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The goal of this handbook is to help create a safer environment that teams will display not only at competition, but also when they return home. This handbook includes a complete safety manual, rules and tests for operating machinery, and a bonus safety contract. Building robots is fun, but can be dangerous. To make sure each team member is safe at all times, they must sign a contract we have created based on this Safety Manual. Each team will receive a copy of the rules and safety regulations. Mandatory written and performance tests are given to make sure everyone is comfortable operating the machines. Everyone should understand the importance of safety and what it means to put “The BEST Safety First!”

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Safety Contract

You must be supervised, preferably by a more experienced individual, while utilizing any and all tools.

Always ask for help when needed (e.g. Lifting heavy equipment, using tools, etc.).

Wear safety goggles/glasses at all times. Do not use broken or damaged tools, and always take care of them. If you are injured get help immediately and report all accidents to your

sponsor (same goes if you see someone else get hurt). Always use tools properly (e.g. Do not use a screw driver as a hammer or

use a rubber mallet to hammer nails). Wear close-toed shoes at all times when inside the pit, around the robot,

and in the shop. Make sure to always wear proper safety equipment for the job at hand. Operate under ideal working conditions only (do not work in unorganized

rooms, in the dark, etc.). Do not eat or drink in the shop. No horseplay. Always clean up your workplace when you are finished in order to maintain

a safe, clean working environment. Always check for wearing and tearing on cord before use. Always do your best in the working zone.

**This sheet must be signed and returned before you can start using any power tools or work on the robot.** Parent/Guardian Signature: ________________________________________ Student Signature: ________________________________________________

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Safety and the Competition Inspiring a culture of safety is a significant value that every individual in the BEST Robotics Competition community must embrace as we chase the mission and vision. BEST Robotics Competitions have taken safety as the most important moral and has established the framework for safety leadership in all features of the curriculum. BEST believes that the teams that take the lead in developing safety programs and policies have a positive and lasting impact on each team member, mentor, their communities, and their present and future work places. BEST recognizes the teams that demonstrate safety throughout their programs and are truly committed to developing and nurturing a safety culture.

Purpose This safety manual is an easy-to-use guide for all about safety at the BEST Robotics Competitions and it provides all BEST participants with a basic set of requirements to maintain a safe environment during the build season and at competition events.

Scope This manual applies to anyone involved with the BEST Robotics Competition including all student team members, mentors, and support personnel.

Responsibilities Everyone is responsible for safety during team meetings and the design, build, travel, and event phases of the competition. Please read this entire manual for details on how to be safe.

Participants As a BEST participant, you are expected to:

Be familiar with this manual as well as the safety-related requirements applicable to your work area.

Be familiar with any site restrictions listed in the “Site Info” on the web regarding competition site location(s).

Work in a safe and responsible manner.

Understand and follow established safety requirements.

Use personal protective equipment, safe guards, and other safety equipment when needed or as required.

Identify and report any unsafe or hazardous conditions to the student safety captain. This includes work practices that may cause an accident.

Mentors: Provide guidance on the safe working requirements associated with the various tasks and

tools involved with constructing the robot.

Offer safety design considerations to the team so the robot itself is designed to eliminate or minimize hazards to an accepted level.

Coach the student safety captain to ensure that he/she understands and adequately fulfills the position’s responsibility.

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Student Safety Captain: Coordinate, deliver and track safety training for the individual team members. Bring your log

to events and continue to make comments about infractions and/or continuing improvements.

Provide support for any safety questions or concerns that may arise. Seek guidance, as appropriate, from your team mentors.

Conduct safety inspections of the general work sites, especially the robot construction area. This also applies to the Pit station during competition events.

Encourage your team to display positive safety behaviors at all times.

INJURY REPORTING REQUIREMENT Regardless of severity, report all accident, injuries, and near misses to your team’s mentor and your team’s safety captain. Even injuries that you determined as minor may become serious if proper medical attention is not provided in a timely manner. Remember, each minor event is usually a precursor to a major event.

SAFETY INSPECTIONS The safety captain should inspect the work areas on a routine basis. Determine and document the frequency of inspections by the potential risk in work.

PPE The proper use of personal protective equipment is an important element to help ensure participants are protected from hazards in the work area.

Eye and Face Protection There are several forms of eye/face protection available to provide protection from these hazards, including safety glasses with side shields, goggles, and face shields. Inspect equipment for damage each time worn. If you wear prescription glasses, and they are not approved safety glasses, you must wear approved safety goggles over them to achieve adequate protection. Eye and face protection is required when there is a risk of exposure to the following:

Flying particles

Chemical Exposure

Wear non- shaded, ASNI- approved eye protection in the following areas:

Your team’s “at home” work stations when doing any work on the robot including sanding, drilling, soldering, cutting, filing, etc.

