared of obstacles.
+### Tool and surrounding area cleared of obstacles.
+- Workpiece should be rotating freely for full length, including at back of machine.
+- Tray should be cleared of swarf and debris.
+- Carriage should be clear.
+
+### Machine has sufficient oil.
 
-### Other workshop users alerted to keep clear.
+### Other workshop users alerted that lathe is in use.
 
-### Stock is secured in chuck and all jaws are tight.
-- The three-jaw chuck should be used for round stock. The four-jaw chuck should be used for all other shapes.
+### Workpiece is secured in chuck and all jaws are tight.
+- The part of the workpiece protruding from the chuck  should be as short as possible
+- The three-jaw chuck should be used for round workpieces. The four-jaw chuck should be used for all other shapes.
 - Unlike the four-jaw chuck, the jaws on the three-jaw chuck are mechanically linked. Regardless, all three sockets should be tightened.
 
-### The key is removed from the chuck and the chuckguard is down.
+### Stock is supported if necessary.
+- A centre can be fitted to the tailstock and used to support the end of the workpiece.
+
+### The key is removed from the chuck and safely stored and the chuckguard is down.
 
 ### The tool being used is securely attached to the toolpost.
 
@@ -56,7 +66,8 @@
 - The gear should only ever be changed when the lathe is turned off and is stationary.
 - Once a gear is selected, the chuck should be manually rotated a full turn to ensure smooth movement.
 
-### The table is clear of the workpiece.
+### The tailstock, carriage and tool are clear of the workpiece.
+- If the tailstock is being used to support the workpiece, ensure it is locked in position.
 
 ## Usage
 
@@ -67,17 +78,21 @@
 - Press the green start button next to the VFD and wait for the tool controller to turn on.
 - Tap in.
 - Press "Fwd."
-- Keep foot on or near brake at all times.
-
-### Loading and Unloading Tools
-- Lock toolholder in table
+- Keep foot on or near footbrake at all times.
+
+### Loading and Unloading Tools to Toolpost
+- Turn lathe off and allow workpiece to stop completely.
+- Ensure new tool is intact and sharp.
+    - The parting tool can be sharpened using the "steel only" wheel on the bench grinder. It should be kept cool via water immersion and short presses against the wheel.
+    - Diamond cutters can sustain chips and damage. These should be replaced. If the supply of fresh cutters is running low, contact tools@edinburghhacklab.com.
+- Lock toolholder to toolpost (or to tailstock, if drilling.
 - Verify height of tool
-    - Close chuck jaws and bring cutter to near centre
+    - Close chuck jaws and bring cutter to near centre (or centre of workpiece, if marked.)
     - Tool should be in line with centre of chuck
 
 ### Changing Chuck
 - Move each of the sockets until the mark on the socket lines up with the mark on the body.
-- Carefully lift chuck off
+- Carefully lift chuck off.
 - Load new chuck and carefully tighten each socket.
 
 ### Stopping the machine
@@ -86,18 +101,16 @@
 - Log out.
 - Press in the e-stop.
 
-<!-- incl estops if necessary -->
-
-
 ### Materials
-- Metals are fine
-- Wood can be turned, provided very low speeds are used and all dust and swarf is removed immediately.
-- Flammable metals (titanium, magnesium, et al) must be turned at very low speeds with coolant, and all dust and swarf should be removed immediately.
+- Metals are fine.
+- Wood should not be turned.
+- Carbon fibre must not be turned.
+- Flammable metals (titanium, magnesium, et al) must be turned at the lowest appropriate speed with coolant, and all dust and swarf should be removed immediately.
 
 ### Cleaning up
+- Swarf must be cleared using the shop vac or a dustpan and brush.
+- If coolant was used, any collected in the tray should be wiped up.
+- The carriage, tray, and motor enclosure should be cleared of debris and other items.
 
 ## Maintenance
-
-### General
-
-## Other
+- If there are any issues, contact tools@edinburghhacklab.com or one of the admins of the Lathe access group to report them. These may include clicking or grinding noises.