The role of safety guards in machine operation

• What are the important machine safety standards
• Role of machines safety guards – why are they so important?
• How to prevent accidents at work

What are the important machine safety standards

Safety in the workplace is a priority for every company, especially in industry, where daily operations involve the handling of various machines. A lathe chuck guard, milling machine spindle guard or drill spindle guard is an absolute necessity in order to ensure an adequate level of protection for employees. To this end, the European Union has introduced a number of directives on the safety of machines and their guards.

The primary legal act regulating machine safety in the EU is the Machinery Directive 2006/42/EC. Its main objective is to ensure that all new machines placed on the market in the European Union meet the essential health and safety requirements. The machines manufacturers must conduct a detailed risk assessment, identifying all potential hazards associated with the machine’s use and implementing appropriate countermeasures. Each machine must have comprehensive technical documentation that includes information about its design, operation, and safety measures. The manufacturer must issue a CE declaration of conformity, confirming that the machine meets all the relevant requirements of the directive. Each machine must be equipped with clear and understandable instructions for safe use, maintenance, and operation.

In turn, a basis for adaptation of machines manufactured before 2004 to the minimum requirements is so called tool directive 2009/104/WE concerning health and safety requirements for the use of work equipment by workers at work.

Role of machines safety guards – why are they so important?

Certified machine safety guards play a crucial role in ensuring operator safety. These are physical barriers designed to protect users from contact with moving parts of the machine, sparks, hot surfaces, and other potential hazards. Guards should be made of durable materials resistant to mechanical and chemical damage. They must be properly mounted to prevent easy removal. Machine safety guards should be designed in such a way that allows easy access to the machine for maintenance purposes without the need for complete disassembly. It is important that locking systems are effective and prevent accidental machine start-up during service work. Guards should be ergonomically designed to not hinder the operator’s work and allow convenient access to all machine control elements.

How to prevent accidents at work

There is no substitute for common sense and regular training on occupational safety. To ensure continuous security, guards should be regularly checked for damage and wear. Any irregularities must be repaired immediately. Proper training of personnel in the use of machines with guards is also crucial. Operators must be aware of all the potential hazards and know the procedures in case of guard failure.

Compliance with Machinery Directive 2006/42/EC and tool directive 2009/104/WE, and adherence to safety rules are key elements ensuring the health and safety of employees. Companies must pay particular attention to the proper design, installation, and maintenance of machine guards and the regular training of personnel. Only then can a safe and efficient work environment be guaranteed.

For your assistance with finding the perfect solution for your individual application ask here.

How to adjust electromagnetic clutch in a conventional lathe machine

Table of Contents

• Adjusting an electromagnetic clutch in a lathe machine – steps to follow
• Regular maintenance for best performance
• Follow the manual for proper clutch adjustment in a lathe machine

Adjusting an electromagnetic clutch in a lathe machine – steps to follow

First, identify the electromagnetic clutch mechanism on your lathe machine. It’s usually situated near the motor or the transmission system. Depending on the design of the clutch, there may be adjustment screws, nuts, or other components that allow you to adjust the clutch engagement. Determine the desired engagement point of the clutch. This is the point at which the clutch fully engages and transmits power from the motor to the lathe’s spindle. Use the adjustment mechanism to make small, incremental changes to the clutch engagement. Test the lathe machine after each adjustment to ensure that the clutch is engaging properly. Verify that the clutch engages smoothly without any jerking or slipping. It should provide consistent and reliable performance during operation. Once you’ve achieved the desired clutch engagement point and smooth operation, perform a final test to ensure that the adjustment is satisfactory.

Regular maintenance for best performance

Remember about regular maintenance: periodically check and adjust the electromagnetic clutch as needed to maintain optimal performance of the lathe machine.

Follow the manual for proper clutch adjustment in a lathe machine

Always consult the lathe machine’s manual for specific instructions on adjusting the electromagnetic clutch. It should provide details on the recommended settings and procedures for adjustment. If you’re unsure about any step or encounter difficulties, it’s advisable to seek guidance from a qualified technician or refer to the manufacturer’s support resources.

Be sure to check our article on how to choose the right roll-up covers for a lathe.

How to choose the right roll-up covers for a lathe

What is it used for and how is a metal lathe built?

Lathes for metal machining are irreplaceable machine tools in the process of producing various elements and machine parts. They are used in the machining industry for machining objects, most often with the surface of rotary solids (rollers, cones, balls, internal and external threads, etc.). The machining tool in a lathe is most often a lathe cutter, a drill or threading tools. Conventional lathes have cast iron bodies that constitute the following machine components: bed, base legs, headstock, feed box (Norton), speed box (Reducer), support box, cross slide, tool support with a tool post, tailstock, etc.