HAND PROTECTION: Hand protection is designed to protect against heat, electrical, chemical and mechanical hazards. Use proper gloves and mechanical tools guard.

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Gloves: Participants should work with the team mentor to ensure the selected glove is the

correct one to use for each project.

Check your gloves for proper size, absence of cracks and holes, and good flexibility and grip before you wear them.

Mechanical Guards:

Provide safety guards for required power tools.

Never use any equipment without safety guards in place.

Notify your Safety captain and mentor of any broken or defective equipment, and take it out of service until repairs are made.

Foot Protection: When engaging in any robotics competition, all participants must wear closed toe shoes that completely cover the entire foot. Shoes must have closed-toes and heels to protect against foot injuries, regardless of work location. Under no circumstances are flip flops, crocs, mules, sandals, etc. acceptable while attending robotics competitions or near the robot. In some cases, safety shoes or toe guards are appropriate for areas where heavy objects can fall on your foot. Notify your team mentor if you encounter such situations, and determine the safest way to perform the task.

Other Preventions: Ensure that team members or mentors are not wearing loose clothing or jewelry such as: ties, hanging key chains, etc. when near or working on moving rotating machinery. Tie hair back or cover it.

SAFETY REQUIREMENTS The following are some areas, practices, and functions for which teams will be inspected and monitored for safety conformity and innovation. This list is not all-inclusive and the Safety Advisors will constantly watch for any positive and negative safety practices. Horseplay is not permitted at any time.

General Safety: Following safe work practices, safe use of all tools, and maintains a healthy attitude regarding

safety.

Always walk and work in a controlled and thoughtful manner.

Wear ANSI-approved non-shaded safety glasses.

Wear closed-toed shoes, gloves where needed, and use hearing protection if necessary.

Keep full control of robot at all times with no one in the robot’s path at anytime.

Assist other teams with safety issues.

Take special care when working at higher-than-normal- heights.

Always fully open a ladder and never stand on the top step

http://www.youtube.com/watch?v=rII2-scpta0

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Competition Safety: Use the buddy system when traveling and while at the event.

Travel safely and careful between the Pit and the playing field.

Demonstrate safe behaviors in the heat of the competition.

Exhibit planes, safe lifting procedure of the robot, including cart removal after the lift.

Make sure the robot is properly secured if you must work underneath it or if the robot is on an unstable surface.

Assist other teams with safety issues.

Pit Requirement: Only students with a pit pass may enter the pit area.

Pit Station Safety:

Control access to your pit area.

Keep your aisle clear for pedestrians and robot transit.

When transporting your robot, politely keep pedestrians alert to your movement.

Be aware of your neighbors. Alert them if there is a hazard in your station or near theirs.

Maintain a clean, neat, and orderly Pit Station at all times.

SOLDERING Soldering can be dangerous because of the heat from the iron and the chemical fumes and the vapors released from the solder and flux, respectively. When soldering observes the following points:

No torches or open flames of any kind are allowed in the buildings.

Wear eye and face protection.

Solder in well-ventilated areas

Never touch the iron/gun. It heats to extreme temperatures that will cause severe burns.

Prevent burns: Wear cotton clothing that covers your arms and legs.

Always wash your hands with soap and water after soldering.

Work on a fire resistant surface.

Keep your soldering iron in its protective holder when not actually being used.

Do not leave any hot tools, such as a hot drill bit, where someone can accidentally contact the hot element.

HAND TOOLS Constructing a robot will sometimes require the use of hand tools. Most people think of hand tools as wrenches, screwdrivers, chisels, and so forth, but the term also applies to any hand held tools or implement used to accomplish a task. This includes all sorts of things used to grasp, lift, push, pull, carry, or clean. Always use the proper tools for the job.

Tool Rules

Before using any tool, check to see if it is in good condition. Don’t use defective, dull, or broken tools. Don’t put them back on the shelf; remove them from service and notify the Safety captain and mentor so they can be replaced or sent for repair.

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When using a screwdriver or other tools, place the work on the bench or hard surface rather than in the palm of your hand.

When using knives/blades, direct your cutting strokes away from your hand and body, and be aware of those around you.

Tool Storage

Store sharp-edged or pointed tools in a safe place. When carrying, cover the point or edges with shields. NEVER carry unshielded tools in your pocket.

Don’t leave tools on overhead work surfaces. They may fall and strike someone below.

Store equipment in a location where it will not create a safety hazard or get damaged.

STORED ENERGY Plan out the required activities when servicing or making repairs to the robot. Make sure all teammates are aware that work is being done on the robot. Address the following:

Ensure no one is working on the robot when it will be energized during repairs.

Electrical Energy: Disconnect the electric power source.

Always de-energize the robot before working on it by unplugging the batteries.

Miscellaneous Energy Sources.

Relieve and compressed or stretched springs.

Lower all raised robot arms or devices that could drop down to a lower position on the robot.

General Damaged Battery Info/Warnings Any battery that is visibly damaged in any way is dangerous and unusable, and should be set aside and handled accordingly because:

It contains stored electrical energy that could cause the battery to rapidly heat up due to an internal electrical short circuit, and possibly explode.

Battery Disposal Disposing of the batteries used in the duration of the competition or at your team’s school is the proper thing to do. Remember to dispose of the batteries in an environmental friendly manner.

Charging and Handling

Keep the batteries charging area clean and orderly.

Place your battery charger in an area where cooling air can freely circulate around the charger. Battery chargers can fail without proper ventilation.

Do not short out the battery terminals. If metal tools/parts contact the terminals simultaneously, it will create a direct short circuit. This may cause high heat to develop in the battery terminal/part/tool area and the battery could explode.

If a quick disconnect is not available and you must use tools to disconnect the battery, make sure metal tools don’t contact both terminals at the same time.

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Ongoing Battery Inspection Periodically inspect your battery for any evidence of damage, such as a cracked case or leaking

electrolyte.

After each competition round, inspect the battery.

Check your battery prior to competing in each round.

Respect of Electricity

Proper use and respect for electricity is paramount. The following are general guidelines for ensuring basic electrical safety requirements are met.

Inspect your equipment cords and extension cords routinely to ensure they are in good condition.

DO NOT overload electrical fixtures and/or receptacles.

Avoid the following electrical/power supply setups to prevent overloading.

Power strip plugged into another power strip.

Extension cord plugged into another extension cord.

Extension cord plugged into a power strip.

Multi-device receptacle plugged into a power strip or extension cord.

At the Events: Follow the following safety considerations when in the Pit:

Registration: An adult will register your team. He/she will be asked to verify and sign a statement that the team has enough safety glasses for all mentors, team members, and team guests who will be entering the Pit.

To gain entrance to the Pit, every person will have to wear a pair of safety glasses and a pit pass.

TABLE SAW SAFETY http://www.youtube.com/watch?v=CPBur0pWtQA

1. Always use a push stick when the fence is set under 3” to the blade.

2. Never stand in line with the blade.

3. Always unplug the saw when changing the blades.

4. Never reach over the blade.

5. Always wear eye protection.

6. Make sure the fence is locked into place after setting the desired width.

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7. Always keep the work firmly down on the table while pushing it past the blade.

8. Keep the work riding against the fence throughout the operation.

9. Don’t allow an excessive overhang of the work beyond the blade.

10. Don’t feed the material faster than the saw will accept.

BAND SAW SAFETY http://www.youtube.com/watch?v=66KQgzY-N3E 1. Remove tie, rings, watch, and other jewelry, and roll up sleeves above the elbows. Remove all loose

outer clothing and confine long hair. Protective type footwear should be worn. Do not wear gloves when operating the band saw.

2. Wear an approved safety shield, goggles or glasses to protect the eyes.

3. Keep the table and floor around the machine clean and free of scrap material, chips, oil, grease, coolant, tools or accessories to minimize the danger of slipping or tripping.

4. Keep guards in place at all times. The blade guard should be from 1/8 to ¼ inch above stock. Keep

hands away from blade and do not open upper or lower band saw doors while blade is in motion. Maintain a balanced stance and keep your body under control at all times; do not overreach.

5. Use only blades that are in good condition. Blades that are not sharp or have missing teeth can

require excessive force and increase the chance of an accident.

6. Make all adjustments with the power off. Disconnect the power service, maintenance or blade changes on the band saw.

7. Give the work your undivided attention. Looking around, carrying on a conversation and horseplay

are careless acts which can result in serious injury.

8. Upon completion of a job, clean the band saw and work area. Never clean the machine with the power on and never use hands to clean up chips and saw dust; use a brush.

9. Do not allow the hand or fingers to come closer than 2 inches to the blade.

Band Saw Operating Procedures 1. Select the proper blade width, refer to a chart which gives the blade width for minimum radii cuts. 2. The teeth on the blade of a properly installed blade should point downward in the direction of blade

travel.

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3. Check tension and tracking of the blade frequently, make adjustments as needed. Disconnect power

and turn wheels by hand to see if the blade is tracking in the middle of the wheel.

4. Be sure material being sawed is free of nails, paint and other obstructions.

5. Plan your cuts carefully. Lay out work clearly, use relief cuts, and avoid back-outs.

6. Do not cut stock until the machine is running at full speed.

7. Always place stock flat on the band saw table.

8. Do not force the stock into the blade at a rate faster than it can be readily cut.

9. If sawing freehand, use one hand to guide the stock into the blade and the other hand to push the stock into the blade. DO NOT PUSH STOCK WITH HANDS IN LINE WITH THE BLADE.