How to work safely on a lathe

An important issue when operating lathes during production is work safety, which involves compliance with occupational health and safety regulations by operators, and securing the working space of the machine by using special safety covers. Lathe operators should be authorized to operate the machine, undergo occupational health and safety training and follow the job instructions so that work is performed in accordance with occupational health and safety rules.
In order to protect the lathe against hazards occurring while operating the machine, the following safety covers should be used:

1. Lathe chuck cover, e.g.: PTO-01/500
2. Tool post cover, e.g. PTO-10/435
3. Rear cover, e.g.: PTO-31/080
4. Roll-up covers PAM series protect the lead screw and the drive shaft.

How to choose the right roll-up covers for a lathe

We select roller covers for lathes depending on the technical parameters of the machine, primarily: the turning length in the centers, the width of the lead screw and the drive shaft, and additional components of the lathe, e.g. location of the tailstock manual feed crank in the place of mounting the roller covers. Depending on the machine construction, for example the feed crank location, it might be necessary to install 2 or 3 pcs of the roll-up covers. A professional supplier or manufacturer of protective covers will always advise the user which of the offered covers will perfectly fit his machine tool and will provide all the necessary instructions for their installation.

Be sure to also check lathe steady rest functions & use.

What are the differences between the FAT WROCŁAW TUR 50 lathe and the TUR 630 lathe?

Universal lathes of the TUR type are devices designed and manufactured by the Automatic Lathe Factory „PONAR” in Wroclaw (FAT WROCLAW). Their production began in the early 1970s and continued until the end of the 1990s. After the factory was taken over by the Haco Group, some models were still produced. The devices from this manufacturer include well-known and highly valued machines such as the TUR 50 or TUR630M lathe. After modernization work and a thorough renovation of the basic components, they are ideal as equipment for workshops and production companies engaged in professional metal processing. Let’s find out what are the basic differences between the TUR 50 and TUR630M lathes.

What do you need to know about the TUR 50 lathe?

The TUR 50 lathe is a universal machine offering a turning diameter over the bed of 500 mm and a turning diameter over the support of 300 mm. Its center spacing and turning length can range from 500 mm to 2000 mm depending on the version, which allows for the processing of large-sized elements. The spindle bore is 71 mm or 90 mm, and the power of the two-speed main engine is 6/11 kW. After a major overhaul, the machine meets the requirements of the Machinery Directive and can be equipped with facilities such as a digital three-axis position reading system, central lubrication and an operating time counter.

What makes the TUR 630M lathe unique?

The TUR 630M lathe is a machine with a turning diameter over the bed of 630 mm and a turning diameter over the support of 380 mm. The spindle passage diameter is 90 mm, and the center spacing and turning length, depending on the version, can range from 750 mm to 3000 mm. After modernization, the device meets the requirements of the Machinery Directive and can also be equipped with additional equipment, e.g., a digital positioning system in three axes, a central lubrication system or an operating time counter. A wide range of overhauled lathes can be found on the MultiMasz website. You can also find FAT Wroclaw Lathe Spare Parts in our offer.

What is the principle of operation of clutch and brake plates (discs)?

Clutch and brake plates are used to transfer torque from the driving part to the driven part of the device. Clutch plates are placed in clutches or brakes, which, depending on the way the plate pack is compressed, are divided into: electromagnetic, mechanical, hydraulic and pneumatic. In overload clutches, the plates are compressed by springs. Their friction surfaces can be covered with metal-ceramic sinter or covered with organic linings in order to change the operating temperature, dynamic characteristics, and the amount of transmitted torque.

What types of clutch and brake plates (discs) are there?

Due to the method of cooling and lubrication, they are divided into plates for operation in oil and for dry operation. Metalworking machines use inserts made of hardened steel. In order to shorten the time of disengaging clutches and brakes, internal or external plates are „waved” or expansion springs are mounted on them.

Dry running brake discs are installed in brakes to brake rotating machine parts as well as in self-braking motors. In order to increase the braking torque, double-disc brakes are also made. After using special materials and housings, they can operate in explosion-hazardous zones.

The plates and discs are appropriately shaped to transfer the torque, e.g., from the shaft to the driver. The most commonly used form-fitting (sliding) joints are splined and toothed.

When and how to replace the clutch plates?

Each clutch plate is subject to natural wear over time and must be replaced. It is worth contacting a professional company e.g., MultiMasz that will easily select the appropriate plates, replace them, set them properly and adjust the gap in accordance with the requirements and technical characteristics of a given clutch. Please remember that any unprofessional interference in the disassembly of the clutch or brake may cause its failure and generate additional costs, including the need to purchase a completely new clutch.