10. Do not place excess stress on the blade by twisting the stock, cut curves gradually.

11. If a problem develops and the blade has to be backed out, shut off the machine and wait until the

blade has stopped.

12. If the blade breaks, shut off the power and move away from the machine. Never try to free a blade while the wheels are turning.

13. An indication of a cracked blade is a rhythmic click as the cracked portion of the blade passes

through the wood.

14. Cylindrical stock should be mounted in a holding device to keep it from spinning and crowding the blade while being cut.

15. Make sure the band saw has stopped before leaving it.

BELT SANDER SAFETY 1. Wear safety glasses at all times when using the belt sander. 2. Wear hearing protectors and a dust mask when belt sanding.

3. Check the electrical cord and its connection to the sander housing for cuts, frays, or exposed wires.

Exposed wires should be repaired before using the sander to avoid electrical shock or damage to the sander.

4. Keep both hands on the belt sander at all times when sanding.

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5. Keep the electrical and extension cords away from the sanding area to avoid being cut by the rotating sanding belt.

6. Do not over-extend and lose balance when using the belt sander.

7. Raise the belt sander of the work, turn the switch to ON, and lower the belt sander slowly onto the

surface being sanded.

8. Place the sander on its side when not in use to prevent it from being accidentally or intentionally turned on and running off the table.

9. Always clamp the material being sanded securely before starting the belt sanding operation.

10. Always unplug the belt sander when the sanding is completed or if you are leaving the sanding area.

Belt Sander Operating Procedures 1. To change the sanding belt hold the belt sander in a vertical position, push down on the front belt

roller until it catches. Slide the old sanding belt off and observe the direction of the arrow on the inside of the old belt. Put the new belt on with the arrow pointing in the same direction as the arrow on the old. Release the catch on the front roller to apply tension to the new belt.

2. Empty the dust bag often for most efficient operation.

3. Before using the belt sander turn it on and adjust the belt tracking so the belt runs true on the front

and rear rollers. Slight tracking adjustments may need to be made during the sanding operation.

4. Move the sander back and forth in smooth even strokes along the direction of the wood grain. Keep the sander moving at all times to avoid sanding uneven spots in the wood.

5. Start the sanding operation with a course grit sand belt, then move to a medium grit belt, and finish

the operation with a fine grit belt.

6. When finished sanding lift the belt sander off the material and then release the on/off switch.

7. Lay the belt sander on its side when setting the tool down.

8. When sanding do not allow the belt sander to extend over the ends of the material. This will prevent uneven amounts of material from being removed at the ends.

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DRILL PRESS SAFETY http://www.youtube.com/watch?v=8a_XLSjl0VU 1. Do not wear loose clothing or jewelry while operating a drill press. Confine long hair with a cap or

hair net. 2. Wear industrial quality eye protection while drilling.

3. Keep all guard in place.

4. Keep work space around the drill press clean. Make certain that cutting oil and cooling lubricant are

not spilled on the floor.

5. Turn off power before making adjustments.

6. Drill only with sharp drill bits with shanks that are matched to the type of chuck being used.

7. Secure bit by tightening in each hole of the drill chuck. Remove the chuck key before the drill press is turned on.

8. Clear the drill press table of all tools, metal, rags, etc. before drilling.

9. Secure all work in a drill press vise or with a clamp before drilling.

10. Never hold material by hand while drilling.

11. Never attempt to stop a revolving piece of work in the drill press by hand.

12. Never allow any part of your body to touch the drill bit or any revolving part of the drill press while it

is in motion.

DRILL PRESS OPERATING PROCEDURES 1. Adjust drill speed and feed to the type and size of hole being drilled. Check drill specifications for

recommended drill speeds and feed. 2. Position long stock so it is to the left of the drill press operator while being drilled.

3. Select proper sized bit by using drill gauge. Make certain the drill shank and chuck are matched, i.e.

use a straight shank drill in a Jacobs chuck and a tapered shank drill in a morse tapered chuck.

4. Tighten the drill bit securely in chuck.

5. Mark all metal to be drilled with a center punch.

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6. Support the end of long stock with a stand.

7. Clamp the metal to be drilled in vise. Place a block of wood under the metal being drilled to prevent

the bit from cutting into the vise after coming through the work.

8. Align the drill bit with the center punch mark.

9. Make certain the chuck key had been removed from the chuck before starting the drill press.

10. Make sure that guard(s) is/are in place and the table locking clamp is tightened securely.

11. Use the proper cutting lubricant for the material being drilled.

12. Set the drill speed to match the material being drilled and hole size. Note that variable speed drill presses require the machine to be running to adjust the operating speed.

13. Turn on the power and apply appropriate cutting lubricant. The cutting lubricant should be applied

to the upper portion of the bit.

14. Apply pressure to pilot feed lever, feed drill bit into metal fast enough to keep drill bit cutting at all times. Continue to apply lubricant as needed.

15. Just as the bit begins to cut through the metal, reduce the feed pressure so the bit will not seize the

metal. Seizing causes the material to be grabbed by the bit, which will cause the material to revolve around the bit or will break the bit. Stop the drill press before removing any revolving material.

16. After the hole is drilled release the pilot feed lever slowly and allow the chuck to return to the

starting position.

17. Turn off power.

18. When work is removed from the vise be careful, the underside of the hole may have sharp burrs which will need to be filed or ground smooth.

19. Remove drill bit, clean, and return it to proper storage place.

Lathe Safety

http://teachertube.com/viewVideo.php?video_id=193697

1. Make sure that the chuck, drive plate, or, faceplate is securely tightened onto the lathe spindle.

2. When removing the chuck, drive plate, or faceplate do not use machine power. 3. When installing the chuck, drive plate, or faceplate do not use machine power.

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4. Move the tool bit a safe distance from the collet or chuck when inserting or removing work. 5. Don't run the machine faster than the proper cutting speed – consult a speed and feed table to

determine the best speed. 6. In setting up the tool holder place it to the left side of the compound slide to prevent the compound

slide from running into the chuck or spindle attachments. 7. Always clamp the tool bit as short as possible in the tool holder to prevent it from breaking or

chattering. 8. Always make sure that the tool bit is sharp and has the proper clearance. Ask for assistance making

adjustments.

9. If any filing is done on work revolving in the lathe, file left handed to prevent slipping into the chuck. Never use a file without a handle.

10. If work is turned between centers, make sure that proper adjustment is made between centers and that the tailstock is locked in place.

11. If work is being turned between centers and expands due to heat generated from cutting, readjust centers to avoid excessive friction.

12. Do not grasp or touch chips or turnings with your fingers, but get rid of them using a blunt

instrument. It is safer to turn off the lathe before clearing chips then to leave it running.

13. Set the tool bit on the centerline of your work to prevent work from climbing over tool or cutting above center and dragging.

14. Don't cut work completely through when turning between centers. 15. Remove chuck key from chuck immediately after using. 16. Turn chuck or faceplate through by hand before turning on the power to be sure there is no binding

or clearance problem. 17. Stop the machine before taking measurements. 18. Before cleaning the lathe remove tools from the tool post and tailstock.

MITER SAW SAFETY 1. Wear industrial quality safety glasses when operating the motorized miter saw. 2. Make sure the saw is securely attached to a table or base support before attempting any cut.

3. Hold or clamp the material securely before making any cut.

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4. Keep hands at least 4 inches away from the rotating saw blade when making a cut.

5. Make sure the electrical cord and plug are in good operating order before using the saw.

6. After the saw blade has cut through the material, continue to hold the saw down, release the trigger

switch, and let the saw blade stop rotating before allowing the blade to return to its starting position.

7. Never attempt to remove scrap material from the cut zone until the blade has stopped rotating and

your hand is removed from the on/off switch.

8. Keep the saw blades sharp and the saw well lubricated where necessary.

9. If cutting long stock, support the long end to prevent the material from binding or jamming the saw blade after the cut is finished.

10. Use a shop vacuum and/or position the saw where dust does not blow back in the operator’s face.

11. If using outside, or in a damp location make sure the saw is connected to a Ground Fault Circuit

Interrupter (GFCI).

12. Position the electrical cord out of the way of the material and operator.

13. Lock the saw blade in its safest position when work is completed and you are leaving the work area.

14. Caution others in the work area to wear safety glasses and be aware of the saw dust generated by the saw.

15. Wear a respirator or good quality dust mask when using the motorized miter saw for extended

periods.

16. Unplug the saw when making adjustments on the saw.

17. Wear hearing protection when using the motorized miter saw for extended periods of time.

Miter Saw Operating Procedures 1. Make a trial cut on a piece of scrap material before attempting final cuts to make sure the saw is

cutting properly and that the miter and bevel angles are set accurately. 2. If the material is bowed or warped, clamp the stock to the saw base before making the cut to avoid

binding or saw kickback.

3. Align the saw blade on the waste side of the cut line.

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4. Hold the saw firmly and lower the blade slowly into the material being cut. After the cut is completed continue to hold the blade in the down position, release the on/off switch, wait till the blade stops rotating and then raise the blade to the up position.

5. If the motorized miter saw is mounted on a slide, pull the saw out to the extended position, turn the

switch on, lower the blade into the material, and push the saw forward to make the cut.

6. Hold the material securely when making cuts.

7. When making multiple cuts of the same dimensions, clamp a stop on the saw table to assure accuracy of the cut and to reduce the time needed to make the cuts.