Be sure to also check how to choose the right clutch for a lathe.

How to choose the right clutch for a lathe?

The electromagnetic clutch allows smooth disengagement and engagement of the drive in a lathe or other machine tool, enabling controlled movements and rotational speeds. Therefore, proper clutch selection is critical to machine performance and safety. In today’s article, we will show the characteristics and use of three types of electromagnetic clutches: multi-plate, single-plate and toothed, and we will suggest what parameters to pay attention to when choosing the right clutch for a lathe.

Types of electromagnetic clutches used in metal lathes

Three main types of electromagnetic clutches are found here:

• multi-plate electromagnetic clutches – they are characterized by a characteristic structure with internal and external plates installed alternately; when power is applied to the coil, the armature is attracted and the clutch plates are tightened, thus transmitting the torque. These types of couplings are used in many metalworking machines, including conventional lathes.
• single-disk electromagnetic clutches – in contrast to multi-plate clutches, here there is a friction disc permanently located in the rotor (body) of the clutch, after supplying power to the coil, the armature is attracted to the friction lining and the torque is transferred. Disc clutches are mainly intended for dry operation (i.e. without lubrication), but special linings are now available that also allow operation in oil.
• toothed electromagnetic clutches – an advanced type of clutches that combine the advantages of electromagnetic and mechanical clutches. They have special shaped teeth on the discs that ensure precise and stepwise engagement and disengagement of the drive. They are capable of transmitting high torques. They are used in precision machining machines, drive systems requiring fast and precise operation, as well as in some types of mechanical transmissions. The clutch can be engaged only at the relative speed of both rings = 0 or at synchronous rotations, while the clutch can be disengaged at any rotational speed and under any load.

How to choose an electromagnetic clutch for a machine tool?

When preparing to select the right clutch for the machine tool, you should first of all take into account parameters such as: dynamic torque, engagement and disengagement time, power supply method, coil voltage and power, clutch design. The operating environment is also important, other clutches are designed for dry operation and others for oil operation. These parameters will be crucial when choosing the right coupling that will be able to safely transfer the required torque. For design reasons, the size of the coupling that we intend to install in a given system is also important. It must freely enter the place intended for it. There are many more factors determining a well-chosen clutch, so in each case it is worth seeking advice from specialists or the manufacturer of the clutch or lathe to choose the right model.

Why an overhaul of a metalworking machine pays off

Conventional metal machine tools, such as lathes, milling machines, grinders, drills or boring machines, still play a very important role both in industrial production plants, repair plants at shipyards or mines, as well as in smaller service and production companies. This type of machine tools is an excellent tool for individual works, but they will also be perfect for serial production after modernization of the control to CNC.

Maintenance of metalworking machines

Major overhaul restores the metalworking machines to practically to the new machine parameters, and costs much less than a new machine tool. It is therefore an excellent solution for companies that want to have an accurate and efficient machine while reducing the required costs.

A very important factor when deciding who to entrust the execution of such a renovation is therefore the experience, and thus the rich portfolio of the company that performs it. It is important that our contractor knows the specifics of the construction and operation of the entrusted machine tool and has access to original parts for machine tools. In addition, each metalworking machines overhaul must finally be adapted to the minimum health and safety requirements, which will be confirmed by a declaration issued by the company performing the renovation.

Metalworking machines repair by MultiMasz

At MultiMasz, we have been overhauling and modernizing metalworking machines for over 20 years. Most of all, we specialize in Polish TR – TPK – TCG – TCC FUM Poreba lathes, TUR50 – TUR630 – TUR710 FAT Wroclaw, Polish and German Schaudt, Jotes grinders, milling machines parts and many other conventional machine tools. Our portfolio is also filled with an individual projects with special purpose machine tools.

The scope of the general metalworking machines repair includes, first of all, the mechanical part with the replacement or regeneration of parts and bearings; electrical – including the replacement of all wiring and the construction of a new electrical cabinet, regeneration of the tailstock, grinding of all sliding surfaces and derivation of the machine geometry in accordance with FAT (Factory Acceptance Test).

Check also: metal grinding machines.

What are electromagnetic chucks used for?

Processing various ferromagnetic materials on metalworking machines would be difficult without the use of special magnetic or electromagnetic holders (chucks), also called electromagnetic tables. These are elements whose task is to immobilize and hold metal details during their processing. They are used e.g. in grinders, milling machines or lathes.

What are the biggest advantages of using electromagnetic chucks?

The greatest benefits of using electromagnetic chucks during machining include:

• Shortening the time of preparing the workpiece for processing (up to ten times);
• The possibility of convenient processing of both the front and side surfaces of the detail, and no risk of deformation of the workpiece.
• The possibility of convenient processing of both the front and side surfaces of the detail, and no risk of deformation of the workpiece.