8. If the saw should kickback, continue to hold it firmly in the down position, release the on/off switch

and wait for the blade to stop rotating.

9. Deep scraps removed from the cutting zone to avoid them being thrown out by the saw blade.

10. When cutting long stock use a helper or a solid support stand to help hold the material steady while the cut is being made.

11. Keep the work area clean and free of clutter when using the motorized miter saw.

12. Do not over-extend or get off-balance when using the motorized miter saw.

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Band Saw Safety and Operation Test

Name_____________________________ Date____________________ Multiple Choice – Place the letter of the most correct answer on the answer sheet.

1. Before operating the band saw the following is required: a. Close one eye to get a sight line b. Wear proper eye protection and have all safety devices in place c. Test the sharpness of the blade by running your finger over it d. Wear head protection such as a hard hat

2. The guards on the band saw should be adjusted to be approximately _____

a. 1/8 to ¼ inch about the stock. b. 5/16 to ½ inch about the stock. c. 5/8 to ¾ inch about the stock. d. 1 to 2 inches about the stock.

3. Your fingers should never get within _____ inch(es) of the blade cutting line.

a. ½ b. ¾ c. 1 d. 2

4. When cutting curved or irregular shapes with the band saw _____ are needed to keep the

blade from binding. a. Miter gauges b. V-blocks c. Relief cuts d. Rip fences

5. When cutting cylindrical stock a _____ must be used.

a. roller bearing b. rip fence c. Forstner bit d. V-block

6. While band saw is running, never use your _____ to remove small scrap from the cutting

path. a. fingers b. push stick c. pencil d. stock being cut

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7. If it is necessary to back the stock out of a cut you must: a. use another board to slow down the blade. b. pull the stock as hard as you can while blade is moving. c. adjust blade tension while blade is moving. d. shut machine off and wait for the blade to come to complete stop then remove

stock.

8. While operating the band saw it is a safe practice to: a. maintain a balanced stance at all times. b. open wheel guards while saw is running. c. reach across material being cut. d. talk to anyone nearby, explaining your technique.

9. When cutting with the band saw you should:

a. make sure you are aware of your surroundings, look around the shop once while cutting stock.

b. make sure you have an audience so that you can explain what you are doing. c. always concentrate on what you’re doing, never talk to anyone nor look away from

the cut. d. remove scrap from the saw and floor only at the end of the hour.

10. If the blade breaks while you are using the band saw you should:

a. try to finish your cut. b. turn off the power and notify the instructor immediately. c. when convenient, inform the instructor, preferably at the end of the class period. d. tell no one and hope someone else gets blamed.

11. The correct blade width to use for a specific job depends on _____.

a. speed of the cut b. the radius of the cut c. material being cut d. does not matter

12. Why is it unsafe to cut with a dull blade?

a. You have to excerpt too much pressure to make the cut which could cause your hands to slip off the work

b. It isn’t. A sharp blade will cut you deeper c. Band saw blades do not dull. This is a trick question d. Band saw blades do not dull. This is a trick question

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Belt Sander Safety and Operation Test

Name_____________________________ Date____________________ Multiple Choice – Place the letter of the most correct answer on the answer sheet.

1. What personal protective equipment should be worn when using the belt and disc sander? a. dust mask b. safety glasses, hearing protection, dust mask c. safety glasses, hearing protection d. safety glasses, gloves when sanding metal

2. Keep fingers at least _____ away from the moving abrasives.

a. 2” b. 4” c. 6” d. It doesn’t really matter

3. Sanding should be done _____.

a. on the up stroke side of the disc. b. on the down stroke side of the disc. c. anywhere on the face of the disc. d. as close to the center of the disc as possible.

4. Abrasive surfaces that are _____ can catch stock and throw it from your hand and should

not be used. a. worn, shiny b. frayed, torn, have holes c. frayed, reddish in color d. old, grayish in color

5. When sanding on the belt sander, your stock should be _____.

a. held with one hand only. b. placed against the belt and worktable at the same time. c. placed against worktable first. d. placed against belt first.

6. The sander should be used for _____.

a. cutting down and sanding the stock. b. shaping and sanding the stock. c. shaping the stock. d. sanding/finishing/smoothing the stock.

7. When sanding with the belt and disc sander, keep the stock moving to _____. a. be sure you don’t sand off too much. b. avoid burning the stock and dulling the abrasive in one area. c. be sure you are still focusing on the task. d. avoid tearing the abrasive.

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Drill Press Safety and Operation Test

Name_____________________________ Date____________________ Multiple Choice – Place the letter of the most correct answer on the answer sheet.

1. When operating the drill press, what should be done with long hair? a. hold it away from the drill bit with one hand b. put it under a cap or hair net and keep your head away from moving parts c. get a haircut d. keep your head back away from moving parts

2. What type of drill press chuck should be used with a straight shank twist drill?

a. Universal 3-jaw chuck b. Jacobs chuck c. Morse tapered chuck d. Any of these are acceptable

3. Which item(s) of protective equipment is/are absolutely necessary when operating

the drill press? a. Leather gloves b. Leather apron c. Steel toed shoes d. Safety glasses

4. Which of the following conditions would be unsafe when operating a drill press?

a. floor is slippery from spilled cutting oil b. drill area is cluttered with tools and scrap metal c. the belt guard is loose d. all of the above

5. If the metal being drilled begins to revolve, you should _____.

a. turn off the drill press and free the metal. b. tap the metal lightly with a hammer to free it from the bit. c. stop it with your hands. d. move the drill press table to foul the rotating piece of metal.

6. To select the proper twist drill, one should check _____.

a. size, sharpness and type of shank. b. drill speed. c. lubrication needed. d. length of the drill cutting lips.

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7. Before turning on the drill press the operator should _____. a. tighten the drill press table locking clamp. b. clamp work in a vise. c. remove the chuck key. d. all of the above

8. Which is not a safe way to secure metal while it is being drilled?

a. hold it firmly by hand, but securely on the drill press table b. in a drill press vise c. clamp d. between supports mounted on the drill press table

9. Which should be done while drilling metal with the drill press?

a. change speed of the drill press b. maintain enough feed pressure to keep the bit cutting at all times c. keep the drill press quill locked d. lubricate the chuck

10. When a bit seizes it may _____.

a. break the bit. b. cause the vise to turn. c. cause the bit to slip in the chuck. d. all of the above

11. After the drilling is finished, which of the following should be completed first _____?

a. turn off the drill press b. remove the drill bit from the chuck c. remove the work from the drill press vise d. none of the above should be done first

12. Metal chips should be removed from the drill press _____.

a. by wiping with the hand. b. by blowing with compressed air. c. by using a brush. d. any of the above are satisfactory

13. When drilling long material what precaution(s) should be taken?

a. support the clamped end with a stand b. put the long end of the stock to the right of the operator c. support the unclamped end with a stand d. none of the above

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14. After a drilling operation is completed what potential hazard should the operator be alert to _____.

a. the twist drill will be dull b. sharp edges and burrs around the hole c. hot cutting oil d. stresses built up in the metal being drilled

15. To prevent seizing one should _____.

a. keep the bit well lubricated. b. reduce feed pressure when the hole is about finished. c. reduce speed of the drill bit. d. put a block of wood under the metal being drilled.

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Motorized Miter Saw Safety and Operation Test

Name_____________________________ Date____________________ Multiple Choice – Place the letter of the most correct answer on the answer sheet.

1. How must the saw blade be held after the cut is finished and before the blade stops rotating?

a. release it to the up position b. hold it in the down position c. raise 1” above the stock being cut d. pull to the out position

2. What special protection must be observed when using the motorized miter saw outside?

a. keep the saw covered b. lubricate the saw more often than normal c. unplug the saw after each cut d. connect the saw to a ground fault circuit interrupter (GFCI)

3. How can the saw operator prevent the blade form binding when cutting warped, bowed, or

long stock? a. clamp the stock to the table b. hold the saw firmly c. push the saw through the material slowly d. hold the saw down securely after the cut is made

4. When is it safe to remove wood scraps from the cutting zone on the motorized miter saw?

a. while the saw is positioned over material and ready for a cut to be made b. while the saw blade is clamped in the down position c. while the saw if off and the hand is not on the on/off switch d. while the blade is up

5. Where should the saw blade be positioned when cutting is completed and the operator is

leaving the work zone? a. up b. down c. in its safest position d. either a or b

6. Hands or fingers never come closer than _____ to the rotating blade when operating the motorized miter saw.

a. 2 inches b. 4 inches c. 6 inches d. 8 inches

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7. What personal protection equipment should be worn by a motorized miter saw operator?

a. Hearing protection, eye protection and a dust mask b. Eye protection c. Eye protection and hearing protection d. Hearing and eye protection, dust mask and gloves

8. The purpose of a trial cut before making the actual cut with the motorized miter saw is to

_____. a. see if the material is positioned correctly. b. see if the saw is cutting properly and is set accurately. c. see how the material will cut. d. test the sharpness of the saw blade.

9. Where should the saw blade be aligned when making a cut with the motorized miter saw?

a. Left side of the marking line b. Right side of the marking line c. Waste side of the marking line d. On the marking line

10. How should the saw blade be moved throughout the stock when making a cut with a

motorized miter saw that has a sliding arm? a. Push down, then pull out b. Push down c. Pull out, then push down d. Pull out, push down, then push forward

11. The purpose of a “stop” when making multiple cuts with the motorized miter saw is to

_____. a. hold the stock securely. b. improve cut accuracy and reduce time required to make cuts. c. reduce time required to make cuts. d. get hands and fingers further away from the cutting zone.