The electromagnetic chucks characterize: resistance to cooling liquids, possibility of use during automated production; waterproof construction; easy installation, and constant clamping force. The workpiece is fixed to the machine tool with only one plane, thanks to which tools can easily reach its other surfaces.

What are Electromagnetic chucks made of?

Electromagnetic machining chucks are designed to hold workpieces made of ferromagnetic materials during machining. They are equipped with a non-magnetic gripping plate, a power cord, two limiting strips and poles with windings. Unlike magnetic chucks, electromagnetic chucks use electromagnets instead of permanent magnets. Therefore, when for some reason the power is turned off, they will stop working and the workpiece will not be properly held. Therefore, when installing them, it is necessary to introduce changes in the machine control, which in the event of a power failure and the release of the electromagnet will stop the machine immediately.

Electromagnetic chucks are used in many metalworking machines used in various industries. These include: grinders, milling machines and lathes. Thanks to them, it is possible to process details in one clamping.

In order to facilitate the removal of details mounted on the electromagnetic table (chuck), a demagnetizer is connected to the table’s power supply system, which demagnetizes the detail and facilitates its removal.

How to sharpen guillotine knives?

The processing of materials requires them to be properly sized already at the stage of preparing the raw material. One of the most frequently used solutions is guillotine cutting, i.e. it takes place with the use of blades lowered in the vertical plane, which penetrates the cut structure due to pressure. An important element of these types of machines is the cutting edges used in them, which must retain their geometry and at the same time guarantee the appropriate strength. As the tool wears out during operation, its shape must be reproduced by the process of sharpening guillotine blades. Let’s see how to sharpen guillotine knives.

How to sharpen guillotine knives depending on their purpose?

The geometry of the guillotine blades and the type of alloy they are made of depends on the type of materials being cut.

In the case of cutting cellulose products, as well as products of the printing industry, they can even be made of tool steel, and their sharpening consists in obtaining an inclined edge at an angle depending on the hardness of the products handled. Similar rules apply to cutting plastics and wood-based products, e.g. veneers.

When it comes to cutting sheet metal, the material used to make the knife must be harder. It can be, for example, high-speed steel, but also an alloy with the addition of cemented carbide. The blades are often coated to increase hardness. For cutting metal, the angle at which the knives are sharpened is usually close to 90°.

Who can sharpen a guillotine?

Sharpening guillotine knives requires experience and the use of appropriate equipment that will be able to plan the surface of the cutting edge with the required precision, and at the same time handle the hardness of the material used. This service is performed only by companies with advanced metal processing facilities.

For many years, MultiMasz has been specializing in guillotine parts, producing custom-made guillotine blades for steel cutting, and sharpening blades for sheet metal processing.

How to get parts for Russian lathes?

Lathes are commonly used in various industries machine tools that are used to perform machining. Thanks to their use, it is possible to carry out finishing machining of objects in the shape of solids of revolution (e.g. shafts, balls, internal and external threads or cones). In order for lathes to function efficiently, ensuring efficient and effective work, they must be maintained in impeccable technical condition. As in the case of other machines, the most important role in keeping them in motion is played by regular technical inspections, during which all necessary repairs are made. Some worn parts of lathes can be regenerated, others need to be replaced with new ones.

How do lathes work?

The operation of lathes is quite simple. The workpiece to be machined on this machine is first clamped in the chuck or centers. Turning is done by putting it in rotation. During subsequent rotations, its surface is gradually cut with a specialized machining tool. Currently, an increasingly popular solution is the use of numerically controlled russian lathes, i.e. CNC machine tools.

What to do when you need to buy spare parts for a Russian lathe?

The condition for repairing the lathe is the purchase of appropriate parts. If you use a Russian lathe or boring and milling machine in your facility, it is important to source parts from Russian manufacturers. Thanks to this, you can be sure that they will fit perfectly, guaranteeing smooth, effective and trouble-free operation. Since many years our company has been cooperating with eastern manufacturers of machines and equipment, thanks to which we have prepared a wide range of various spare parts for Russian lathes for our customers. You will find parts for both universal center lathes 1K62, 1M63, 1M65 and vertical lathes 1512, 1516, 1525.

How to get russian lathes?

You can buy mechanical and electrical parts for Russian lathes from us, such as: shaft mounted clutches, electromagnetic brakes, clutch plates, pneumatic clutches, brush holders, clutch shafts, friction plates, discs, gears and shafts, valves and distributors, oil pumps, oil filters, step selectors or slide switches for vertical lathes.