12. If a kickback should occur when a cut is being made the saw operator should _____. a. jump out of the way. b. turn loose of the saw immediately. c. raise the saw to the up position immediately. d. hold the saw firmly in the down position and release the on/off switch.

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Performance Test for Band Saw

Name_____________________________ Date____________________ Class_______________ The Student performs the following while using the band saw: Yes No N/A

1. Safety glasses are worn. ____ ____ ____

2. Safety guards are kept in place. ____ ____ ____

3. The table is cleared of other materials. ____ ____ ____

4. Clothing and jewelry are not hazardous. ____ ____ ____

5. The guard is 1/8-1/4 inch above stock. ____ ____ ____

6. The stock is fed properly into band saw. ____ ____ ____

7. All adjustments are made with power off. ____ ____ ____

8. The band saw and the work area are cleaned after use. ____ ____ ____

9. Work procedures are safe and acceptable. ____ ____ ____

10. Correct procedures are used when cutting stock. ____ ____ ____

Comments________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ I do hereby certify that the student has satisfactorily demonstrated the ability to operate the band saw by passing the above performance test. _________________________ __________ _________________________ _________ Signed (Student) Date Signed (Teacher) Date

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Performance Test for the Belt/Disc Sander

Name_____________________________ Date____________________ Class_______________ The Student performs the following while operating the belt sander: Yes No N/A

1. Safety glasses are worn while the sander is being used. ____ ____ ____

2. The table is cleared of other materials. ____ ____ ____

3. Hands are kept at least 2” away from the moving ____ ____ ____ belt/disk.

4. Sanding is done on the downward stroke. ____ ____ ____

5. Work is constantly moving and correct pressure is ____ ____ ____ used to prevent burning.

6. Gloves are worn when sanding metal on the belt/disk. ____ ____ ____

7. The student can safely control the work and perform ____ ____ ____ satisfactory sanding.

Comments________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ I do hereby certify that the student has satisfactorily demonstrated the ability to operate the belt sander by passing the above performance test. _________________________ __________ _________________________ _________ Signed (Student) Date Signed (Teacher) Date

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Performance Test for Drill Press

Name_____________________________ Date____________________ Class_______________ The Student performs the following while using the drill press: Yes No N/A

1. Safety glasses are worn at all times. ____ ____ ____ 2. Work area is cleared of tools, stock, rags, etc. ____ ____ ____ 3. Good footing is maintained by the student. ____ ____ ____ 4. Loose clothing, long hair, and jewelry are secured or ____ ____ ____

removed before operating the drill press. 5. Stock is secured in a vise or clamped down while ____ ____ ____

being drilled. 6. A proper size bit, with shank matched to chuck, is used. ____ ____ ____ 7. The drill press table is locked securely. ____ ____ ____ 8. The drill bit is tight in the chuck. ____ ____ ____ 9. The metal is marked with a center punch. ____ ____ ____ 10. The long end of the stock is to the left of the operator ____ ____ ____

and is supported. 11. The drill press speed is matched to the work. ____ ____ ____ 12. The lubricant is appropriate for the material being drilled. ____ ____ ____ 13. Proper feed pressure is maintained. ____ ____ ____ 14. The machine is turned off immediately after the drilling ____ ____ ____

operation is completed. 15. The chuck key is removed from the chuck before ____ ____ ____

drilling is started. 16. Correct procedures that are safe and acceptable. ____ ____ ____

Comments________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ I do hereby certify that the student has satisfactorily demonstrated the ability to operate the drill press by passing the above performance test. _________________________ __________ _________________________ _________ Signed (Student) Date Signed (Teacher) Date

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Performance Test for the Motorized Miter Saw

Name_____________________________ Date____________________ Class_______________ The Student performs the following while using the motorized miter saw: Yes No N/A

1. Safety glasses and saw guards are in place when cut ____ ____ ____ is being made.

2. Electrical cord is out of the way of the blade and work ____ ____ ____

when cut is being made.

3. The stock is held securely or clamped while being cut. ____ ____ ____

4. Hands and fingers are at least 4 inches away from the ____ ____ ____ saw blade at all times.

The student demonstrates acceptable ability to:

5. Start and stop the motorized miter saw. ____ ____ ____

6. Adjust the saw and make miter cuts. ____ ____ ____

Comments________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ I do hereby certify that the student has satisfactorily demonstrated the ability to operate the motorized miter saw by passing the above performance test. _________________________ __________ _________________________ _________ Signed (Student) Date Signed (Teacher) Date

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